Manco Thunderbird Resto-Mod

[KartFab]

And so it begins with a seized tecumseh OHH60 with 1/8" ring gap, and an abused manco thunderbird frame with bent front forks.

 

[KartFab]

Electronics and getting the plastic cam no bearings anywhere teCRAPseh engine to run were by far the biggest challenge. But first, the frame modifications had to happen to support the battery, larger risers, and all sorts of wiring that would have looked really tacky outside of the handlebars and frame.

 

[KartFab]

battery box covers cut by hand with a plasma torch, and stainless steel exhaust custom fabricated to clear not just the frame but that stupid placement of the intake (same side as exhaust). Next it was on to prepping everything for paint and figuring out just how everything was going to come together. The old seat wasn't going to be able to comfortably hold my fat butt. Needed new wood, and thicker, high density foam.

 

[KartFab]

Straight shank cover buttons added to marine vinyl with red welting separating the vertical and horizontal edges of the seat. Next the front fork springs were polished, along with the ape hangars, hand control wiring was a nightmare, but just barely was able to fit it into the long handlebar sections and shoot it down the middle of the triple tree, hidden behind the battery box cover. New chrome rear shocks, brake, turn, and tail light added to the metal section that was now painted, and the seat looks alright for any size booty.

Engine goes on the dyno, its a pos tecumseh that probably flows worese than a flathead and has the contact patch of the microscopic valves more towards the valve stem than the valve edge..... hmmm.... well at least I got the carb tuned. $20 ebay special carb(pz22?) drilled from .033" stock to .035" at 12.2:1 AFR @ WOT, and about 13.2 at idle and part throttle. clip on top position, stock pilot turned out 1.5 turns.

Things are starting to come together, but tecrapseh rears its ugly head by throwing the flywheel charge magnets at 4200 rpm..... @!#$%!@#$^ well there goes the regulator/rectifier/charge idea....Lets just bust the rest of the magnets off, and remove the coil.

Still.... this is missing a bit of flair still. What to do for that little bit of extra pop? hmmm....

 

[KartFab]

The missing piece of the puzzle, pinstriping for the first time didnt go so bad, and tig welding and plasma cutting up a nice little clutch cover for that ankle destroying clutch. This is starting to look a bit more low rider/custom now with the apes, lights, pinstriping, and clutch cover. I had to buy a new hard drive just to fit all the footage, which is going to be a bear to edit, but Im glad I got to finish this build on schedule and this is just a nice little cruiser bike, runs on pump gas, is loud, and makes a pretty good statement. Cant wait to just cruise around at the car shows where we race, and maybe sell it after showing it off a bit. After all, I am a bit of a hoarder and i need SPACE to fix up the rest of the pieces of steel and rotten rubber in my garage.

 

[landuse]

Very very nice work!!!!!!!!!

 

[J.S.@SMS]

Nice build. You really put some work into this bike.

 

[Budget GoKart]

I wish! mine doesnt even have suspension i got the most clapped thunderbird in the usa