First Time Build, GI inspired bike

Discussion in 'Photos & Bicycle Builds' started by D_M, May 23, 2008.

  1. D_M

    D_M Member

    Hopefully this is the right place to start this thread. I am building a bike that was inspired in part by the bike in this post here, and also the bikes here. However, I am not trying to build a complete replica, just something with that kind of flavor.

    Here is what I have so far:

    1950 Columbia 5-Star Superb frame (early Columbia WWII bikes had the curved bottom bar like mine, most had a straight bar, but again I am not being exact).

    Correctish fenders that are a little dented up.

    WWII Army surplus handlebars (the item that basically started this project off)

    Old olive drab canvas handlebar bag

    Reproduction Columbia rear rack (not found on army bikes, but needed to hold the....)

    Old olive drab canvas saddlebags

    Old olive drab mechanics bag (will hold tools/parts and be on the top of the rack. About the size and shape of a shaving kit).

    I was trying to think how I'd attach the bags, and I came across a bag of random hardware at an estate sale for $1.50. There were old sash window hangers in the bag and they will work perfectly. You can see them in the shot of the rear of the bags.

    I haven't photographed the rack or handlebar bag, plus these are cellphone shots. I will use a proper camera as we move along.

    edit: Forgot to mention that I got an old metal Russian Army canteen in a canvas holder. I am going to try to figure out somewhere to mount it and use it for reserve fuel. I'll stencil GAS + OIL on the can, just to be 100% nobody drinks it.

    Attached Files:

    Last edited: May 23, 2008

  2. D_M

    D_M Member

    Here are the basics that I still need (by my reckoning, I am sure there are things I am forgetting.)

    Run flat tubes
    Bearings (bottom bracket/head)

    I originally noticed the frame wasn't that expensive and thought "Why pay Spooky Tooth a lot of money (no offense to them, I like their bikes a lot), when I can build something cheaper and more unique." Everything else is adding up fast though. If I were to re-do this from the beginning I would try to buy a complete bike. Finding straight fenders is a pain in the rear, and someone offered to sell me a suspension fork with fender for that bike for $160. I'd like it, but $160?? Hmm.
  3. D_M

    D_M Member

    I ordered a couple cans of Jeep restoration paint from TM 9 Ordinance, but his latest batch from his supplier did not meet his standards, so he is refunding his customers money.

    While that says a lot about his business, I still need some paint. So I am going to try this.

    Here is my list of things I have thought about for a bike. Some of it is just half formed, some of it is 'nice to have', some of it is useless, some may appear on a later bike.

    I think I will probably put a long pipe on it and paint it BBQ black. But I have looked into the X-Can, which apparently can fit these engines and looks cool, but is noisy. You can fit an external silencer, but the X-Can wouldn't go with this bike anyways. Maybe the next bike......... People who run 1/5 scale R/C buggies sometimes run an X-Can into a silencer. There are also silencers that could maybe piggyback on an HT pipe, but this stuff is all made for smaller motors. I keep trying to think of the stuff that is out there that could be adapted to these bikes. I am sure these are thoughts a lot of people have had though.

    You can order vintage looking cloth covered wire for motorcycle restoration, and it isn't all that much money. I don't know how the gauge compares to HT wire, but I'd like to learn more about electrical systems in this build. Which brings us to...

    HT can supposedly run one light ok off the white wire (what I gather from reading here anyways.) I have wondered about running the wire to a brake lever with switch from a scooter, so I can have a brake light. For a front light, it would be cool to somehow fit a modern LED into an old fixture. I have looked at the expensive "bottle battery" lights. I could put the "bottle" in the OD canvas handlebar bag and run the wire down to the light.

    I did see this Cat Eye system on eBay (hopefully that works), and it got me thinking about ways to run lights. The rechargeable battery looks a lot like my old R/C batteries. If I could create a set-up that operates off a hidden R/C battery (in the saddlebag or something), I could have a couple in the bag and switch them if I need to. I have batteries, connectors and chargers in a box in my basement.

    Tank: I don't really love the bicycle motor tanks, so I am keeping an eye out for other types of tanks. I haven't found anything amazing, but it is possible I might come up with something different than stock.
    Last edited: May 23, 2008
  4. HoughMade

    HoughMade Guest

    Looks like you have a really good plan and have done your homework. For the tank, I would consider a small cylinder attached behind the seat.

    Good luck and please keep us updated.
  5. D_M

    D_M Member

    I have thought about that too. There are some old Briggs and Straton tanks (see here and here) and even old chainsaw tanks but that one has a separate chain oil compartment, so it is configured weirdly.

    But it is something to keep in mind.
  6. HoughMade

    HoughMade Guest

    Those all look great. If you are up for a challenge, I noticed that those military bikes often had an I.D. plate or some sort between the upper and lower top bars. You could fabricate a tank to mimic that look- it could be flat on both sides and if it was only a couple of inches thick, it would still hold plenty of fuel. Just a thought.
  7. DM,do you know how much this information has been so needed here?
    Those are some awesome tanks. Would ge perfect behind a seat.
    I'm keeping an eye on this thread.
    WELCOME to MBc!!!
  8. D_M

    D_M Member

    Thanks Large, you led me here, which I mentioned in my intro thread.

    By the way, regarding old tanks, one thing I remember the instructor telling us in a small engine class I once took - if you have gunk or rust or are just using an old tank, a good way to clean it up is to put mineral spirits and pea gravel inside and shake the heck out of it.
  9. D_M

    D_M Member

    That is a good idea, but my metalworking skills consist of some things half remembered from an autobody class years ago. I did try working the dents out of my fenders with a hammer, with very minimal success.

    I can imagine exactly what you are talking about though, and it is a good idea.
  10. HoughMade

    HoughMade Guest

    Very true, but if there is more than loose rust and varnish, use toilet bowl cleaner with hydrochloric acid in it- diluted a bit, and let it sit in the tank and hour or so. It will take the surface rust right off. However, you have to rinse, rinse rinse, then follow with a wash with a phosphoric acid solution (Jasco Metal Prep is one). It converts any remaining rust to a phosphic oxide that will not rust and coats all the steel with a layer of phosphic oxide that will not rust. On exterior sheetmetal, the phosphoric oxide is a great base for primer, in a tank, it can be left as is.

    If you don't follow with the phosphoric acid, metal etched by hydrochloric acid will flash rust in minutes to hours depending on the humidity.
  11. motoschwinn

    motoschwinn Guest

    Where did you get the canvas bags? SO COOL!
  12. D_M

    D_M Member

    The saddlebag ones were on ebay i think. They claimed they were dispatch rider saddlebags, but I have no idea what they were really for. The handlebar one was from some army surplus place.

    If you want cool saddlebags, check these out. Made for a bike, easy to fit if you have a rack, and cool. They describe them as "children's toy" saddlebags, but they look like they'd hold quite a bit.
  13. sjackson

    sjackson Member

    Oh man I wish I saw those a few hours ago. I just bought a pair of these musette bags in olive drab. I've got a bunch of spare 1/4" peg board. I was going to cut some to fit in the bags so they stay rigid and don't get sucked into the wheel.
  14. D_M

    D_M Member

    My project has changed a little. I found an entire Columbia bike, which is now the basis for my first build.

    Anybody know if Cleveland Welding forks fit Columbia frames?
  15. D_M

    D_M Member

    I took the newer bike and gave it a night time primer (I am sure that will look awesome in the morning, but I got impatient). The forks seem to work.

    I have an engine arriving from Dax, but Fed Ex has it bopping around. Since I won't be around to sign for it, I will have to wait til it lands 25 miles away in a few days and go get it. It will give me time to figure out what I am going to do about wheels, I don't have any usable ones yet. I'd like to get a front with a drum brake, but I can't figure out where to buy one. I guess I could get a drum and pay someone to set it up.

    Attached Files:

  16. D_M

    D_M Member

    I got my motor kit. For starters, I was impressed how well it was packed. I saw some photos here of how some kits arrive, and this one was in good shape (save for some sort of liquid which melted a few of the foam peanuts onto some parts, but I cleaned that up. Also, the throttle has a small crack in one side of the housing, but I think that might not be a big deal).

    My kit came with a one page instruction sheet in Engrish, so I searched out better instructions and have been following those from here. All has been fine and dandy except I have already assembled the rear wheel twice after finally figuring out I could grind the coaster brake dust cap. Since putting the sprocket on, I have read elsewhere that I should have put both rubber o-rings on the inside, or that you MUST put them both on both sides. I am tempted to leave it as is, since I am following those directions, but who knows.

    When I was originally looking for wheels, I went to the local Trek dealer and they said they could order something. Later on, I passed a seedy looking little bike shop with wheels hanging in the window. I went in and the owner set me up with wheels, a chain, and a chain breaker. Finding that shop was probably the coolest thing about the build so far. (I did have to buy two front wheels because the first had an axle that was too fat for my old fork. I painted it before I realized it wouldn't work.)

    Anyways, I tried test fitting the engine and it will not fit with the standard mounts. Now I am researching different mounting techniques. It seems that a metal plate in my kit with holes and a bolt through the center might be an extended mount. I'd rather not drill the frame, but if I have to, I guess I have to.

    Attached Files:

  17. If there is a fab shop down the road have them extend (FRONT ONE) it where your hole is drilled on the plate youd have to make then extend that with blocked square stock with ears and use your outside clamp on the inside with washers for space behind the stock half circle then go to ace hardware and buy the conduit or metal pipe v hangers with the double holed ears on each side and cut one in half then use that for your outside halfcircle clamp. then run bolts through those ears back to the overlapped square stock caps(ears).
    Last edited by a moderator: Jul 9, 2008
  18. D_M

    D_M Member

    Added some pictures here.

    Had my first ride today. It was very cool for about four blocks, then an exhaust bolt came off, and it got noisy. Then the engine wouldn't run, but fixed itself somehow. Then the clutch handle came completely apart and seems to have lost some internal piece, making it so the lock doesn't work and the clutch doesn't operate properly. So I guess I will have to find a better clutch handle.

    It was a fun four blocks though.
  19. RedGreen

    RedGreen Member

    I have a set of 1940 Elgin Peaked fenders that might be helpful. I made the bike called Hardly Davidson.