ConverT

[Klinkhammer]

Found myself a Convert!!
They are really rare here in Sweden. About 20 were ever imported. Not many have survived.
This is a 1976, almost drives (has a leaky final gear) and has been converted (!) to manual gearbox about ten years ago. The seller claims that all the specific Convert parts are there, and as far as I can see they are. Wrong seat of course, but original saddle bags are there (not in pics).
I talked to the PO (not the seller) and he says its nothing wrong with the converter etc, he just wanted a manual gearbox. Hopefully he’s right!
Apart from the boxes with Convert parts, the bike seems to be in decent shape with some new parts (FAC dampers in fork, Valeo starter, brake hoses). I will know better when I get it home and start take it apart. However, it sits on the second floor in a barn presently without a driveway. The seller is building one but it will take some time.

At this time I am debating with myself whether I should do an original resto or a 850T exterior with Convert drive. Time will tell.

[Groover]

congrats. I think since you have all the parts and the rare aspect them in that area, I'd aim for an original resto for convert. Either way, you can't go wrong!

[Turin]

That's a nice one!

[Klinkhammer]

Got the Convert to the garage last week.
As of now it has a manual 5-speed and all of the  specific convert parts sits in a box (engine front cover with trans oil pump still on the engine).
Most stuff seems to be there. So far the only thing missing is the transmission oil cooler bracket. (I have just placed an ad in the Swapmeet section).
Haven’t had time to take any pictures yet but they are coming.

[Klinkhammer]

Some progress made.
Got the bike apart and engine out last week and today I disassembled the engine.
Everything seems to be in good, or at least decent shape. Tomorrow I will inspect the engine parts more closely but from what I saw today the only obvious thing was some pitting on the cam followers.
I believe I have everything for the transmission except for the bracket that holds the oil cooler, however Charlie M has very kindly donated one. Thank you!!

I have also decided some more on the build. It will be a 850T look-a-like (green with gold stripes) with twin discs, foot boards and convert transmission. The 850T looks has really grown on me, it’s a no-nonsense, basic bike, and the plan is that this will be my bike to use around town.
I already have the 850 T parts I need (tool box lids, instrument cluster, triangular crash bars, seat bar, etc). And don’t fear; I will keep the critical Convert parts If I ever change my mind.
I think I will call this one a ConverT.

[Antietam Classic Cycle]

 

[Scout63]

Some progress made.
Got the bike apart and engine out last week and today I disassembled the engine.
Everything seems to be in good, or at least decent shape. Tomorrow I will inspect the engine parts more closely but from what I saw today the only obvious thing was some pitting on the cam followers.
I believe I have everything for the transmission except for the bracket that holds the oil cooler, however Charlie M has very kindly donated one. Thank you!!

I have also decided some more on the build. It will be a 850T look-a-like (green with gold stripes) with twin discs, foot boards and convert transmission. The 850T looks has really grown on me, it’s a no-nonsense, basic bike, and the plan is that this will be my bike to use around town.
I already have the 850 T parts I need (tool box lids, instrument cluster, triangular crash bars, seat bar, etc). And don’t fear; I will keep the critical Convert parts If I ever change my mind.
I think I will call this one a ConverT.

I had the same dilemma Klinkhammer and converted my G5 to a T3 FB lookalike in black.  I’m happy with the look but the stock convert/G5 look grows on me every day.  Either way you’ll have a great ride.

[Klinkhammer]

I had the same dilemma Klinkhammer and converted my G5 to a T3 FB lookalike in black.  I’m happy with the look but the stock convert/G5 look grows on me every day.  Either way you’ll have a great ride.




[/quote]

Thats a great looking bike!!

[Turin]

I don't think you will be able to fit the 850T toolboxes, as the trans fluid tank sits there on the left hand side.

I think she is beautiful as is. The black and white is classy, like it's wearing a tuxedo. If it were mine, I'd get rid of the wind screen and fine some black side cases.

[Klinkhammer]

I don't think you will be able to fit the 850T toolboxes, as the trans fluid tank sits there on the left hand side.

The toolbox will not fit on neither side, I'm just fitting the lids 

[Klinkhammer]

Inspected the engine parts more closely and was pleasantly surprised. The only thing that needs replacement is the cam followers, the rest of the engine looks as if it was recently rebuilt. I will clean out the crank and do a careful honing.
After vapor blasting it will be ready for reassembling.
Also got the 850T valve covers out.

[Klinkhammer]

Received new cam followers from HMB along with gaskets and seals. Heres a picture of new and old pitted ones.





The cam looked alright





Also received the oil cooler bracket from Charlie  :)
Thank You!

[Klinkhammer]

Have been much more busy in the garage than with the computer.

Got the engine apart and off to vapour blasting.
New seals in converter housing and transmission. New crown wheel seal ring in final gear.
Frame and assorted parts media blasted and of to the painters
Engine coming together, just waiting för the heads to come back from the shop after new seats and guides.




Before





After

[Groover]

Very nice results. thank you for sharing,

[Canuck750]

Your vapour blasted engine looks fantastic!   

[Scout63]

The engine looks great. Now the rest of the bike will have to keep up.

[Klinkhammer]

The other day I ran in to the first real problem of this build.
I have assembled the engine with new cylinders, pistons, rings and lifters. Mostly new o-rings in the gearbox.
I made a bracket for the dial indicator and tried to dial in the converter. Spent most of the afternoon getting more and more frustrated. Finally I discover that the hub on the converter is oval… about 0.25mm!
Called a workshop specialized in converters for trains and autos and after some persuading, he agreed to see me (and my converter) on friday.
Hopefully he can fix it, otherwise I’m on the market for a good used converter.

[Klinkhammer]

45 mm



44.8mm
 

[Klinkhammer]

Went to see Dr. Converter this morning.
He was amused by the size (small) and the set up in the gearbox (old-time) and agreed to fix it.
He had a hub that he could use, but as I understand, he will have to open up the whole converter and then weld it back. Then manufacture a new race and drive in. Finally balance it all. Hopefully done in a week or two!

[Canuck750]

Went to see Dr. Converter this morning.
He was amused by the size (small) and the set up in the gearbox (old-time) and agreed to fix it.
He had a hub that he could use, but as I understand, he will have to open up the whole converter and then weld it back. Then manufacture a new race and drive in. Finally balance it all. Hopefully done in a week or two!

Wow, that s a lot of work, 'Dr. Converter' has some impressive skills!

[Klinkhammer]

Wow, that s a lot of work, 'Dr. Converter' has some impressive skills!

Yup!
After talking to him for a while and seeing his extensive shop with robot welders, etc I have confidence in his knowledge. Hopefully it will be ok.

[Klinkhammer]

Finally!!!
It took some time but finally I got the converter back.
It was not cheap (approx 500$) but rather than getting a used one and not knowing the condition I chose to have this one fixed. Impressive workshop.
Today I dialed it in. More work than I expected but now it is within spec.
Also had to put in a Helicoil in the gearbox. Tomorrow I will unite the engine and gearbox and hopefully get it into the frame!






Lasse doing his thing








Some of the machines. That blue thing is the welder




Finally dialed in!

[Klinkhammer]

This converter has been fighting me in every step...
The other day I united the engine and gearbox only to realise that the engine would not turn anymore. Something was binding. Pulled the gearbox and converter housing apart, measured everything and came to the conclusion that the neck of the converter was approx 1 mm to tall. Had to rip everything apart and back to Dr Converter for the adjustment.

Today I dialed in the converter again, such an annoying labour, united the engine/gearbox and to my relief it did not bind anymore.
Got the frame on and started assembly, I decided to start with the plumbing of the converter. So got the trans oil tank and oil cooler mounted. (Thanks for the bracket Charlie;))

[Antietam Classic Cycle]

 

[Klinkhammer]

Some progression. Got the plumbing of the convert and crank case ventilation done.

I foolishly assumed that the drive shaft would be the correct one, however when this Convert was converted to manual gearbox, the PO got a UJ for a manual gearbox welded to the drive shaft. It was In perfect shape and I didn’t realize the splines was different until I tried to mount it…
Luckily TLM had a used UJ/driveshaft in great shape. It arrived yesterday, so today I got new swing arm bearings and UJ bearing in and got the swing arm in place!

As I’ve said before. I love this stage of building. The bike is perfect at this stage. Soon the compromises will start to come…

[Klinkhammer]

Fitted 850T crashbar, foot boards, foot controls, starter, side stand and exhaust system. Got the Lafranconi DGM12505. Down pipes are stainless, the rest chrome.

Have been waiting a long time for triple clamps and lower fork legs but the polisher guy ended up in hospital for a really bad case of erysipelas. Hes back home since a few weeks, but can still only work a few hours at at time. It will probably be another couple of weeks before he gets to my stuff:

When I got the bike, the coils were mounted by the battery tray by some PO. I guess one coil originally was fastened to the bracket under the top frame tube, but where does the other coil go originally?

[Antietam Classic Cycle]

When I got the bike, the coils were mounted by the battery tray by some PO. I guess one coil originally was fastened to the bracket under the top frame tube, but where does the other coil go originally?

Both coils are clamped together, one above the other, and fit into the space just behind the steering head.

[Klinkhammer]

Ah, ok. Thanks!

[Antietam Classic Cycle]

If I can find a photo of how they mount, I'll post it here.

[Klinkhammer]

That would be really helpful. Thanks!