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Frame, Fork, Swing Arm and Shocks - 6/10/2024
Frame & components assembly
Frame & components assembly
Frame & components assembly
Front fork
Frame & components assembly
Frame & components assembly
swing Arm & shocks
Frame & components assembly
swing Arm & shocks
Zinc Plating Miscellaneous Piece Parts
Zinc Plating mixture
REar brake hub components
REar brake hub components
White vinegar, a couple tablespoons of salt. Initial setup with 2 zinc bars in solution one connected to the positive (red) electrode and the second one connected to the negative (black) electrode for approximately 2 hours. Once complete, the solution is good indefinitely. The power source is a 120 VAC step down to 5VDC, 1 AMP output.
For plating, the positive connectors are connected to the zinc bars and the negative connector is connected to copper wire which holds the parts inside the solutions for approximately 40 minutes.
WARNING: Please follow all safety precautions as found on YOUTUBE or other sites, if you plan to use this method. The description here is for general information only and should NOT be considered complete!
REar brake hub components
REar brake hub components
REar brake hub components
Example of parts prepared for Zinc Plating.
Electrical / Wiring
Headlight wiring
Schematics vs. physical wiring
Schematics vs. physical wiring
Figuring out wiring connectivity in the headlight shell. Wires on right have different colors than on the wiring diagram and physically from the old wiring system,
Schematics vs. physical wiring
Schematics vs. physical wiring
Schematics vs. physical wiring
Laying out the wiring diagrams and physical wiring on the kitchen counter to discuss wiring color match-up's with the Bultaco parts distributor.
Written information only covers the color of the wires and not the functional purpose. This make it very difficult to figure out.
ignition coil connectivity
Schematics vs. physical wiring
ignition coil connectivity
Munting and connecting the ignition coil. have tested the system for spark at the spark plug and all is working fine I also wired in and tested the ignition kill button and it also works well!
wiring harness / horn
wiring block secured to frame
ignition coil connectivity
Laying out the new wiring harness to see how the lengths work basing the distances from the harness block mounting point behind the fork tree.
wiring block secured to frame
wiring block secured to frame
wiring block secured to frame
Mounting th wiring harness block to the frame and beginning the wire connectivity and testing process.
horn & headlight dimmer
wiring block secured to frame
wiring block secured to frame
Headlight high and low beam switch and the horn button mounted on the handlebars.
Mock-up with Gas Tank and Seat
Right Side View
Right Side View
Right Side View
Rear fender, wheel tire installed and brakes connected and adjusted properly.
Gas tank and seat for mock-up visualization only at this point.
Left Side View
Right Side View
Right Side View
Front fork, speedometer, wheel, tire and brake connected and adjusted properly. Handlebars installed with grips, brake & clutch levers and headlight dimmer / horn switch on the left and kill button on the right side.
Bultaco - 99% Ready to go
need to install the new chain
waiting for the new light bulb for the front light
waiting for the new light bulb for the front light
waiting for the new light bulb for the front light
waiting for the new light bulb for the front light
waiting for the new light bulb for the front light
filled with gas and ready to start
filled with gas and ready to start
filled with gas and ready to start
filled with gas and ready to start
filled with gas and ready to start