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Finished

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Getting There...

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Finally finished mounting the seat cowl...I can now see how much room I have to play with underneath for mounting the ignition coil & control box.

Seat Cowl

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I've been test-fitting the seat cowl, and I also installed the hand-shaped aluminum 'skeleton" that will provide support from the inside. I drilled & tapped threads so the frame will be screwed directly to the seat cowl:

Fitting the Tank

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I've been playing around with some different ideas for mounting the tank. I fabricated some brackets for the front of the tank which has threads built in for bolts. I will use a pair that have a wing-nut head: After finding a spot where the tank was resting without interfering with the handlebars, I made two brackets and painted them: With the tank in a good spot I can now move on to finding anchor points for the rear straps as well as fitting the seat cowl. Trying to position seat it in a place that will still allow the ignition electronics to be hidden underneath might be tricky:

Ignition System Installation

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Back when I had the engine on the workbench, I installed the first portion of the Powerdyanmo Ignition system. I had previously installed this system on my other bike and have enjoyed excellent results, so I repeated the process here with photos: After removing the side cover the clutch and factory alternator are visible. I removed the clutch plates & basket along with the alternator in order to install the Powerdyamo magneto: After reinstalling the clutch the next step was to install the control box and ignition advance unit. As with the other bike, I chose to mount these together below the seat cowl: At this point, it's simply plug and play - no more adjusting points or worrying about having a fully-charged battery. The Powerdyamo also 'upgrades' the ignition system from 6-volt to 12-volt and provides a more reliable spark as well as better lighting. I will be taking my time with the wiring as to make sure everything is a clean installation.

Engine Is In

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After popping off the valve covers and checking clearances, I installed new gaskets. Then we put the motor back in the bike. At this point there will be lots work done for attachments for cables, wires and other fittings.