Gomer the Ratster Makeover, 2010-2012

I have started a makeover for the Rat Partster; here is an incomplete list of the tasks for this job: 

R&R motor & transmission 
remove transmission and disassemble motor 
clean parts 
evaluate case integrity 
transmission door tab 
transmission output bearing conversion 
dynamic balance flywheels 
cylinders 
rocker cover leaks 
rear head/rocker cover leak 
circuit breaker 
generator setup-if ng convert to alternator, DelcoRemy integrated regulator alternator 
tool box lid 

Frame 
weld crack 
true 
side stand retainer 
bend side stand 

paint ammonia salt water

Rewire 

Front end
replate? 
fork seals 
brake caliper mounting bushings 
gators 
fork oil 
6” spacers 
shorten brake line 
horn 
signal indicators
handlebar 
bushings 
grips
levers 
front brake master cylinder 
gauges 
tachometre 
speedometre 
oil pressure 

Exhaust 

Shift linkage

Brake setup 
brake drum/sprocket 
evaluate brake shoes/pads 
linkage 
brake pedal 

Rear chain 
tensioner 
oiler

Battery 

Rear fender 
repair cracks 
reinforce 
luggage rack drawer(s) 
paint ammonia salt water
saddlepack bracket 

Front fender 
rivets 
paint ammonia salt water

Oil tank 
braze 
protector 
oil filter 

Wheels 
true 
bearings 
drum/sprocket 

Seats 

Tail light 

Relocate highway bar inward 

Replace kicker pedal 

Gas tank 
expand or replace 
luggage rack & drawer(s) 
paint ammonia salt water


 I will post pictures and updates from time to time.

more pics at https://photos.google.com/album/AF1QipM7oxxi0oe-aQyIK6QQhmuvqOLot4VK5CQfuM9j

The next thing I have to do is remove the bottom end from the frame.

2011.01.09: I removed the lower end from the frame. I had to wheel the bike out of the storage unit first. I had to use a pallet supported on a short 2 by 4 as a ramp. I had a few hard moments whilst removing the motor. Eventually I got 'er done. Next I get to clean the motor before I disassemble it. 

2011.01.18: I sprayed degreasing dish washing detergent on the motor, let it set for a bit and hosed the motor down. There was still plenty of oil-hardened dirt on the motor, so I will be scrubbing with a brush and detergent. I removed the circuit breaker, the generator, the gearcase, and cams, and the oil pump. I had a bitch of a time removing the gearcase and oil pump. Didn't break anything. All of the cam shims were wrecked and I will have to replace them. Next stop: remove the primary drive and transmission. I like the way my hands smell after working on the motor. 

2011.02.01: I removed the primary cover, pulled the clutch plates, set up clutch basket and drive retainer tools, and could not loosen the clutch hub nut. I will have to take the lower end assembly to somebody with an impact wrench to loosen it. 

2011.07.16: I took the motor to a neighbor who loosened the clutch hub nut with his air-powered impact wrench. 

2012.04.22 I removed the clutch hub nut, the clutch hub, clutch basket, motor sprocket, primary chain adjuster, and the primary drive chain. This took me long enough to get to this...