2013 April 15: Purchase tap for fork tubes (0.00 hours ) Updated: 2013 April 15
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After conferring with several people who have used the commonly available replacement fork tubes with no trouble whatsoever, I've come to believe that my original bolts/fork tube combination are a bit of an anomoly (I also checked with another set of fork tubes I had previously purchased and a pair of disc brake fork top bolts). I found a 29 mm × 1 mm tap for sale and purchased it. Once it arrives, I hope to be able to open up the threads on the fork tubes just a bit.
Just another joy of working with 40 year old parts from a small production manufacturer. I don't mind, really...and I've always wanted to own this tap, anyway.
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Additional entries for this project
2012 October 10: History and plans 2012 October 11: Let the fun begin... (1.25 hours ) 2012 October 12: A possible vision... (0.00 hours ) 2012 October 12: More disassembly (1.25 hours ) 2012 October 13: Organizing (0.50 hours ) 2012 October 14: Degreasing (2.50 hours ) 2012 October 15: More degreasing (1.75 hours ) 2012 October 16: Remove tires (0.35 hours ) 2012 October 17: A revised vision... (0.00 hours ) 2012 October 17: More cleaning and dregeasing (1.75 hours ) 2012 October 18: Prepare wheels for un-lacing and begin engine disassembly (1.35 hours ) 2012 October 20: Engine and transmission disassembly and cleaning (6.40 hours ) 2012 October 21: Flywheel and clutch cleaning (1.15 hours ) 2012 October 22: Clean engine internals (3.15 hours ) 2012 October 24: Getting organized (1.50 hours ) 2012 October 25: Rear drive disassembly (3.50 hours ) 2012 October 25: Tappets (0.00 hours ) 2012 October 27: Transmission bearing removal (0.50 hours ) 2012 October 28: Remove spokes from wheels (3.25 hours ) 2012 November 02: Powder coat prep (0.35 hours ) 2012 November 03: Frame prep (1.25 hours ) 2012 November 07: More frame prep (1.50 hours ) 2012 November 08: Drop off parts to be repaired (2.00 hours ) 2012 November 10: Clean replacement cylinder head (0.15 hours ) 2012 November 14: Drop by Bronson's house (2.00 hours ) 2012 November 15: Cylinder stud (0.10 hours ) 2012 November 15: Make new tabs (1.00 hours ) 2012 November 19: Cylinder stud revisited (0.10 hours ) 2012 November 19: Pick up repaired frame (1.50 hours ) 2012 November 20: Frame finishing, cleaning (3.00 hours ) 2012 November 21: Drop off parts at Arizona Powder Coat (2.00 hours ) 2012 November 29: Order new bearings (0.00 hours ) 2012 December 03: Drop off parts at my machinist (2.00 hours ) 2012 December 07: Pick up parts from Arizona Powder Coat (2.00 hours ) 2012 December 08: Unwrap powder coated parts (0.50 hours ) 2012 December 10: Clean transmission parts (2.00 hours ) 2012 December 10: First attempt to get a polish and chrome estimate (1.00 hours ) 2012 December 10: Getting ready for a trip to the polish and chrome shop (3.60 hours ) 2012 December 10: Ship small triangle cover to Timbucktoo Machine (0.50 hours ) 2012 December 11: Drop off polish and chrome parts (1.00 hours ) 2012 December 12: Acid wash engine and transmission cases (4.15 hours ) 2012 December 13: Polish spokes and nipples (2.30 hours ) 2012 December 13: Ship gas tank (1.00 hours ) 2012 December 14: Clean threads on all nipples (0.50 hours ) 2012 December 18: Starter disassembly, etc. (2.00 hours ) 2012 December 31: Triangle arrived back from Timbucktoo Machine (0.00 hours ) 2013 January 03: Pick up polish and chrome parts (1.00 hours ) 2013 January 03: Valve guides ordered (0.00 hours ) 2013 January 05: Valve guides arrived (0.00 hours ) 2013 January 07: Dropped off valve guides (2.00 hours ) 2013 January 11: Gas tank delivered (0.00 hours ) 2013 January 29: Visit the chrome plater (1.00 hours ) 2013 January 31: Bronson picks up my gas tank (0.00 hours ) 2013 February 01: Minivan repaired (0.00 hours ) 2013 February 01: Order side covers (0.00 hours ) 2013 February 02: Chat with Bronson about the gas tank (0.25 hours ) 2013 February 03: MGNOC breakfast (0.00 hours ) 2013 February 04: Contact Eric Lussier of Second Avenue Scooters (0.25 hours ) 2013 February 04: Side covers arrive (0.00 hours ) 2013 February 05: Pick up gas tank from Bronson's house (1.00 hours ) 2013 February 10: Purchased single gauge dash and speedometer (0.00 hours ) 2013 February 11: Remove broken petcock from tank (0.75 hours ) 2013 February 12: Check gas tank for leaks (0.50 hours ) 2013 February 14: Single gauge dash and speedometer arrived (0.00 hours ) 2013 February 15: Drop off tank at chrome shop (1.50 hours ) 2013 February 15: Speedometer sent out for repair (0.00 hours ) 2013 February 16: Cylinder head and connecting rods ready (0.00 hours ) 2013 February 19: Speedometer shop called (0.00 hours ) 2013 February 21: Call the chrome shop (0.00 hours ) 2013 February 21: Picked up cylinder heads and connecting rods (1.50 hours ) 2013 March 30: Rebuilt the starter (2.50 hours ) 2013 April 05: Forks (1.35 hours ) 2013 April 07: Wheel assembly (1.70 hours ) 2013 April 09: JB Weld (0.50 hours ) 2013 April 11: Powder coat clean up (1.35 hours ) 2013 April 13: Start on fork assembly, rebuild distributor (3.50 hours ) 2013 April 15: Purchase tap for fork tubes (0.00 hours ) 2013 May 02: Take tank to get leak repaired (1.50 hours ) 2013 May 08: Create a sacrificial gas cap (0.50 hours ) 2013 May 09: Take panel pattern and sacrificial gas cap to chrome plater (1.50 hours ) 2013 May 11: Assemble forks (4.00 hours ) 2013 May 18: Finish fork assembly and start on the generator (1.60 hours ) 2013 May 25: Finish wrapping the field coils, prep for TimeSert (0.75 hours ) 2013 May 27: Begin transmission assembly (3.65 hours ) 2013 June 08: More transmission work, begin engine assembly (3.50 hours ) 2013 December 11: Drop off more parts for polish and chrome (3.00 hours ) 2014 January 10: Pick up parts that have been polished and chromed (1.50 hours ) 2014 March 24: Resume work on transmission assembly (2.00 hours ) 2014 March 25: Found missing transmission part (10 minutes ) 2014 March 26: Clean up metal sealing ring for layshaft seal (30 minutes ) 2014 April 08: Attempt to torque layshaft nut (10 minutes ) 2014 April 12: Transmission complete (60 minutes ) 2014 September 22: Drop off more parts for polish (1.50 hours ) 2014 September 24: Pick up parts that have been polished (1.50 hours ) 2014 October 01: Drop off tank at another chrome shop (2.00 hours ) 2014 October 04: True front wheel (1.60 hours ) 2015 February 20: Rebuild handlebar switch (2.25 hours ) 2015 June 07: True front wheel (2.50 hours ) 2015 August 08: Replace spline assembly in rear hub (1.00 hours ) 2015 November 01: Assemble rear wheel (1.35 hours ) 2015 November 13: Clean rear drive, true rear wheel (4.50 hours ) 2015 November 23: Pick up tank from chrome shop (2.00 hours ) 2015 November 29: Assemble and prepare parts for zinc plating (4.00 hours ) 2015 December 01: Drop off parts to be zinc plated (2.50 hours ) 2015 December 06: Rear drive thread repair (0.85 hours ) 2015 December 11: Pick up parts from zinc plater (2.50 hours ) 2015 December 12: Work on generator (2.00 hours ) 2015 December 13: Work on generator (3.00 hours ) 2015 December 17: Flatten engine case and sump (2.15 hours ) 2015 December 17: Work on generator (3.70 hours ) 2015 December 18: Front main bearing (1.50 hours ) 2015 December 18: Work on generator (0.85 hours ) 2015 December 19: Engine assembly (2.00 hours ) 2015 December 20: Engine assembly (1.50 hours ) 2016 January 31: Triple tree, oil pressure relief valve, etc (4.50 hours ) 2016 February 07: Connecting rod shells, oil pump, swing arm (3.00 hours ) 2016 February 20: Install universal joint, misc (1.25 hours ) 2016 February 21: Clean carburetor parts (2.00 hours ) 2016 February 28: Clean throttle and polish small bits (1.00 hours ) 2016 March 06: Throttle and rear brake (1.50 hours ) 2016 March 27: Front brake (1.00 hours ) 2016 March 28: Engine assembly (4.25 hours ) 2016 April 24: Engine assembly (3.00 hours ) 2016 April 30: Generator studs, transmission alignment, clutch hub (1.50 hours ) 2017 November 15: Engine assembly (3.30 hours ) 2017 November 22: Initial assembly (4.50 hours ) 2017 December 01: Assembly and testing for proper fitment of components (8.25 hours ) 2017 December 10: Assembly (3.50 hours ) 2017 December 15: Assembly (5.00 hours ) 2017 December 16: Assembly (5.00 hours ) 2017 December 18: Side covers and breather (1.50 hours ) 2017 December 20: Transmission shift linkage (0.25 hours ) 2017 December 22: Side covers (1.50 hours ) 2017 December 23: Cables and side covers (2.00 hours ) 2018 June 23: Test fit all painted parts (4.50 hours ) 2018 June 30: Remove left cylinder head (0.50 hours ) 2018 July 01: Drop off painted parts and cylinder head to be repaired (2.00 hours ) 2018 July 20: Pick up repaired cylinder head (1.00 hours ) 2018 November 19: Pick up painted parts (2.00 hours ) 2018 November 23: Install painted parts (4.00 hours ) 2018 November 24: Install painted parts (3.50 hours ) 2018 November 30: Install generator and breather (0.50 hours ) 2018 December 07: Install generator and breather (0.75 hours ) 2018 December 17: Brakes, spokes, old header pipes, etc. (3.00 hours ) 2018 December 18: Tires and lower from jack (4.00 hours ) 2018 December 19: Create wiring harness and misc (5.00 hours ) 2018 December 20: Install wiring harness (3.00 hours ) 2019 February 10: Rebuilt ignition switch (3.00 hours ) 2019 February 23: Install wiring harness (2.00 hours ) 2019 March 10: Airbox (1.00 hours ) 2019 September 02: Wiring (3.00 hours ) 2019 September 04: Mufflers, rear brake switch, generator cover (2.50 hours ) 2019 September 06: Install speedometer and dash (2.50 hours ) 2019 September 15: Spark plug wires (1.50 hours ) 2019 November 30: First start up (4.50 hours ) 2019 December 22: Reflector, shift lever, generator (4.00 hours ) 2019 December 23: Neutral switch, parking lights, generator (3.50 hours )