1977 Mugen 125 # 12 Steve Wise replica build

Working on more parts that are impossible to find. These are going to be steering stem nuts for mounting Simons forks to the 77 Honda Elsinore type frame.

The frame is painted. I used Limco single stage polyurethane automotive paint. I am going let it cure for about a week before I start doing any reassembly of the bike. Now I will start cleaning up small parts. Also, I have to prep the gas tank and get it ready for paint.

Got the tank repaired, primed and ready for paint. Planning on painting the tank tonight

Got the tank painted last night. I’m really happy with the results. I went ahead and painted a 79 gas tank as well for a future project.

I also worked on the top steering stem nut for the Simmons forks last night as well. Finally, finishing them up. Using a rotating table on the vertical Mill to cut the hexagon top to fit a 1 inch wrench.

I got the frame hung up in the shop ready for reassembly.

The very first part to go on the frame… Lol

I’ve installed the swing arm for a test fit. I will have to move. The shock mounts back to the proper position before the final, mounting.

Also installed the NOS Simmons fork triple clamps.

Next I will install the completely rebuilt Simons forks.

The Thor swing arm that I was able to get was made for the forward mounted shorter shocks for the CR 125. And I am using the 17.5 inch Shocks.

So I had to modify this swingarm. Cut off the shock mounts and move them to the rear in the proper position to except a 17.5 inch shocks in the lay down position. 

 It’s a very time consuming large modification. But I have no choice.

After cutting off the outer shock mound, I had to modify the top edge of the swing arm and remove the material all the way back to where the new rear shock mount will be.

After the swing arm modification was finish, I had to mock  up the swing arm into the frame and test mount the shocks with clamps to locate the correct position of the new shock mount hole.

After locating the whole position, I drilled and tapped the swing arm to accept the new shock mount position bolt.

And and then did a second mock up, mounting the swing-arm in the frame and bolting the shocks into place and test fitting the outer shock mount bracket. Which I will have to weld on this weekend.

I’m pretty happy with the results.

I made a couple of spacers to bolt in to the rear shock mount of the swing arm to hold everything into place. While I weld back on.

Last night I was able to get out into the world shop, and TIG weld the rear shock mount back on.

The Swingarm is finally done. Got it cleaned up and ready to install for the final time.

I had to custom make swingarm pivot bolt and rear axle and chain adjusters.

The swingarm is finally installed onto the frame for the final time. Very happy with how everything came together.

I was also able to install the Simons forks last night as well, with custom-made front axle and brake stay.

Front and rear suspension is installed. And test fitting the gas tank. The bike is actually starting to look somewhat like a motorcycle.