93 Years Can Be Hard on Steel

One of the projects that was undertaken when preparing Lydian for the Cannonball was to make sure the frame was up to the task. These four-cylinder motorcycles were used hard during their day…many as Police bikes. They were smooth and fast and able to out-perform many automobiles of the 1920s and ‘30s. Primitive roads, minimal suspension and rapid speeds means powerful forces fed into the forks and frame. So, more than 90 years later, I wanted to be sure that we could go straight down the road with the suspension working as it should. The parts were disassembled and laid out for inspection:

Frame and fork parts for inspection

First up: fix the front forks. When we looked closely at the major and minor forks, it was clear that all was not right. In the photo below, you can see that the forks had suffered…bending back and hitting the head stock of the frame. Once straight, proper geometry was assured.

Forks hitting the headstock

Next up: foot boards need leveling. When you are riding day after day, it is important to have flat, level foot boards. Ours needed some straightening and welding to give proper position and feel:

Leveling the footboards

For the seat, I removed the original pan with its cracked leather and substituted the old-style Harley seat which I had used on the 1917 Henderson. With its springs and sheepskin cover (provided by Frank Westphal), comfort would be as good as a rigid rear end can offer.

Today we worked on packing and loading tools, spares, generator, cooler (for beer) and work lights. Hopefully the nightly maintenance will not be too demanding. Tomorrow, we will load in both the 1917 and 1928 bikes. Almost ready to start the drive to Michigan!

Resurrecting the Mighty Side Valve

Unlike the Detroit-era Henderson four cylinders with their inlet-over-exhaust valve arrangement, the Chicago-era bikes were side-valve “flatheads”. The engineering of combustion chambers was evolving rapidly in the 1920s and particular accolades are given to Harry Ricardo, a British engineer. He developed a combustion chamber design that minimized pinging (aka, knocking) with improved fuel turbulence and combustion, smoother operation and greater horsepower than previous designs. Numerous motorcycle, automobile and airplane companies licensed the Ricardo design including Schwinn for the Henderson Deluxe. Finding some cylinders with Ricardo chambers in good condition was accomplished my our engine builder, Mark Hill of 4th Coast Fours.

The assembly of our ‘28 engine incorporated some enhancements used to overcome certain design weaknesses. Most importantly, we need to assure reliable delivery of clean oil at adequate pressure to the crankshaft, pistons, rods and transmission. The oil pump was modified to provide additional lines to an external, spin-on filter cartridge and to the main shaft of the 3-speed transmission. That main shaft was line drilled with oil outlets into the shaft bearings. Here is a picture of the rear of the engine showing the shaft and gears:

Transmission

The crankshaft is supported by three main bearings but this engine got “special treatment” as shown here with Carrillo rods and custom bearing shells:

Next up, frame repairs and preparation.

Motorcycle Cannonball 2021

Here we are. After three years, it is time to ride old bikes with old friends down 2-lane back roads in rural America. After the 2018 Cannonball, the 1917 Henderson (aka, Bluebird) received an oil change and was allowed to rest for 2.5 years. The distraction? Our 1928 Henderson Deluxe motorcycle – which we had planned to ride in the 2020 event. You know what happened…COVID de-railed the timing which was a good thing as our engine was not complete at 4th Coast Fours in upstate NY.

The goal with this blog is to bring you along from Sault Saint Marie, Michigan out to Myrtle Beach, SC and then down to South Padre Island, TX. You can read about the ride and see the planned stops at the Cannonball website: https://motorcyclecannonball.com

We are finishing last minute bike adjustments and packing the Sprinter for the drive from Seattle to Michigan over the next few days. While on the trip across the upper mid-west, I will share some details and photos of the ‘28 Deluxe (aka, Lydian…see if you get the connection) as she was made road-worthy. Here we are during some initial break-in miles on the lovely Vashon Island.

Getting some initial miles on Lydian

I look forward to the ride…feel free to share!