What could possibly go wrong?
We’ll be re-using the Guzzi gauges, and rather than try to cut complex holes in the full length dash panel (aluminum) I’m going to copy a page from the Mini we had and create a dash “pod”, or a separate panel to hold the gauges which is removable to access the gauges, without having to remove the entire dash. I went back to my Manufacturing/CAD/CAM roots, and designed a dash pod using Autodesk, did a milling plan using Meshcam, and then cut it out on my Nomad 883 desktop CNC. Metal is 6061-T6.
Not knowing whether this project was actually going to happen, I hesitated to strip the donor bike because it is (or should I say was) a solid runner. If things went south, I could still sell the bike. But given things look imminent, let’s commit.
Starting with a solid runner is important, as knowing the bike ran before you took it apart is a very significant data point later. If, after you reassemble, it doesn’t run – you knew it ran before, so it’s clearly your fault. If it didn’t run before, or its condition is otherwise unknown, there are all kinds of gremlins you may chase down before you get on stable footing.
With all the auxiliary items removed, the cradle unbolts from the top-frame, and the top frame lifts off the cradle leaving the engine and gearbox behind. Quite ingenious.
Stunning how much crap was on this bike in terms of trim, and chrome, and heavy junk.
Engine is on the bench along with the gearbox. Seals ordered (might as well), plus some other items. Front cover and alternator cover paint had bubbled, so those are with a friend to be powder coated before re-installing.
