3rd wheel

Been doing at least a little bit of work on this every day. I've mounted a couple of my electrical things, and I think I have a plan for the rest of them. I'm working on a ignition switch bracket that's a little longer than a original hardtail bracket. And I have my tracing of the brake light switch bracket.
My plastics are due here on Monday. I ordered a 90s CT70 rubber "suspension" that I think (hope) I can make work with the dratv CDI. Probably a week out, for that.
My motor is hangin in there, but I'll probably drop it back out before I weld the brackets and touch up paint. The carb/intake might work as is. It's pretty close at the top, and I forgot to try removing the topset while it was mounted. If I can pull the slide out and get it back in without having to remove the carb from the engine...I'll be good with that.
Haven't tried fitting the foot bar, or the exhaust yet. Probably should do that while the motor is in there.
The clutch cable that came with the clutch cover kit is gonna work. I just had to modify the original clutch lever slightly. Otherwise, the length and all seems good... I'm getting pretty lucky here with things fitting, and working, fairly easily...(knockin on wood.)

I got a really good start on my wire harness yesterday. And I have a couple of my brackets made, almost ready to weld on and paint.

I had the ignition switch mount laid out wrong at first...almost goofed and cut it the same size as my original piece/pattern.

This is the second time I've had to rebuild a wire harness. I kinda like it. It really forces you to have to sort out how things work. VERY good learning experience. Maybe if I do it 5 more times, it'll stick, and I'll have it ALL figured out

Kirrbby just a thought here - if your making your own harness why not move the key switch up top between the handle bar clamps like Honda did on later bikes? Makes it easier to get to and keeps it out of any potential slop.

kirrbby said:

This is the second time I've had to rebuild a wire harness. I kinda like it. It really forces you to have to sort out how things work. VERY good learning experience. Maybe if I do it 5 more times, it'll stick, and I'll have it ALL figured out

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I've thought that. In reality, unless you're set up for production this is really tedious, time-consuming and painstaking work. It seems easy enough and quite satisfying...once you're done. Dive back in months, or years, later and you may conclude that Murphy was an optimist. That said, I agree with you on the learning experience. Once you sort-out the basics of these systems well enough that you can access that info from memory, troubleshooting & modifications become much less daunting...I'll stop short of saying "easy" - you know how electrical diagnoses can be.

Been a few days since I've been able to work on my wire harness, but I am making progress with my taillight bracket.
I wasn't happy with the Z50 style taillight.
I read that Honda had offered a optional light kit for early ATC70s which used a ATC 90 taillight with a bolt on bracket. So I picked up a taillight, and I'm kinda copying the bracket.
The TL is a TL only...no brake light provisions. So I'm thinking of rigging it up with a couple tiny LED light...bulbs/diodes. One for TL, one for BL. But that might end up being more trouble than it's worth.

I'm pretty proud of my TL bracket so far tho.

Looks like an old dome light from a car. With a red lense.

Nice job on the bracket.

Tripod said:

Looks like an old dome light from a car. With a red lense.

Nice job on the bracket.

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Thx Tripod.
The TL is actually a used part from a 70s ATC 90. Same one Honda offered on the pages I posted above. The bulb socket looks just like the ones in a K0 CT70 speedo. Single filament bulb.
And, you're right. The housing looks VERY much like a dome light.

I needed a piece of edging for my seat pan. The plastic channel to protect the seat cover from the sharp edge. I had a old one from a CT70 seat but it came up about 2" too short...believe it or not.
I shopped around...dratv, nevc, but didn't really like what I was seeing. Didn't like that I couldn't see it better in their ads. I wanted dimensions, and I wanted to see the shape of it, etc.
Anyway, I found this on Amazon. I was happy with the dimensions, especially the 25' length.
I should get it tomorrow. I'll let y'all know what I think after I get my seat recovered.

https://smile.amazon.com/gp/aw/d/B00NL4BXEE?ref=ppx_pt2_mob_b_prod_image

Gary said:

Kirrbby just a thought here - if your making your own harness why not move the key switch up top between the handle bar clamps like Honda did on later bikes? Makes it easier to get to and keeps it out of any potential slop.

Click to expand...

I did consider that briefly Gary. Make a little dashboard mount.
I thought I could mount the key switch, and maybe put a neutral indicator light in it too. I thought it might be a good way to draw some attention away from the extra room in front of the tank too. But I was worried that what I could make, might not be very attractive...right up front and center. My mount would need to be attractive, because a key switch is not. So I took the easier route, which also looks kinda... stock Honda design.

One reason that I chose to use a Z50 key switch, is because it has the rubber cover...made to be exposed and keep some of the slop out. Hopefully it'll work out.

I still haven't finished with my wire harness, and still haven't welded my tabs on.

I use automotive door edge guard Kirb.

OLD CT said:

I use automotive door edge guard Kirb.

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I've seen some...but it was a lot bigger than I wanted. It seemed like it would be too tall and interfere/partially cover, the pointed tabs for attaching the cover. I like the stuff I bought very well. I'll post some pics when I do my seat. It's nice and small. Very close to the size of the original. But it's more rubber than plastic, the original stuff is more plastic. I figure I'll need a little glue to hold it in place.

I finally got my ignition and brake light switch tabs welded on.
Removed the motor and most of the electrics so I could roll the bike over, and stand it up. Welding went fine.
I tried to locate the BL switch tab...in a good spot. But I didn't install the exhaust for mock up. Well the exhaust comes pretty close. I think it will be ok tho. It might need a little heat shield, and/or a clip to hold the wires away.
Clutch cable too. I was expecting that tho.

The muffler is in the way of my bracket for the tail light too...back at the grab bar. Forgot to picture it. It'll be ok, but right now the outer bolt for the TL bracket clamp hits on the muffler. A sure rattle, and scratch.

The "wave" shift lever from spanglers won't work with my setup unless I cut and reweld it. I'll post more about that later too.

My wire harness is ready to wrap. Then I have a buttload of ends to crimp on...basically ALL of them. I'm even going to change the ends on the ignition switch so I can use a smaller plastic plug.

I think I have everything I need now, bought and received. I just have a lot of work to do to be ready to ride.

I'm working on my wire harness.
I was going to tell a little story about these 3 terminals for my taillight, but I think this picture tells the whole story.

Forget to slide on the sleeves before crimping.....twice?

allenp42 said:

Forget to slide on the sleeves before crimping.....twice?

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That was my guess too.

I recognized it because I have done it myself ...several times. Even twice more than once. That's why I usually order more terminals than I expect to need for months because I know I will screw up a few times along the way.

That's exactly right...like a big dummy, I did it twice. I did get it right on the 3rd try tho. I have all the ends crimped onto the harness now. I still need to do the ignition switch. Then, I'm gonna have to talk myself into soldering them all. I'm about over the wiring. I need it done, I need to move on.
Maybe if I hit it hard today after work. 6 more ends on the switch, solder everything, wrap it and strap it. Suppose I have to test thru it too.

I'm changing the big plug on the ignition switch to the small 6 spot CDI type plug. I want the plug to end up under the tank. The big one would have been a problem.

I'm planning to put ends on for the battery after I get the harness wrapped and in place. Hopefully make it neat and tidy...have a fuse holder to deal with there.

Still have work to do for the TL too.

My plan for the neutral light will not work. Gonna need a NEW plan. Maybe a indicator light in the HL bucket, or pick a light, then make a mount similar to the K3.

None of that will keep me from riding this trike tho. Needs to be done, but not a show stopper.

35 terminals crimped on, plus the 6 that I goofed. I didn't solder any of them tho. Hopefully my crimps are good. I did solder all of the wire splices tho.
I'll lay it in and test thru the lighting before I wrap it. Then I'll celebrate, and move forward with some funner stuff

No need to solder those crimped on terminals kirrbby and actually in some cases bad. What has been found is that the solder actually makes the wire too ridged and can fatigue crack. Aircraft and cars etc are all crimped. In the telephone business all our splices were wire displacement no soldering at all. On a side note what brand and model is your crimper? Your workman ship with it look great and I have been thinking of getting one for some Delphi connectors.