Been working on other bikes but got back to the Pan. Pulled the front wheel and tire.. It's kind of an odd bird with the disc in front with star hub.. Front wheel cleaned up pretty well. It did need rollers. Wheel has Buchanan SS spokes that were way too tight but was able to loosen without sripping or seizing the nibbles. The hubs and rims appear to be aftermarket.. The grease nipple is directly in line with the brake bolt hole. WIF? Wheel trued right up.

 

When I started to put the front end back together I found that the axle didn't line up on the 2 fork lowers. The hole through the left lower was off. I guess it was one of the reasons why pulling the front wheel was such a PITA.. The axle is straight and if I clamp it in the right lower, the end lines right up with the hole in the left.

With the spacer nut tight, I could still slide a feeler gauge between the upper part of the spacer and the lower.

 

I have some cheap adjustable reamers that work OK. I made an extension that allowed me to line ream the right lower to the left..

 

After some research, I figure out what was going on... It wasn't HD that miss drilled the hole but someone else. The finish inside the hole looked factory. When the front end was modified for the disc brake, the lower fork hole was machined to fit the brake drum spacer. What was funky when I took it apart was the seal setup on the disc hub.. The stock drum spacer had ridges, one to connect to space the wheel spacers and the other to hold the drum backing panel in place. The ridges are / were 1 1/4 inches in diameter and the sel was setup for a 1 1/8 inch shaft. I machined off the panel ridge and made a 1 1/8 inch spacer so the seal fit reasonable. Looking at the now I suspect that the best way to fix things would be to make a new drum side spacer 2 pieces. That way in order to remove the wheel, I would not have to unbolt the disc from the wheel to remove the wheel. One spacer would simply fit in the fork leg to bring the hole to axle size (5/8) and the other to fit into the wheels spacer, go though the disc brake and setup the side to side spacing..

 

Subscribed, Love to watch you guys work old iron.

 

You get an A for the effort but - always a but - the adulators go into a multi piece in the fork tube held in place by a snap ring and its shimable up and down in some cases shims on top or the bottom - not everyone knows that

so the lower fork leg to tube location can be off from the multi piece that needed to be shimmed on one side and sometimes both sides so the leg length matches

 

"adulators" ... do you get those at a Sex Shop?

 

Played the shimming game with mismatched swap meet legs before. Another long buried memory from the broke days

 

So the forks can be different lengths. I checked that.

Right now I don't see where I failed anywhere. If the forks were different lengths, then placing the axle in either fork lower so that it pointed at the other side would show a mismatch on both sides. I only got a mismatch on one side. The axle is straight.

How many shovels have you seen with a 13/16 hole in the left side?

I found what I believe is a shovel front axle. It's diameter is 3/4 for most and 0.667 on the end that goes through the left fork. The left I have one I have uses a the brake sleeve on a pan that is 0.813. I would expect that the stock disk brake shovel has something like a 0.670 hole in it.. Not larger than 0.813.

 

we see this all the time and most times a adjustment that the center screw thread location in the bottom is movable up or down can and does fix the issue

we just use a simpler approach in that adjustments can and usually fixes the issue - is all - your problem is you have way too much talent and time < the time is my issue cant make a guys bill stupid expensive what you did in my shop would have been a 1000 dollars alone to do that - its your piece and i get it

i over spend all the time on something for me — i get it .