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banana4monkey

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Reply with quote  #1 
Finally started the reassembly of the Diablo Rouge. I put the tractor portion on the lift and started with the undercarriage. I put the drive assembly on first and then the bumper. Next I drove in some new ball bearings for the idler sprockets and put the idler sprocket assembly together. Then it was on to the boogie wheel assemblies. I took a break and will probably work tonight until I have the tracks installed and most of the under carriage complete.

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banana4monkey

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Finished up the undercarriage this morning. I installed the remaining boogie wheels and exhaust. I then mounted the snow flap and then installed the tracks and adjusted the tension. The tracks used on this sled are split tracks. Hinges and pins are used to connect the tracks. So far so good.

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banana4monkey

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I spent some time last night assembling the Diablo Rouge. I put the brake caliper on first. This sled uses a mechanical disc brake system. After that I hooked up a chain fall and rigging to support the motor. This is a little overkill but it is nice not having to hold the motor while I mounted it to the frame. Spending a little extra time for set up can save a lot of paint scratches and extra rework later. The motor is suspended over the tractor body using 4 rubber motor mounts. This is only a 15 HP 300CC single cylinder so it works. Anything much bigger would need extra reinforcement. I next put the gas tank in and then I put the handle assembly on. This assembly is what the top motor mounts bolt to. It is starting to look like something now.

 

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Brake installed

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rear motor mount installed

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Motor suspended by chainfall

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Motor, gas tank, and handle installed. It's starting to come together.

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banana4monkey

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Reply with quote  #4 
Continued work on reassembling the tractor portion of the Diablo today. I mounted the hood hinge, added gear oil to the chaincase, and mounted the front dash panel. I also got started on the wiring and should finish that later tonight. So far it is going back together great. These old machines are so simple - it is a nice change of pace.

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Front hood hinge mounted

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adding full synthetic gear oil to chain case

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Mounted dash.


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banana4monkey

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I installed the wiring on the Diablo last night. First thing I did was lay out the wiring to see what needs to be repaired or replaced. After looking at the simple wiring system this sled uses I decided that it was a no brainer to replace all of the wiring. I also used a new light switch since the old one was broken and new 14 gauge wire. I like to use quality wire, solder all of the connections, and use shrink tubing. The solder and shrink tubing tend to last longer than just using crimped connections.  Having all new wiring is a positive selling point on such an old machine. I will keep the original wiring and set it aside in case the buyer wants it. Some people are big into originality. I did have to change the color of some of the wires. I remember I used to be able to buy all different colors of wire. All the stores near me only had black, red, white, and green.  I also installed the light and ignition switch in the dash. The whole job took about two hours and this was a fun task so I was really taking my time. I still need to wire the lights up but this will wait until the hood is installed.


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Old wiring

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Crimped connection

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Set up in clamps to solder - This tool is simple and works great.

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Soldered crimped connection

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Install shrink tubing

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melt shrink tubing with lighter

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New wiring all set up and ready for installation

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New sticker for dash switches
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Light and ignition switches installed.

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Wiring installed.




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banana4monkey

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Still pluggin away. Hooked up the brake, put the stickers on the dash, installed the pullstarter, put the choke cable on, and polished the gas cap. IMG_4258.JPG  IMG_4259.JPG  IMG_4265.JPG 
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banana4monkey

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Reply with quote  #7 

I installed the heat shield and the carb on the Diablo Rouge last night. The heat shield makes bolting down the carb difficult due to access. I had to use a crows foot wrench. Next is hooking up the throttle cable, choke cable, and gas line. Getting closer to cruising around the property on this vintage machine.


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Before

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Heat shield and carb installed.

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banana4monkey

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Before I put the hood on I want to finish up some details while I have a lot of open space. I got the carb, throttle cable, return springs, and fuel lines installed. I then moved on to polishing the primary and secondary clutches. I used a scotch brite wheel and a die grinder to take off all the varnish. Having a flow regulator for a job like this is important. If the speed is too high the wheel will come apart. After the scotch brite I used the bombs away polish to finish the clean up. Little details like this are important to a restoration in my opinion. Dull dirty components stick out when the surrounding parts are clean. Next is hood installation. Getting very close to completion.



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Much better

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banana4monkey

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Reply with quote  #9 
I spent some quality time out in the shop today. Ambient temps are below zero so it was a good day to stay inside. I assembled the hood of the Diablo, installed the nose piece, and wired the lights up. Now it's getting close to completion. I need to put the decals on and then get it running and driving again.
See pics below of progress.

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Hood with screen and cover installed

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nose piece and lights

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Rusty bulbs. These were replaced with new bulbs.

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Wiring for lights all hooked up
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Hood installed on tractor

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banana4monkey

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Reply with quote  #10 

I had a lot of fun putting the decals on the Diablo yesterday. This is one of my favorite parts of the restoration since I typically wait do this at the very end. I ordered the complete decal kit from gogodiablo.com and it was a quality set. I took pictures of the original decal locations before I started the restoration so I had a good reference. I then marked the body with a pencil to help me locate the correct position. Crooked or off center decals look terrible so make sure you get it right. I used sticker on when putting the decals on. This is a big help. I will do a review on this product so you get a better idea of what it does.http://forums.whatsintheshop.com/post/sticker-on-decal-application-spray-review-allegany-county-ny-7301988?pid=1286237805#post1286237805


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banana4monkey

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Reply with quote  #11 
I wired up the taillight on the diablo Rouge this morning. This represents the last task left before a test ride and touch up. I had the test ride and I tell you it was fun. See attached video of me rippin around the back yard on this vintage machine.

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Hookin up the taillight

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All lights work

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The first time this Diablo has seen snow in over 20 years.


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MR. X

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Reply with quote  #12 
Good work on the resto. It came out great.
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banana4monkey

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Reply with quote  #13 
Just wanted to post some finished pictures of the Diablo Rouge. I am in the process of getting it registered and then I am going to put it up for sale.

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