used a 3 part tank prep and sealer inside the tanks after welding on the tank strip mounts,still waiting on the emblem mounts to arrive,
 

Thanks i'm loving this project. I remember 30+ years ago watching my BIL doing a U model from scratch, including making the exhaust out of 2 inch pieces.

May I ask what that hollow, second looking tank inside the main one is?

that football type bulge is (fuel tank ) left side of bike . ,
the  tank with indent (oil tank ) right side tank.. it has 3 oil line fittings under side as well as a drain plug,
unusual looking tanks and hard to find...
 

cut the piece l needed of the large hunk of alloy with a hack saw, traced shape on it using the gasket, cut it out and sanded to shape by hand, threaded the 3 holes,mounted it back in the lathe to machine the face,

bolted it to the wla manifold,didnt use the gasket or thick spacer ,used 3 bond to seal it instead,

since there will be a rubber boot slid over the 40mm shoulder and to the carb,that will stop the heating of the carb. so i'll save the gasket for when or if l decide later to fit a linkert in place of the mikuni.

 making up some handlebars to run the internal throttle & internal advance/retard. these were an old set of 06 softail standard bars,

cut in half and widened a bit..

l used an internal throttle kit(aftermarket) both ends of the bars after cutting about 65mm of end of bars,
spot welded the sleeves on instead of the (1)grub screw the manufacturer supplied , to hold the sleeve in place,
ive used the grub screw system before and found it a flimsy way of attaching the sleeve.welding takes all movment out a good rigid mount. 

since its a throttle on the left side bar the advance/retard will work in reverse,,,thats the trade off..

bought a set of grips from brit-am , they are the correct look and good quality,
turned up some bar stock and press fitted them to the ends of the grips/spirals.
the carb arrived and l have loosely fitted it up to work on the internal throttle cable set up,
it took the best part of a day to get it all right ,it works as it should...

the name plate mounts arrived from geelong harley today,  l can finish the tanks

This thread is one of the most interesting I've seen!

the cylinders are back,
l can clean & assemble next..(old photo shown)

some washers, bolts,keys were missing or damaged on the bike ,

hack saw and file to cut and shape the keys..

l had the right thread of button die and some hex steel to make the timing inspection bolt and oil drain bolt under side of right tank, (both same threads)

& some brass for the crush washers..

4 new valve guides fitted and reamed to size, + 4 new valves and seats re-cut to suit..

cut a piece of 3mm plate and welded it to an old clamp for the valve spring compressor , it works..

the cylinders where surfaced for a good flat mate to the heads,the dark surface is where they have been die grinder-ed,and a little bit lower,
 relieved for flow,they were like that, well see how it runs?

the heads were skimmed as well,both cylinders and heads had minimal amount cause there was a bit of warp in both..good now..

the cylinders were not bored ,honed only and the existing pistons and a new set of piston rings used..

Great post, Im enjoying reading your progress.  

pretty much there now, motors in has oil & fuel,

wiring done,used some of this and bought some,

front/rear lights/brake light,dash lights, all good...new 6 volt coil,new 6 volt horn,

sifting through speedometer parts stash, should have enough to make the correct one for this,

 a green military face or a civilian face ?? civi face...

had most parts to make it, most is all s/w , except the repop face(civilian) the pointer l made,& a couple of small bits in the trip meter return assembly.
a bit of surface rust here n there, scratch on the curved glass....many hours of fun... 
the chrome dash cover has extra holes in it,above and below the red&green,and the 2 in the middle, that will need attention..

Let me know when you want to sell her mate?

the bikes up and running,did 1 lap around the block ,back home for a few adjustments, easy to kick over and starts within a few kicks, the carb needs jetting its lagging,l bought a wla jet kit with the carb so will tinker with the mixture ,running straight 60wt oil it likes it,of course  the generator light stayed lit ,not charging,it was the only part left on the bike l havnt touched,

so will start with the generator its a 32e 3 brush 6 volt,  did strip it and clean it once l got the 2 sheared off bolts out,seen in above photo,
insides were gunked up with many years of gunk.thorough clean through out, washed and greased both bearings,brushes are good,no obvious damage or wear,hard to test without the right equipment, so put it back and tried it, light still on, 
 

did a test  on the mechanical relay,cleaned and adjusted the points as the book shows, seemed to be o.k. but light still on..

had this 6 volt (electric franks regulator) on a panhead model 52 generator,on the shelf, worth a shot, that was the problem the mechanical reg.its charging now,
these bolt to the end of the generator usually, not with a foot clutch set up its in the way.  a temporary mount bracket made to hold it on the down tube,its a bit un sightly but will do ...

Well done K. You are very resourceful. Helps to have a few bits and pieces around the place. Keep the pics coming

yes,got lucky with the reg, forgot l had it,dont have 6 volt parts laying around ,thought id moved the elec frank on years ago..

One of the best tjreads here.  Please keep it coming, this reminds me so much of hood memories as a teen.

Bike ran good on the 75th anniversary ride last year !!,l dont have  photo's of the event  to show , theres plenty on face book n other social media,l think it got a plug in heavy duty mag? it was a well organized event with a good turn out of wla's couple of wr's couple other models of the era,some guys have had their bike for 40 years,about 60 in total turned out, thundering through out back NSW towns and country,what a sight!

congrats on the out come, nice work.