Well gentlemen, it was a productive evening.
I did not take a bunch of pictures.
Drilling the cases
Piece of cake. I honestly expected it to be a bit more eventful, but it went really well. I started the holes with a 7/8" twist bit until I had it about a 1/4" deep. Hindsight, I could have stopped with that one at about 1/8". At that point I could switch to my 3/8" Dewalt (versus a more cumbersome 1/2" drill that is older than the 360). With the 3/8" drill I had a 7/8" hole saw in it. I found that cut much smoother and faster than the twist bit. Most importantly, it did not grab. Afterwards, I cleaning out all the shavings and pushed the bushings in. They needed a tap with the hammer each. So, the holes stay tight enough.
Putting the case back in the frame
This was even less eventful, it dropped right in, I got the swing arm lined up and pushed the bolt through with a bit of wiggling and adjustment alignment of the parts. The engine is big in the frame but fitment is as would be expected by two engines so closely related.
Intake boot
Since the engine dropped in so nicely, I figured I'd take some time and see about opening up the intake a bit as Walt had shown way back. After searching for it, I found his pictures in a TT thread. I wasn't really sure how much I should try to open it up, so I kept it pretty small and matched the two pieces.
Cooling hoses
I had already picked up a few feet of 5/8" coolant hose and the lower hose from a 2008 250, the plan was to remove the thermostat set up on the 300, but this project came along, so I installed these tonight. You can see in the picture above if you look real close. The bottom hose is right on the powervalve, so it fits pretty tight, but it fits. The top hoses I cut at 12.5" inches in length and that seems to let them do their needed bends without and kinking.
Lectron Fitment
This part had me a bit panicked. I had to undo the top bolt of the shock to get the carburetor in place. It's a tight fit, so I'm glad I had already decided to use the Lectron, as I should never have to take it out. I can still access the top of the carb to get in and adjust the metering rod.
Countershaft Sprocket
The 360 had a 15 tooth sprocket on it. That's nice and all, but the largest you can fit on the 300 frame is a 14 tooth. I found some 13s I had laying around until I realized the spline is different and they will not fit. Looking through the box of extras from the 360 I came across a 14 tooth, score! On it went, I now have clearance for the sprocket to not have to worry about the swing arm.
Clutch cable
This is my current problem. The cable from the 360 had a 90 degree bend which is needed to clear the water hose. That cable is about 8 inches shorter than the 300 cable, so I was messing with routing it along the left hand side, straight up. That's when I realized it had a much different cable end that wouldn't work with my ASV setup. I grabbed the perch and lever from the 360 and realized that that lever was way too long to fit my cut down bars and my Cycra probends. I have a spare 300 cable, so I'm going to see about pulling the end off that, shortening the sleeve a bit, and putting the bend on it. Hopefully that can get me by for the time being, and I will get measurements from that so I can try to get a terminator cable from Motion Pro made up.
CDI and Coil
There isn't a good mount in my opinion on the 300 from to fit these electronics. I'm working on making up a bracket. Nothing fancy, but I'll take some pictures tomorrow.
I did not take a bunch of pictures.
Drilling the cases
Piece of cake. I honestly expected it to be a bit more eventful, but it went really well. I started the holes with a 7/8" twist bit until I had it about a 1/4" deep. Hindsight, I could have stopped with that one at about 1/8". At that point I could switch to my 3/8" Dewalt (versus a more cumbersome 1/2" drill that is older than the 360). With the 3/8" drill I had a 7/8" hole saw in it. I found that cut much smoother and faster than the twist bit. Most importantly, it did not grab. Afterwards, I cleaning out all the shavings and pushed the bushings in. They needed a tap with the hammer each. So, the holes stay tight enough.
Putting the case back in the frame
This was even less eventful, it dropped right in, I got the swing arm lined up and pushed the bolt through with a bit of wiggling and adjustment alignment of the parts. The engine is big in the frame but fitment is as would be expected by two engines so closely related.
Intake boot
Since the engine dropped in so nicely, I figured I'd take some time and see about opening up the intake a bit as Walt had shown way back. After searching for it, I found his pictures in a TT thread. I wasn't really sure how much I should try to open it up, so I kept it pretty small and matched the two pieces.
Cooling hoses
I had already picked up a few feet of 5/8" coolant hose and the lower hose from a 2008 250, the plan was to remove the thermostat set up on the 300, but this project came along, so I installed these tonight. You can see in the picture above if you look real close. The bottom hose is right on the powervalve, so it fits pretty tight, but it fits. The top hoses I cut at 12.5" inches in length and that seems to let them do their needed bends without and kinking.
Lectron Fitment
This part had me a bit panicked. I had to undo the top bolt of the shock to get the carburetor in place. It's a tight fit, so I'm glad I had already decided to use the Lectron, as I should never have to take it out. I can still access the top of the carb to get in and adjust the metering rod.
Countershaft Sprocket
The 360 had a 15 tooth sprocket on it. That's nice and all, but the largest you can fit on the 300 frame is a 14 tooth. I found some 13s I had laying around until I realized the spline is different and they will not fit. Looking through the box of extras from the 360 I came across a 14 tooth, score! On it went, I now have clearance for the sprocket to not have to worry about the swing arm.
Clutch cable
This is my current problem. The cable from the 360 had a 90 degree bend which is needed to clear the water hose. That cable is about 8 inches shorter than the 300 cable, so I was messing with routing it along the left hand side, straight up. That's when I realized it had a much different cable end that wouldn't work with my ASV setup. I grabbed the perch and lever from the 360 and realized that that lever was way too long to fit my cut down bars and my Cycra probends. I have a spare 300 cable, so I'm going to see about pulling the end off that, shortening the sleeve a bit, and putting the bend on it. Hopefully that can get me by for the time being, and I will get measurements from that so I can try to get a terminator cable from Motion Pro made up.
CDI and Coil
There isn't a good mount in my opinion on the 300 from to fit these electronics. I'm working on making up a bracket. Nothing fancy, but I'll take some pictures tomorrow.
I One swapped a 331 caddy 8 into a 49 studebaker
you checked your compression? that started like a 125... mines a tough bugger but i am about 5'6"
