Minor update time.
Went to see the welder, told him what I needed him to do, and asked him the big question... Would he be able to finish it, on that day, before 2pm? Otherwise, I was going to have to walk over to the next frigging suburb to catch a bus home so I could be back in time to pick the kids up from school. Well, a couple of the bits were easy--a bracket for the handbrake and electrical plug onto the frame, and spot-weld the mirror bracket--but the big question was raising the mudguard. He wasn't sure about that.
In the end, though, he and his apprentice did it proud, had it all done and me back home by lunchtime.
Issues breed Issues
Raising the mudguard shifted around the wires a bit, of course, and I noticed when I got home that the tire had been rubbing on one of them and had stripped the insulation. In the process of investigating that, I notice that the insulation on the wiring inside the stoplight was partially melted. That wire was a bit short to do anything useful with, anyway, so I replaced it with some longer pieces, and then looked for a different place to put it where whatever was melting it wouldn't be a problem. About the only place I could find was pushing it out underneath the stoplight unit and to the side. The stoplight was then pressing down on the wires, but there's some foam there, so hopefully it would be OK.
Yeah. It wasn't.
The foam was actually quite thin, only meant to flatten out the curved mudguard, not protect wiring, and the edge of the metal stoplight managed to cut through the wire insulation and cause a short. Back to the drawing board, cut out a new, thick
bit of foam, cut a well out of the middle of it to hold the wiring safe, and stick grommets everywhere. Basically, do a proper job.
The engineer also wanted a new headlight. Apparently the glass wasn't right on the old one. So I get a new headlight (fortunately, 7", a standard size) and stick it in.
Huh. The new headlight is deeper than the old one, just enough that the tail of my nice LED globe won't fit properly without pressing hard against all the mass of wiring inside the headlight cavity. Just have to replace it with an incandescent until I redo the wiring on this bike. What I figure I'm going to do is shift everything I can to a box I'll put in the handy space behind and under my seat. But until then, oh well.
Now none of my lights are working? Oh. The LED pressing against the wiring pulled a wire loose from its connection.
Fix that. OK. Now
is everything working properly?
I noticed on the ride home the front forks were juddering badly under brake. I need to tighten the bearings, so I jack the whole front up, undo the top of the forks, and get to the bearing nut, tighten it all up, and put it back together. When I let it back down on the jack, I notice the forks aren't working right. There's no bounce.
I press the forks down as far as they'll go, and they don't bounce back up. What's wrong now!?
Jack it back up again, take the tops off the forks, can't see any issue, tops back on, won't go back on properly, go back on properly, damn you, lower it back down again on the jack, and there's no change. It still won't bounce. Even when I climb up on the mudguard and bounce on it (It's Russian. I can do that.)
What's wrong?! Noooooo......!
It hates me. It hates me. It.... hang on....
Take the jack out
from underneath the front of the bike, and try again.
Hey look! It bounces!
(Half a frigging hour wasted trying to work out why a bike sitting on a fucking jack won't bounce. Bloody hell.)