Over the last three yeas I've been rebuilding a Heathkit Hilltopper solely for riding in my mountains,not for show.
From a rolling frame to operational has been an interesting journey that while it was fun to do it had very frustrating times as well.
I bought it here in the desert of NM where rust is not an issue,however dry rot is. I had no engine as the original had seized up and was thrown away by the original owner!
While I wanted to put an 8 HP engine on the mini,none would fit without cutting the frame. 6 HP Briggs or Tecumseh engines are not to be found here in NM.
I did have a non-running 5 HP Tecumseh engine that I spent many a week end rebuilding and installing onto the Hilltopper frame. While the engine ran very well, it was gutless at my 7,000-10,000 foot ASL riding area. The only thing the engine torque through the centrifugal clutch
did do is destroy the original rear tire. The sidewalls were so badly cracked the tire had to be replaced.
Both brakes were worn off the shoes completely.Both head and tail lights were smashed beyond repair. The front forks had to be rebuilt and the rear shocks were in bad shape and needed welding. I did photo essays on most of these repairs.
Even with all the mechanical and electrical repairs needed the rear tire replacement was the hardest to complete. The original tire size is no longer made in 4-ply. Only 2-ply which will not hold up where I ride. Many times I will be miles away from the trailer riding in the mountains with no cell service. Not a place to deal with a flat or blown tire.
I found a tire that was a true 4-ply and made for off-road running on a Quad. Getting it to my home was a real task as the delivery driver kept stealing the tires being sent. I was able to video the "delivery" and the driver was fired and I finely got my tire delivered.
With the advice from a couple of members here I was able to mount a 7" wide tire on an 8" wide rim. I was very leery of doing this but as it worked out, the tire is rock solid ( pun intended) on the trails I ride on. Not a hint of slipping. Traction is 1st rate over rocks,boulders,rotten granite and sand/mud.
I put on a Greyhound 6.5 HP engine and tricked it out a little for high altitude riding and added an alternator to run my new head light and LED tail light.
I also installed a torque converter which really allows the rider to control power to the rear wheel much smoother than the centrifugal clutch did.
The handlebars were supposed to fold,which hadn't for many decades. Carbon steel bolts had be used in the aluminum castings and corroded badly. I found a fellow who had the original "wing-nut" type bolts and they work very well.
I did have to make and install a heat shield for the exhaust. Since the original Tecumseh exhaust was at a different angle than the Greyhound engine,burning my left calf was a problem. After five minutes of riding the heat was unbearable. Now it is no longer a problem.
The Heathkit Hilltopper rides the trails again and for the last year of so has racked up some serious mileage climbing the mountain trails. The ride is very comfortable with my only complaint that the foot pegs are too far back and too low to the ground. I did put some "Easy-Rider pegs" on the front crash guards but, they change the center of gravity where it can be dangerous on some trails.
It has been an interesting three years or so. But I have to tell you I really like this mini bike on my trails.
From a rolling frame to operational has been an interesting journey that while it was fun to do it had very frustrating times as well.
I bought it here in the desert of NM where rust is not an issue,however dry rot is. I had no engine as the original had seized up and was thrown away by the original owner!
While I wanted to put an 8 HP engine on the mini,none would fit without cutting the frame. 6 HP Briggs or Tecumseh engines are not to be found here in NM.
I did have a non-running 5 HP Tecumseh engine that I spent many a week end rebuilding and installing onto the Hilltopper frame. While the engine ran very well, it was gutless at my 7,000-10,000 foot ASL riding area. The only thing the engine torque through the centrifugal clutch
did do is destroy the original rear tire. The sidewalls were so badly cracked the tire had to be replaced.
Both brakes were worn off the shoes completely.Both head and tail lights were smashed beyond repair. The front forks had to be rebuilt and the rear shocks were in bad shape and needed welding. I did photo essays on most of these repairs.
Even with all the mechanical and electrical repairs needed the rear tire replacement was the hardest to complete. The original tire size is no longer made in 4-ply. Only 2-ply which will not hold up where I ride. Many times I will be miles away from the trailer riding in the mountains with no cell service. Not a place to deal with a flat or blown tire.
I found a tire that was a true 4-ply and made for off-road running on a Quad. Getting it to my home was a real task as the delivery driver kept stealing the tires being sent. I was able to video the "delivery" and the driver was fired and I finely got my tire delivered.
With the advice from a couple of members here I was able to mount a 7" wide tire on an 8" wide rim. I was very leery of doing this but as it worked out, the tire is rock solid ( pun intended) on the trails I ride on. Not a hint of slipping. Traction is 1st rate over rocks,boulders,rotten granite and sand/mud.
I put on a Greyhound 6.5 HP engine and tricked it out a little for high altitude riding and added an alternator to run my new head light and LED tail light.
I also installed a torque converter which really allows the rider to control power to the rear wheel much smoother than the centrifugal clutch did.
The handlebars were supposed to fold,which hadn't for many decades. Carbon steel bolts had be used in the aluminum castings and corroded badly. I found a fellow who had the original "wing-nut" type bolts and they work very well.
I did have to make and install a heat shield for the exhaust. Since the original Tecumseh exhaust was at a different angle than the Greyhound engine,burning my left calf was a problem. After five minutes of riding the heat was unbearable. Now it is no longer a problem.
The Heathkit Hilltopper rides the trails again and for the last year of so has racked up some serious mileage climbing the mountain trails. The ride is very comfortable with my only complaint that the foot pegs are too far back and too low to the ground. I did put some "Easy-Rider pegs" on the front crash guards but, they change the center of gravity where it can be dangerous on some trails.
It has been an interesting three years or so. But I have to tell you I really like this mini bike on my trails.