When the package arrived with the new BDL belt drive system in it we had a little problem. Unfortunately when our hell hound doesn't get the chance to chase the delivery truck he takes it out on the cardboard.

Fortunately none of the contents were damaged (this time) so I got everything spread out to make sure I had everything I needed and also to make sure nothing had been consumed by the beast . In this package they sent the instructions on a disc but if your computer isn't able to read it I recommend you simply go to their website where you can download the instructions and or just check out some of the various install info here on Bikernet.com.

In the last round I had already installed the inner primary with a new sealed bearing so I went right to the business of assembling the front pulley.

Following the supplement instructions in the box, I installed the spline insert into the pulley and to keep from scratching it up I used a clean red rag on the bench while I installed the supplied roll pins from the back side of the assembly.

Next, I turned the pulley over and set the outer plate into the pulley, applied red Loctite (supplied with the kit) to the three 5/16x18 fasteners and bolted the pulley, insert and outer plate together.

After flipping it over again to install the inner plate, I started checking over the pulley alignment and spacing the front pulley as needed, this process is not too complicated. It is important to rotate the motor to be sure the belt is tracking properly. It's critical to avoid extreme belt wear and a big problem on your hands later.

Once you are ready to install the pulleys it is recommended to use red Locktite on the transmission spline shaft, but I skipped this step because it will come back apart for paint later.

But for Sin's project we discussed chopping up the outer primary cover. This will not only vent the hell out of the primary system but it will provide a different look too.

Most of the time I like to vent the inner primary cover by drilling holes in it while I have it off and on the bench and before I press in the new main bearing.

I also normally cut spacers on the lathe to space out the derby cover to vent the outer cover as I did on this other project bike.

This is actually a very old trick and with all the narrow belts that have been run over the years. I think it's safe to say it's been done before. I think it might be cool to fabricate a belt cover similar to the covers on the open primary systems to give it a cleaner look and keep rocks out?

The next thing on the choppin' block for this project will be to get the rear section set up with the new Paughco bobber style rear fender and twin tanks mounted

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