[8 October 2006]
I ordered a pump that seems to be the only one that I know will fit onto the stem with the drive ring in place. I ordered a Topeak Micro Rocket Carbon MasterBlaster from Amazon for $23.99 plus shipping. The aluminum ones probably would work just as well, but they had a 3-5 week delivery estimate. Silca also makes a couple similar mini-pumps (with press-on/non-locking presta heads).
I also got to work making an extra muffler. I found that I had some 1/2" steel tubing on hand that almost fit onto the existing muffler pipe, with a bit of reaming the end will slide on enough that a hose clamp will grab on well enough, after I cut a couple slits into it. I looked around for what to use for the muffler itself and found that I had a small disposeable cylinder of oxygen that I wouldn't be using (it was for a small welding kit that I didn't use anyway). So I blew off the gas inside, drilled a hole in the bottom and cut out the top with a dremel tool. It's a bit larger than I'd have chose but it is built pretty stout for this use, so it should kill a lot of the noise.
The muffler itself will just be a two-tube type, no interior baffles as such. An extension tube will connect to the existing muffler and run down into the added muffler (bolted to the motor mount leg, underneath the engine) and the exit will be on the lower edge, and stick in a couple inches with s small side-hole inside, to let any water drain/blow out. I didn't want the squared bottom cap on so I pulled and ground it off, but the very center (the spot of sheet metal left on the end in photo #12) appears to be brazed on.
Otherwise, the original rear fender fits back on, with no modifications other than moving the upper support mount. And the front-end uses a simple clip, and it looks like I'm going to drill a hole and put a small bolt in there. I'm not sure why Rans didn't do that anyway--there's already a hole in the frame. Only the fender tab lacks a hole.
Also I got a front rack mounted--or rather, a rear rack mounted on the front.
After the muffler is made I still need to make something to mount the front lights on. I wanted to have a handlebar bag as the "usual" riding bag, but that takes up the only room for clamping the headlights, as it would block them--but a headlight mount is easy to make to put somewhere else. The rack will have folding side baskets added but I didn't want to have to use a cargo trunk bag all the time, and with the headlights on the handlebars, the cargo trunk partially blocked the headlight beams anyway. I've seen the little "T"-bar extenders for mounting extra accessories, but I don't think they're real solid. I have what I think will be a better plan than that.
The bicycle engine isn't leaking at all but now that it has fuel in the tank, it does smell a bit like gasoline. I had the bike sitting in the living room but will need to move it out to the shed once I can clean out enough room.
So much left to do and wait for, and the weather's getting colder by the day.