Unofficial Royal Enfield Community Forum
Royal Enfield Motorcycles => Vintage Royal Enfield => Topic started by: grumbern on May 25, 2019, 09:55:11 pm
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Well, I didn't know if I'd start a thread about this, but Adrian encouraged me to do so, so here we go.
Behind the project called "Laubfrosch" (German for "tree frog") stands an old, worn out Continental frame an Indian 350cc engine, British gearbox and some spares taken from another Indian Bullet. The goal is to build a small, lightweight and versatile bike for trials riding. Nothing competitive, just for fun and ideally street legal. There also are some goodies, like Fury top yoke, a '40s Smiths Chronometric 80mph speedo, a Lucas MO1 magdyno and a narrow primary housing.
So here is what I started with.
The frame an engine block and gearbox casing:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_001.jpg)
Quite obviously, there are some areas that wouldn't fit:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_002.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_003.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_004.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_005.jpg)
So I started by cutting off any parts that might be in the way:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_007.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_008.jpg)
Everything cleaned propperly:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_009.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_010.jpg)
Used a factory made stencil for the radius ;D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_011.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_012.jpg)
Fits much better now:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_013.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_014.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_015.jpg)
More tomorrow!
Andreas
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Oh, boy, here we go again, just in time!!!
(https://advrider.com/f/styles/advrider_smilies/jive.gif)
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This was quite a popular conversion in the UK. I sent Andreas the link to a part-finished one for sale on Hitchcock's forum, which has some more interesting pictures, though no S1 Interceptor in the background!
https://messageboard.hitchcocksmotorcycles.com/viewtopic.php?f=5&t=9447
A.
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Trying on the magdyno:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_016.jpg)
Looking good!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_017.jpg)
Since one of the coolest things about the Enfields is the ability, to remove the top end without removal of the engine, I naturally wanted to keep this feature. So I adjusted the frame to do so:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_018.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_019.jpg)
I also have an old Interceptor tank that might be used here - or an aluminium one?!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_020.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_021.jpg)
The donor for some of the parts:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_023.jpg)
The whole rear section is going to be used here and fits perfectly into the 250 frame:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_024.jpg)
A quick mock up with the front end put together - gotta love these half width hubs:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_026.jpg)
The wannabe- Chopper handle bars fit much better on a trials bike, don't you think?
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_027.jpg)
I also got two packages from Austria:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_029.jpg)
Inside was a ready-to-salvage 350 parts collection:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_030.jpg)
As I want to use the narrow primary housing, the crank shaft had to be shortend. So first was the disassembly:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_031.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_033.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_041.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_042.jpg)
More to come...
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The wannabe- Chopper handle bars fit much better on a trials bike, don't you think?
Not a bad match, the Fury top yoke looks the business, what parts do you have for the stanchion top fixings?
A.
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Hi Adrian,
I found the original bolts/nuts/gauze-thing that belongs there in a box that I got with the Interceptor! I'll show what I've done with it soon :)
Andreas
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Well, not that much participation here, so let's tickle your imagination a bit more ;)
As I wanted to use the Fury yokes, but didn't have a handle bar clamp and these are unobtainable, I thought I might just make a pair... Why a pair? Well, I need something to clamp the first one to, so why not just make two of them? ;)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_035.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_037.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_038.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_039.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_040.jpg)
Next will be the fork stanchions ;)
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That is nice work, but check clearance against the top of the fuel tank (in its final position) carefully , I think the factory clamp is a bit thinner.
(https://i.ibb.co/bs4Nwf2/DSCN8052.jpg) (https://ibb.co/gS0tqnP)
A.
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Yes, it will be trimmed a bit.
But first, why would anyone buy a pair of 4" longer stanchions? To shorten them of course!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_043.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_044.jpg)
Only to cut a thread in them to accept the fork nuts!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_045.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_046.jpg)
Also you can clearly see the differences in the types of stanchions. Top to bottom:
-new type
-vintage '50s type
-early Indian type
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_047.jpg)
Turned the lower part to fit the lower bushes used on the old folk legs:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_048.jpg)
Looking good:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_049.jpg)
Next I will continue with the crankshaft.
Andreas
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Still no one interested?
Ok, now here we go...
Completely disassembled the crankshaft:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_050.jpg)
To make the promary cover fit, I trimmed the end of the driveshaft:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_051.jpg)
Gave it a centre bore:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_052.jpg)
And cut a new thread to accept the primary sprocket nut:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_053.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_054.jpg)
As the crankshaft was already in pieces, I thought I might give it a new bronze bush, instead of the weak original one. While waiting for the material, I decided to chop off the passager peg holders:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_058.jpg)
Naturally I cleaned everything, but I have no picture of that...
When I finally got the bronze, I started by turnign the outer diametre, just a few 1/10mm larger than needed, and contunuing with the inner and a groove for the oil:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_059.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_060.jpg)
Comparing the old one against the new one:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_061.jpg)
You can see the old one is already damaged:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_062.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_063.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_064.jpg)
The new bush is pressed on the crank pin, instead of being a floating one:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_065.jpg)
Turned the bush to its final diametre, exactly the same as the old one:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_066.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_067.jpg)
Fits perfectly:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_068.jpg)
And while I was at it, I did a little job on the connecting rod as well:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_069.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_070.jpg)
And finally I reasembled the crankshaft and trued it to just ~2/100mm of runout:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_071.jpg)
Stay tuned for more...
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Well, I am interested, the rest of us are too much in awe of your skills to reply or have gone off to buy new 650 twins! :P
Is that leaded bronze for the new big-end bush?
A.
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Haha, I'll go with that explanation ;)
The bush is CuSn12 and was recomended to me from someone who has done that some times and he was advised by the creator of the Duese V12 (http://www.motortechnik-traupel.de/v12.html). I guess he would know 8)
Doing this wasn't very hard really, I tought it would be tougher.
Some more tomorrow...
Andreas
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Ace Cafe was offering bronze big-end bushes for his Fireball Bullets a few years ago, and John Hutchings of Tollgate Classics in the UK was hoping to offer leaded bronze bushes if he could buy the material in reasonable quantities, so there is a good precedent for this material.
One advantage is that if the bronze bush DID fail it would not spray sharp little pieces of steel roller all over the inside of the engine.
A.
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I'm in good hope, it can't be worse than the original bearing ;)
The engine block was milled in the back, to provide a flat surface for the magdyno mount:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_078.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_072.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_073.jpg)
This now is a little too low, but can be kompensated with sheet metal:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_074.jpg)
I also made an engine stand (actually, it's five of them):
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_077.jpg)
The broken steering stop was repaired:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_076.jpg)
Worked a bit more on the front mounting plates:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_079.jpg)
Also straightened the lower yokes, as these were bent back by at least 5mm!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_080.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_081.jpg)
Now it was time for new bearings, so I put the engine halfs in the oven:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_082.jpg)
Ready for reassembly:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_083.jpg)
I fitted the magneto drive gear with a bearing inner ring to give it a hard enough and smooth surface for the seal:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_084.jpg)
That's it for now.
Andreas
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Ever bake cupcakes in the oven ?
Curious how one would align the two parts of the crank ?
Did you have to make a jig before separating it ?
My real question would be how do you adjust it if you press it together a bit off ?
David Graves
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The oven was rescued from its last journey to the junk yard, so it's ok ;)
I wouldn't bake a cake in there anymore, though... still perfect for burning in paint on the barrels, or bearing change :)
You of course have to align the crank as close as you can before pressing the halfs together. Then you'd check the run out and give it a whack with a copper hammer, depending on where and how you measure it. There are a lot of instructions out there for that :)
Good to see there's someone else reading this out there :)
Andreas
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Thanks Andreas
You are also an excellent photographer and archivist of your work.
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The new bronze bearing will be interesting but had I done it I would have pressed it into the connecting rod and kept the slip fit on the crankshaft journal.
My reason for this is twofold.
First, the oil supply is thru the crankshaft journal which directly feeds the bearing surface. This eliminates the need for the multiple holes that feed the outer area of the bearing. Of course, the annular groove in the inside of the bearing is still needed to distribute the oil completely around the sliding surfaces.
Second, the journal velocity in the bore is lower than it will be with the moving surface at the outside of the bearing.
Velocity speed is a definite limit on sleeve bearings and keeping it as low as possible would be a goal in my design.
For what it's worth, the original design of the rod bearing is a "floating" design.
With both the inner and outer surfaces of the bearing moving with a oil film between them and their mating parts, it serves as a cushion to lessen shock that can be imposed on the crank journal and the connecting rod.
This isn't very important for the large steel crankshaft journal but it could be for the rather flimsy aluminum connecting rod.
Anyway, good luck with your projects. :)
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Still no one interested?
What, my little happy dance means nothing to you?!? :(
;D
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Sorry! :-[ ;)
About the bush: This is the way I was advised to do it
like. The reason is to enlargen the bearing surface and actually rise the speed, to keep the oil film stable. There also are not a number of holes, like in the floating bush, but just one opposed to the pressure side. The bearing speed should not exceed 12m/s under normal conditions and the material is rated good for up to 20m/s under dynamic lubrication. So everything cool there, I guess ;)
Yesterday I sand blasted the major parts and put on primer.
Andreas
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I too have been paying close attention to your beautiful work.
I'm much less talented than you, so I don't have much to offer other than an occasional "WELL DONE!!!!!!!" ;D
Loving everything I've seen so far. :)
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Thanks a lot, now I know there's some people reading this ;)
Here's a picture of the primered parts an the rear frame:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_085.jpg)
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I can't speak for Germany or the USA, but watching Grumbern's paint dry is better than anything on UK television at the moment!
A.
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I can't speak for Germany or the USA, but watching Grumbern's paint dry is better than anything on UK television at the moment!
A.
Trust me, it's pretty much the same here in the USA...
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Today, there was a Chackie Chan movie, but usually it's pretty much the same too ;D
The parts now have the second coat of primer and If I had a web cam you could watch it dry in real time ;)
I also did some more on the rear frame an am hoping tomorrow I can paint everything in "palm green hammer paint".
Andreas
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Heres two pictures of the seam of the rear frame. To be able to propperly weld, I turned and pressed in a little lug:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_086.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_087.jpg)
As well welded on the brackets for mounting to the frame and seat:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_088.jpg)
I don't like the welds, so I'll have to re-do these.
As well it was time to paint. Hammer tone palm green! I really think this colour is beautiful, it's robust, easy to retouch (I believe...) and gives the machine the looks of ... well, a machine:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_089.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_090.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_091.jpg)
Gorgeous, eh? I love that structure, very old school! I absolute liked that on the Heinkel "Perle" (Pearl) (https://upload.wikimedia.org/wikipedia/commons/9/93/Heinkel_Perle_bild_2.JPG).
In combination with raw aluminium this is ought to look perfect.
So long,
Andreas
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Very cool color! I'm liking this so far... 8)
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We have Hammerite in the UK, a very similar finish, though I don't think we have it in quite that shade of green. A real 70's flashback for me, though, I used black and green Hammerite to repaint my first BSA (a C15) back in er... 1976!
A.
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Beautiful job!!
your cat is drinking your beer?
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That colour looks very similar to the new Bullet Trials that Enfield have produced for 2019. Excellent blog and obviously a very good engineer. All I ever had was hacksaws, files and a hand drill in my youth, but I did produce some good machines.
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@Adrian: Well yes, the Hammerite is way too dark and after some experiences I had with that brand I stay away.
@Chuychacon: Didn't know what you meant at first, but no, the bottle there is ATF and it's a dog (and not drinking it, of course ;D ).
@symmo: And that again is based on the ISDT machines of the early sixties! I guess that influenced the colour scheme a bit, though I wanted a bike this colour anyway.
I put in the steering head, finished the stanchions and put some parts together. Not firmly mounted yet though:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_092.jpg)
And I got me something nice again and would like to use it on that bike. The patine would fit perfectly and I love these, but I guess I had to paint the tank in green too to go with them. I don't think they would look good on bare aluminium?!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_093.jpg)
Andreas
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@Adrian: Well yes, the Hammerite is way too dark and after some experiences I had with that brand I stay away.
@Chuychacon: Didn't know what you meant at first, but no, the bottle there is ATF and it's a dog (and not drinking it, of course ;D ).
@symmo: And that again is based on the ISDT machines of the early sixties! I guess that influenced the colour scheme a bit, though I wanted a bike this colour anyway.
I put in the steering head, finished the stanchions and put some parts together. Not firmly mounted yet though:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_092.jpg)
And I got me something nice again and would like to use it on this bike. The patine would fit perfectly and I love these, but I guess I had to paint the tank in green too, to go with them. I don't think they would look good on bare aluminium?!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_093.jpg)
Andreas
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Try a different tank?
(https://i.ebayimg.com/images/g/zlkAAOSw2k9ZetQB/s-l1600.jpg)
ebay item 264098824564
Paint the side panels green (the badges ought to fit this one) and leave the tank itself chrome plated?
This tank always looked a bit awkward to me, as though someone in India misunderstood the small chrome panel tank and came up with a small panel tank fitted with large panels, or else they wanted a way to use the larger badges on an Interceptor export tank. HOWEVER it might just work on your Projekt. ;D
All contrary opinions fully understood!
A.
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Oh no, I can't do that! This thing looks soooo ugly in any fashion :o
I'll find a solution!
By the way: Yesterday I "tried on" in the engine and gearbox:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_094.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_095.jpg)
As you can see, it'll still come up quite a bit in the front, when the wheel is in place. I like the looks of the engine plates in the front too - just as I planned! :D
The wheel looks a bit tiny though?! ??? May be I'll have 3.50-19 tyres front and rear to cover that up ;D
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I can see why you didn't like the panel tank. I know the Indians make a slimline version of the stock fuel tank, though I haven't seen one which is meant to take the large badges.
The wheel looks a bit tiny though?! ???
Fit the fork sliders and the front wheel into them, and have another look. I think that having the front wheel quite some way from the ends of the forks in your photo is acting as an optical illusion. Otherwise, it might need a 21" front wheel!
A.
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21" wheel surely, a must for an authentic looking replica.
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Alright now. I found a 21" Yamaha DT175 wheel I think I'm going to use! As soon as it get's here we'll see how it looks. I guess I'll use MItas tyres then.
Until then I cleaned out the fork sliders and also removed the stuck bush in one of them. The internals are done for, so I'll need replacements for those.
Doesn't look bad though?!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_096.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_097.jpg)
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Doesn't look bad though?!
Shaping up nicely.
Although these are of more immediate relevance to Dirge's restoration project, you might be interested to see these Indian Westerner drive-side factory photos courtesy of Hitchcocks' Instagram account. Your Projekt seems to be heading into similar visual territory.
Top one is a 350 with the '55/56? only air cleaner box, based on the roadster Bullet's with some extra breathing holes. Obviously not a success as it's not fitted on the later 500 shown beneath it.
A.
(https://i.ibb.co/YZR5v0s/Screenshot-2019-06-21-Hitchcocks-Motorcycles-on-Instagram-Another-factory-shot-from-the-archives-a-1950-s-350cc-Indian-mot.png) (https://imgbb.com/)
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(https://i.ibb.co/WpgSkJ3/Screenshot-2019-06-21-Hitchcocks-Motorcycles-on-Instagram-1957-Indian-Westerner-500cc-single-scrambler-original-factory-ph.png) (https://imgbb.com/)
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Comes close!
The rims were cleaned up a bit and new tyres pulled on:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_098.jpg)
Tight fit!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_099.jpg)
Next I'll do some aluminium welding - the break plate needs some repair and customizing and about 3.8 of the 4 taps in the fork tubes are done for... :-[
So long,
Andreas
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This is such an interesting blog, can't wait to see this machine finished and fired up. Great work.
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Of course there is a bit of a tradition of this, look what's on ebay UK at the moment. I'm tempted to buy it for the timing cover! ;D
https://www.ebay.co.uk/itm/60s-Royal-Enfield-bullet-reditch-trials-restoration-project-spares-or-repair/113805048510?hash=item1a7f4f3abe:g:7LcAAOSwQ-BdG6tA
A.
(https://i.ebayimg.com/images/g/7LcAAOSwQ-BdG6tA/s-l1600.jpg)
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For this price I'd take it no questions asked ;)
Seems to be a 350 frame, with shortened rear and an older gearbox fitted. Also has aluminium cylinders! Nice project bike indeed. And of course there's tradition, where if not the trials did the Bullet exceed? And that's why mine should look like it was built in the 1960s!
I was thinking of adding this rev-counter provision to the timing cover, just because of ease of ignition timing. That's also why my Chief has the ex-sprocket bolt of the interceptor, used for the rev-counter behind the cover ;)
Some parts are on order and others in the making. After thinking back and forth I finally spent that extra cash to get an aluminium cylinder instead of using the cast iron one in almost perfect condition... Why not?!
Andreas
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I finally spent that extra cash to get an aluminium cylinder instead of using the cast iron one in almost perfect condition... Why not?!
Looks right for a trails bike and will save a little weight, enough to compensate for the extra weight of the magdyno.
That timing cover has exactly the came footprint as the Indian or standard late Redditch Bullet timing cover, though to modify an Indian Bullet timing cover to match you'd have to remove/reprofile the "blob" area as well as recreate the rev-counter drive boss. I suspect that you are one of a rather small number of people on this forum who could actually do this. You did say you were going to do some aluminium - sorry, aluminum welding...
A.
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Yeah, thought I'd allow myself the luxury of an AC/DC-TIG welder - cheap China device though, but it does weld ;)
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Yeah, thought ' I'd allow myself the luxury of an AC/DC-TIG welder - cheap China device though, but it does weld ;)
Being an aficionado of cheap yet fuctional Chinese crapola, I'd love to see details on that welder.
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It's a "Rotenbach" AC/DC 200 P, 5-in-1. Basicly the standard TIG welder you get in different styles and brand names. What made me buy it instead of a different one was the posibility to use an air-powered plasma torch.
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Engine plates type "Special" :)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_100.jpg)
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Now, second layer of paint applied:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_101.jpg)
That's how they look on the bike. It's still missing the bolt to the gearbox and the one through the frame is too thin - didn't have anything fitting at hand right now. But you get the picture:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_102.jpg)
The bottom view shows the purpose of the latches. They give some more rigidity, but mostly a good posibility to mount the side stand and skid plate to:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_103.jpg)
I also melted some aluminium... Not exactly beautiful, but it's doing the job and to my defence I have to say, that a) welding a 20mm deep hole is darn hard and b) cast alloy, espacially these old ones are ugly to weld, bubble alot and contain a lot of junk.
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_104.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_105.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_106.jpg)
Today nothing else will happen here, but next week I can start the machining.
So long,
Andreas
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I also melted some aluminium... Not exactly beautiful, but it's doing the job and to my defence I have to say, that a) welding a 20mm deep hole is darn hard and b) cast alloy, espacially these old ones are ugly to weld, bubble alot and contain a lot of junk.
.
Once that is all cleaned up and re-machined it will look a lot better. Were the holes too damaged for helicoil inserts?
On the Bullet rear engine plates there are hexagonal holes to lock the hexagonal footrest bar in position, as well as a spacer tube between the plates, do you have some other arrangement in mind?
A.
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Yes, the threads were done for and I don't have any 5/16-BSF inserts nor tools for that. I didn't want to use M8, so this was the way to go.
The distance tube will be made from Aluminium and instead of the hex rod I'll simply use a round and shorter one. The footrests will be set backwards below the swinging arm axle, so there's no need for an unnecessarily complicated mounting plate with hexagonal cut outs.
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It's been a long time since anything happened here. But as I am on vacation finally I have some time to concentrate on the Laubfrosch again.
So I first went with the fabrication of the axle and bushes for the front wheel. The DR's hub fits pretty well, but is 2mm less wide and only has a 12mm axle, instead of 9/16". So that's too thin for the Bullet's clamps. So I turned two bushes from Aluminium, allso providing the needed distance on the inner face. First reamed the bore to 12mm:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_107.jpg)
The outside is turned to 14,3mm (9/16"):
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_108.jpg)
Finally slotted it using a hand saw, so the axle, simply a piece of 12mm 1.4301 round stock, can be clamped:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_109.jpg)
Thas looks pretty much like this:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_110.jpg)
I mocked up the Engine a bit more as well. Apart from the slender primary case, there's a nother fine detail that found it's way there. Can you find it?
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_111.jpg)
And as the mail man brought some pieces of stainless tubing, I could start to try a little on the exhaust. I like how it turned out. Fit neat an tight, but has enough clearence to the carburettor and especially: The pushrod cover! I wouldn't want to block this by any means, because easy maintenance is a must!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_112.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_113.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_114.jpg)
I'm still a bit worried about the muffler though, because I don't need a fried leg! Well, it will get a shied anyway, maybe that's good enough.
So long,
Andreas
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DEFINITELY fit a heat shield. You could justifiably use exhaust pipe wrap for the middle section, but it wouldn't look so good. I usually had some bits of melted plastic to scrape off the old Electra-X's woodsman high-level exhaust pipe from boots or over-trousers.
A.
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If you were to make your exhaust system a copy of the Woodsman rather than the normal Trials type you could have the muffler/silencer further back where it would be more out of the way.
A.
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Yeah, I thought of this option, but it builds just so big. So I think I'll just go with the trials-type muffler.
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The view inside the combustion chamber. All nice and new:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_117.jpg)
As my magneto is newly wound and re-magnetized I took care of the rebuild. First the old bearing races had to go, which wasn't that easy at all. Those races sit i little paper cups to insulate them and the rotor from the housing, as erosion caused by a missguided current could lead to premature waer of the bearings. Those cups of course were not to be used any more, and the one on the drive side was destroyed anyway when driving out the race:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_118.jpg)
First the measuring:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_119.jpg)
And then cutting new ones from a suiting piece of paper:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_120.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_121.jpg)
It wasn't easy to find a piece of paper of 3/10 of a mm, but I found a greeting card that had the right dimensions.
The new race titted with the paper cup:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_122.jpg)
And a picture of the rebuilt rotor. Primary and secondary windings, as well as the condensor were professionally replaced:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_123.jpg)
So long,
Andreas
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Next I needed an adaptor for the timing chest. I used a piece of aluminium that was roughly cut and turned:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_124.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_125.jpg)
Fitting the magdyno:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_126.jpg)
Drilling the taps:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_128.jpg)
Some spare parts:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_129.jpg)
Finishing the adaptor:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_130.jpg)
The rest was done with my highly sophisticated CNC centre - Completely Non Computerized (flat file):
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_131.jpg)
With the shaft seal in place:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_132.jpg)
And with the pinion. You can clearly see there's still some missalignment:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_133.jpg)
That's why I put the engine on the mill once more:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_134.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_135.jpg)
Took off another 2mm in width:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_137.jpg)
As well as 1/10mm in hight, so I could use a 3mm shim, instead of several ones combined to 2.9mm:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_138.jpg)
The three bores were counter sunk:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_139.jpg)
After that the positioning holes for the magdyno had to be made. There are two in the right case and the shim:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_143.jpg)
The magdyno has two coresponding pins locating it on the crank cases:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_144.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_145.jpg)
this gives perfect alignment of the pinions:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_146.jpg)
The timing chest cover is in bad shape. Some idiot drilled a 1/4" tap, breaking through the pump housing:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_142.jpg)
But I found a nice small headlamp, that will look gorgeous on there:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_140.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_141.jpg)
So long,
Andreas
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It's very appealing to see a special build that needs (and gets) some engineering. I do have vague plans to get a set of Electra-X crankcases modified for a magneto* (the Electra STILL has the cut outs for the magneto straps), your work on the Laubfrosch is the beginnings of a "how to".
My specials (bitsas) tend to rely on choice of components to minimize the need for serious machining, with a view to everything either being able to fit or being made to fit without too much effort for my limited skills/facilities. Some jobs I still have to pay someone else to do, though.
What are your plans for the damaged oil pump chamber? Repair or just replace the timing cover? I think I can guess the answer.
Also notice the rack of Bullet engines lurking nonchalantly in the background, guys...
A.
* one of these would be nice...
(https://i.ebayimg.com/images/g/bnEAAOSwy1NdvV0y/s-l1600.jpg)
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Hi Adrian,
yeah, it's one of the advantages of a professional trainer in the m+e industry to be able to use some of the equippment, but this could have been done on one of these small hobbyist mills as well. The earlier housings are better to use, as they still have that cast in provision on the oiltank, that was used as a platform for the magdyno and you wouldn't need an adaptor plate/shim. If you're planing to use just a magneto without a generator, you could use one of the later mags like the K1F, that just bolt to the timing chest as the distributor does. This wouldn't even need any machining. With the lean burn engines though, and some Electras, where they don't have the machined flange, you might run in some problems and still need to modify it to fit a mag to.
Your suspicions about the timing cover are right: I'll try to repair it. If it doesn't work I haven't lost anything and the cover itself has a very nice engraving job done to by the previous owner that I'd like to preserve.
The BTH is a nice unit and would shurely suit a vintage trials single!
So long,
Andreas
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Yes, that's the KD1TT magneto also used on some Manx Nortons and JAP speedway bikes. As with the Lucas competition magnetos, people tend to know what they're worth!
Fitting a magneto to an Electra-X crankcase also involves re-instating the two idler gears as well as either machining for a flange-mounted magneto or doing the same as you have for a platform-mounted magneto.
The K1F and its BT-H equivalent, the KC1, are not a straight fit, though they can be MADE to fit! ;) I shall post something about this in a while. The Lucas SR1 magneto however DOES bolt straight onto the crankcase of any pre-electronic ignition Indian Bullet, though the automatic advance/retard units built into the drive gear can be hard to find.
I have a couple of projects on the go at the moment but have had trouble getting my picture hosting website's links spat out by this forum's dreaded database error. Maybe it's time for another attempt.
A.
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Meanwhile this would be even more appropriate for your trials Bullet, only 480 GBP!
BSA Goldstar Lucas wader competition M01 magneto - ISDT Magdyno, ebay UK item 123984943206
A.
(https://i.ebayimg.com/images/g/vgoAAOSw0Axd2BRN/s-l1600.jpg)
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As for now, I'll stick with my rebuilt "simple" mag ;)
Today I did some machining again on my lathe and made the end pieces for the distance tubes of the front forks:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_147.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_148.jpg)
I then put them in place and filled up some oil.
Some other parts were made also, but all in all nothing much to show.
So long,
Andreas
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Just need a couple of these, now. :)
(http://accessories.hitchcocksmotorcycles.com/33246-1200.jpg)
http://accessories.hitchcocksmotorcycles.com/4988?qty=1&continue_url=https%3A%2F%2Fwww.hitchcocksmotorcycles.com%2Fpartsbook-pages%2F964
A.
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Now I **know** you just found a bottom-mounted headlamp, but these just showed up on ebay.
https://www.ebay.co.uk/itm/ROYAL-ENFIELD-1940S-HEADLAMP-BRACKETS-ORIGINAL-USED-MODEL-G-MODEL-J-/392540250204?_trksid=p2385738.m4383.l4275.c10
A.
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I do have the caps, though I'm not sure if I'm going to use them. They might look too posh 8)
Today I finally started on the rear mudguard. Of course all perfectly professional and with the best material to start with ;D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_149.jpg)
Bash it!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_150.jpg)
Getting in shape:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_151.jpg)
Well, still a lot to do...
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_152.jpg)
So long,
Andreas
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Making progress! I always have a few minutes only for hammering, but small steps are better than none.
The skirt is deep and the shape is slowly showing:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_153.jpg)
And it's getting time to work on the details.
Before:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_154.jpg)
And after:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_155.jpg)
About one third is in acceptable condition now and you can see how it might turn out:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_156.jpg)
More to come...
Andreas
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Hope you have a good English wheel to finish that off. lol ERC
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Or else it's to match the hammer finish of that green paint!
A.
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You're right! I allso though of laeving it in a hammered finish, like some of the old competiotion motorcycles used to have. It might add to the overall appearance, just as it was made in the 60s.
Here's some more impressions, of how it might look like:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_157.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_158.jpg)
So long,
Andreas
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Like the Fred Flintstone centre stand. ;D
The frame colour is spot on. Excellent. Following with interest.
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You're right! I allso though of laeving it in a hammered finish, like some of the old competiotion motorcycles used to have. It might add to the overall appearance, just as it was made in the 60s.
Here's some more impressions, of how it might look like:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_157.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_158.jpg)
So long,
Andreas
Beautiful!!
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Still working on the front mudguard. The surface is getting better and better:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_159.jpg)
Used a 1-1/2" pipe bend as an anvil:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_160.jpg)
I think I'll keep the hammered surface as it fits the purpose of the bike and the idea behind it. I looks like these old NSU and DKW racers of the 60s and goes perfectly with the hammer paint. 8)
Here's what I mean:
https://thevintagent.com/2019/06/20/the-original-triple-dkws-singing-saw-racer/ (https://thevintagent.com/2019/06/20/the-original-triple-dkws-singing-saw-racer/)
A merry Christmas to you! I need to join the family for a bit now ;)
Andreas
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Here's what I mean:
https://thevintagent.com/2019/06/20/the-original-triple-dkws-singing-saw-racer/ (https://thevintagent.com/2019/06/20/the-original-triple-dkws-singing-saw-racer/)
A merry Christmas to you! I need to join the family for a bit now ;)
Andreas
Interesting article - Thanks! I first learned about the DKW 3's in Vic Willoughby's book 'the racing motorcycle' back in 1980.
Have a good Christmas with your family.
Frank
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Christmas well spent, there was some time again to wield the hammer ;D
I have no clue how many thousand blows it took to get here and how many will still need to come, but it were a lot! So a good 5 hours more and the front mudguard was in a state I could live with. So I set it in place and marked the final shape to cut:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_161.jpg)
Now it already looks like a mudguard:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_162.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_163.jpg)
Now it only needs the edges folded and some final shaping.
Isn't this finish just gorgeous?
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_164.jpg)
Ok, I guess it's not to everybody's taste, but I wouldn't want to change it for a baby butt smooth finish anymore!
So long,
Andreas
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That is a superb job, the hand beaten finish is absolutely fine. Would you perhaps have made it to a slightly larger radius to allow clearance for the tyre/tire? It is a very snug fit, even for a roadster.
A.
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Yes, it curled in a little during hammering, so I need to stretch it a bit again. But that's no big deal, I guess. ;D
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After trying with a pice of wood, which instantly broke off, I pulled an old piece of steel out of the trash bin and ground an improvised lever:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_165.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_166.jpg)
After the first run you can already see a nice crease forming:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_167.jpg)
As soon as this is done, it is folded down with a hammer:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_168.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_169.jpg)
I should have made the edge a little wider though, as it was very hard to get a hold of it. But I made it and hope I can even out the damage done by this (distortion of the mudguard). But there was no time anymore for this yesterday.
So long,
Andreas
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For working on the edges, I ground a shoemaker's anvil to my needs. I only evened the surface and rounded the edges a bit. It's very versatile because of it's different radii.
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_170.jpg)
Here its easy to see how the outer edges warped by folding:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_171.jpg)
After straightening it's not noticable:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_172.jpg)
Then I started working on the front:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_173.jpg)
In hindsight it probably wasn't smart to bend down first, as it figured to be very hard working on the rear crease now. But somehow I managed to do it anyway:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_175.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_176.jpg)
I'm not quite sure if I want that for the rear as well. Maybe I'll leave it straight as it is, or even ad a mudflap?! I know these aren't exactly a symbol of beauty, but ti would fit the era and purpose. A little more dirt deflection for the engine sure is no bad thing. What do you think?
So long,
Andreas
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Which is most important, form or function? ;)
A.
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I quite like a good mud flap. This is a labour of love. Thanks for sharing.
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Two newer pictures:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_177.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_178.jpg)
Looking pretty sleek! Early this week I was able to almost finish off the rear mudguard and do a rough cut. Of course there's still some detail work to be done. Allso I was wondering if skirts like on some production bikes would look good. Not all the way round, just to the (at the moment still non existing) subframe/mudguard stay. We'll see.
So long,
Andreas
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And yet some more with the mudguard, worthy of the name:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_179.jpg)
After a quick steel whool polish:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_180.jpg)
And the whole bike:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_181.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_182.jpg)
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Allso I was wondering if skirts like on some production bikes would look good. Not all the way round, just to the (at the moment still non existing) subframe/mudguard stay. We'll see.
Since you do such a decent job with hand-beaten alumin(i)um, some competition number plates might suit this bike, something vaguely Cheney-esque.
A.
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Nah, that'd be too much, I guess. 8)
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Today I welded the exhaust pipe. Sadly the beads didn't turn out very nice (I don't have enough practice and those winding pipes are quite hard to do...). But they're not hideous either and thanks to purging with gas the inside became nice and smooth and didn't burn at all. Actually even better than the outside. Should have given it more gas, probably! But after a lot of welding on a fork leg and the purging the bottle is as good as empty just by that.
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_183.jpg)
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Looks lovely to me, albeit an untrained eye. Only you will ever notice it :)
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Thats more fab than ill have done in my whole life,very impressive.
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Thanks, some more coming on.
I started working on the exhaust. This will be made of Aluminium and I started with a lenght of installation tubing. First it is widened to 38mm to fit the downpipe. For this I painted all the tube with marker and heated it, until the marker vanished - that's a very easy method to determine the correct temperature. At the beginning only the furthermost part, that's going to be widened:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_185.jpg)
Then, using a fitting piece of round stock driven into it with a hammer, it's widened:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_186.jpg)
After that I heated the whole tube and the following tool was used:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_187.jpg)
It's a modified drill press, with a prism and an HSS tool attached:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_188.jpg)
It allows to create such holes:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_189.jpg)
If you do that for some time and take a little care about positioning, this is what you get:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_190.jpg)
It's going to be the absorber parts of my silencer. We'll see, if it works :)
For now, the sight through the pipe is spectacular 8)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_191.jpg)
So long,
Andreas
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Also I started the rear subframe. It's made from one single lenght of hydraulic pipe.
First tried on with the shocks fully compressed:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_192.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_193.jpg)
Looking good and there's even enough space left for the tyre.
Then with the shocks fully expanded:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_194.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_195.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_196.jpg)
Well? Doesn't look too bad, does it? :D
Of course it still needs all the brackets, but it's coming along.
So long,
Andreas
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Taking shape, going to be a head-turner. That baffle is a work of art. Well done.
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Taking shape, going to be a head-turner. That baffle is a work of art. Well done.
+1!
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Originally the mag is held in position by two short pins and strapped down onto the housing by a metal band. This had to be made. I didn't have the original one and also didn't want to spend a lot of work on it. I then had the idea to use a hose clamp. First I planned to cut a bigger one in half and form a hoose on both ends and weld them, but a buddy had a better idea: Just combine two shorter ones and use the existing hooses on each one!
So I bought two clamps with a range of 60-63mm. Another benefit about these is, that they are made from stainless steel and will not rust:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_197.jpg)
Dismanteled and combined they form this:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_198.jpg)
Also I turned two bushes from stainless, as the bolts in the housing only are 5/16" and the hooses are 12mm. I still need to change the bolt to a shorter one.
Mounted it looks like this:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_199.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_200.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_201.jpg)
Sometimes it can be so easy ;)
So long,
Andreas
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I heard that back in the cold war, one of the ways the Soviet intelligence had for checking for fake Russian documents provided by the West was to check the staples. Western fakes used stainless steel staples which didn't rust, Russian staples did. Check your local auto accessories store for some rust-effect paint!
Seriously, though, that's a good bit of lateral thinking.
A.
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Great solution Andreas, and it comes very handy for me as I have (had) the same problem with my Bullet (swap the magdyno with a Lucas N1).
Ludo
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Andreas,
I've been lurking here and watching your project for quite a while and just wanted to thank you for sharing what must be a heartfelt project. Those fenders and rod bearing are works of art! I admire your explanations and photography skills as well as your craftsmanship. Your tree frog looks like a wonderful ride.
Stan
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Yes, I thought this might be useful for some of the owners of older mag-fired bikes. If you guys like my projects it's already worth documenting and knowing someone out there appreciates it keeps me going :)
For now I started working on the head. Nothing big, but the valve springs were weak and the smaller on of the exhaust even broken. So I went with a set of NOS Terry's:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_202.jpg)
The rocker bearings had some wear as well, so I ground them 2/10mm each and reamed the bore. Clearence is a bit more than standard now, but at least I have a clean surface. Only near the joint it left some out:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_203.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_208.jpg)
Allso the generator's field coil needed some refreshing. The wires were allright, but the binding completely deteriorated over the last 70 years and was repaired using cloth tape:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_209.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_210.jpg)
So long,
Andreas
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Started cleaning the timing chest cover. Still needs repair and some modification:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_211.jpg)
Allso I sealed the magdyno against the housing. Not visible, but yet important.
But I fabricated a fixture for the headlamp. Close, but ok!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_213.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_214.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_215.jpg)
The rear subframe is coming along as well:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_212.jpg)
The rear mudguard brackets welded on:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_216.jpg)
Looking cool:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_217.jpg)
But two German sayings happened to come true:
-Wer misst misst Mist. (Who measures measures crap)
-Was nicht passt, wird passend gemacht. (What doesn't fit, is made to)
Because the gearbox colided in the rear and the rear rocker cover would not pass the frame. So I had no other option, than to weld some holes, alter the brackets and drill again:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_218.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_219.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_220.jpg)
But now it fits. Both in the rear and on top there's enough space:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_221.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_222.jpg)
And on the subframe I added some plates for stiffening as well as for mounting the mudguard's front and the seat:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_223.jpg)
Unfortunately I don't have any more gas (hardware stores are all closed due to Corona virus) and have to wait to weld the parts. But I think you can guess how it's supposed to look like :)
So long,
Andreas
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Was nicht passt, wird passend gemacht. (What doesn't fit, is made to)
Preach it, brother!
Similar headlamp mount on the Electra-FT.
(https://i.postimg.cc/yYPTf0Wf/DSCF8171.jpg) (https://postimages.org/)
Coming on nicely, we're looking forward to seeing this one ready.
A.
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8)
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The brackets are welded. Not very beautiful, but it will do ;)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_224.jpg)
One can easily see how these brackets strengthen the braces and at the same time provide mounting points for the mudguard and seat:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_225.jpg)
More to come...
So long,
Andreas
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Forget cute pictures of cats, what with this, Michael Waller's YamBSA scrambler and Project Binky, the REAL reason why internet was invented is to provide lots of pictures of people making custom brackets! ;D
A.
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This thread joins Michael Waller and Tatro Machine as my favorites. Watching a bracket being discussed, designed and produced is my therapy.
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Haha, yeah. The fork legs on this machine actually were a gift from Mike and I made the sprocket for his Trailblazer -for the ones who saw that episode ;D
I allso enjoy these "how things are made" chanels and threads. I don't have the video equippment and probably would miss most of what I am doing, so pictures will have to do though ;)
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The mag is assambled and does it's job:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_226.jpg)
And I started with the hammer again:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_227.jpg)
If you hit it long enough and remove some of the excess, something like this may be the result :D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_228.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_229.jpg)
Now it needs the left side panel and some good detail work and maybe I'll be able to tack weld it this week end.
So long,
Andreas
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He's doing it again! All that's missing is the pictures of Andreas mining the bauxite ore and smelting it for the alumin(i)um sheet! ;D
I hope that you're planning to use a small (2inch) Monza-pattern filler cap. How will you mount the tank?
A.
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Haha, that would be just a bit too much ;)
I'm struggeling with the Monza cap. Already got one on my Café XS and it's become a bit "mainstream". My initial choise was and still is on of those winged caps they had on many bikes in the 40s and 50s. The tank mount will either be the same as in the original, by a bolt in the front and a clip in the rear, or even something special. not quite sure yet :)
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If you want that type of filler cap, think BSA export. While on the subject of BSA you could fit an alloy tube down the middle and you could have the thing all rubber mounted.
ebay item 143231834430, 2 inch. Only £20.
A.
(https://i.ebayimg.com/images/g/22AAAOSwAPVZJeiB/s-l1600.jpg)
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Yes, something like this. I also found a nice "Bonora" cap, but those are stupidly expensive! :'(
Maybe a self-build? :o
Yesterday I allmost finished the left hand panel and top.
Here it is roughly cut out and started to shape:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_230.jpg)
Getting close!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_231.jpg)
After that I masked the right hand panel using tape:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_232.jpg)
Peeled off and turned inside out it makes a good but sticky stencil for a mirrored panel:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_233.jpg)
Excess material marked to be cut:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_234.jpg)
Here are the three parts for the tank body. At first glance the panels look quite symmetric:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_235.jpg)
I taped the parts together and they fit quite well. The left side seems a bit more flat to me though. I will need to work on this. But the "tank" makes for a nice slim shape. It's still a bit high in the front, but tihs will be taken care for by the tunnel cutout:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_236.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_237.jpg)
So long,
Andreas
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That shape reminds me of the BSA B50MX alloy fuel tanks.
A.
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You're right, but I guess this really is just the perspective. I was going more for something like Ariel HT5 combines with the Interceptor tank...
Today I tried a little with a thinner rear and it made me wonder. I really need to put some thoughts in this before I gon on.
Andreas
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The following version is now what I think of is best (top has yet to be trimmed to fit):
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_244.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_245.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_246.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_247.jpg)
Also I did a quick and therefor not very accurate test. I think its noticable, what it is supposed to (or might) become. What do you think?
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_248.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_249.jpg)
Obviously it gets better in the lower right corner and I would have to practice quite a bit before applying it to the tank. ::)
If I should do it and which Logo and size, shall be thoroughly evaluated ;)
So long,
Andreas
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I really enjoy watching your progress with this current masterpiece, especially the hand-wrought bodywork.
The bike's colors and textures add to an artistic showpiece that also begs to be ridden.
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Thanks, Stanley!
I made some progress again.
First I improved a bit on the lettering. Here's what I started with:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_250.jpg)
The tools used:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_251.jpg)
Doing the outlines:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_252.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_253.jpg)
Adding some texture:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_254.jpg)
Now it might once look like this:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_255.jpg)
Allso made some welding clamps. Much more convenient than tape:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_256.jpg)
Then I made a layout for the script:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_257.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_258.jpg)
All the letters cut out twice and sprayed with glue:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_259.jpg)
Stuck on the tank:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_260.jpg)
A thin layer of paint:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_261.jpg)
And the stencils removed:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_262.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_263.jpg)
Now I started the hammering. First panel is half way done:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_264.jpg)
Just some more hours...
Andreas
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Since yesterday the panel is hammered completely and today I poured in molten tar as support for the chasing:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_265.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_266.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_267.jpg)
Pretty messy and time consuming, until all was molten. But this provides me with a heavy, plane support that allso sticks well to the panel, making it easy to work on without the danger of deformation and having to hold it down by hand. 8)
So long,
Andreas
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Worked a little on the script. What is seen here took me about 2 hours ::)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_268.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_269.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_270.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_271.jpg)
So long,
Andreas
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Incredible work, how thick is that ally sheet?
A.
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Hi Adrian,
it's 1.5mm. It will be thinner in these areas for sure, but since it's just dent in, I think the change will not be too much.
Andreas
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Ace Cafe was offering bronze big-end bushes for his Fireball Bullets a few years ago, and John Hutchings of Tollgate Classics in the UK was hoping to offer leaded bronze bushes if he could buy the material in reasonable quantities, so there is a good precedent for this material.
One advantage is that if the bronze bush DID fail it would not spray sharp little pieces of steel roller all over the inside of the engine.
A.
Our Ace bronze bush retains the floating design of the original floating bush, but with different clearances to account for different materials and their thermal expansion characteristics. And we used a steel con rod.
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Moved out to the balcony, as the weather was too nice to stay inside 8)
I allso used the opportunity to digitize some of my records during. Time was enough for "Ace of Spades", "March or die" and A side of the "Bomber"-EP ;D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_272.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_273.jpg)
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Today I finished the script and peeled the panel off the tar. Still needs a bit refining, but before this a thorough celaning.
But first I scraped off the burrs:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_275.jpg)
And that's how it looks like now:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_276.jpg)
So long,
Andreas
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incredible craftmanship. Great to follow this build. Thanks for sharing.
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Not much has happened with the frog. Too much other stuff to do. But I could at least prepare the timing cover for the tachometer drive:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_277.jpg)
Of course the bolt won't stay there and is only meant to check for allignment. The tap fits the Magneto pinion nut and was a perfect "dummy." Later it's going to look a bit like this:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_278.jpg)
Ok, that's not exactly right. I will probably not mount a tachometer. And why should I, on a trials machine? The reason really is a different one: The flange makes timing the ignition a lot easier, because you can simply set up a timing disc. I made an attachment to use on the twins and I want this for the Bullet, too. It's a little hint to the genuine works trials as well :)
The script was already done by the previous owner and is one reason why I wanted to use this damaged and beat up cover to begin with.
Last week, after fixing my welding helmet I was finally able to weld up some material for the tach-drive and repair the broken tap. The face and side is already filed, but the inside, drilling and tapping still needs to be done:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_279.jpg)
The welded and roughly shaped tach drive flange:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_280.jpg)
And yes, I did it! ;D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_281.jpg)
So it's definitely not low budget anymore, but finding a fitting used 21" rim for the bullet isn't easy! The Yamaha wheel wasn't bad either, but just not as authentic ;)
So long,
Andreas
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Glad you're still with us Andreas, that wretched Covid 19 isn't finished yet.
A.
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No worries, I'm fine. Just lots of different stuff to do :)
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I'm stunned! Love what you did with the tank!!!!!!!!
:o ;D
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I just dug out the picture of an original rev-counter type timing cover, I almost bought this for Not A Fury but Hitchcock's wanted a lot of money for it. Note the area where the rev-counter drive screws on is flatter, i.e. no bulge for the SR1 magneto's auto-advance unit, as the Fury/Westerner had manual advance magnetos. Photo taken from Hitchcocks' site.
A.
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@heloego: Thanks, left still is in work ;)
@Adrian: Yes, I first thought I might cut down the "bulb" and make it flat like the original, but then it's a homebuilt solution and no exact replika, so it wouldn't really make a difference :)
But that's a great view of the original cover without an agle drive attached, or covered up, quite rare! I immagined it would be like this but now I know for sure, thanks!
P.S.: I haven't forgotten about the fork ears... :-[
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They're still available! ;)
A.
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It's also interesting to see your reclamation work on the oil pump housing. I still have the timing cover off my old Electra-X, the scavenge side is badly scored where little pieces of big end still manged to get through the sump plug strainer. I was wondering if machining out for some sort of oval insert could be done, though welding and a good milling job would do just as well.
A.
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@Adrian: Probably it's even the better way.
Finally I started work on the gear change mechanism!
I was thinking about several options, but none of them was really good or would have worked without having bad side effects. After all I found one that pleases me.
The main problem was the rear set foot rests and a resulting position of the gear change lever.
The lever just turned backwards would result in a very short lever, high forces and a switched shift pattern - not accepable!
One could just fit a lever and some sort of linkage. But still you'd have to find a good way of mountig it on the bike and you'd have a lot auf links and joints on the outside. Not an issue on a racing bike, but on a "dirt bike" that's crap.
So I chose a different approach.
Here's the basic layout of the Albion gearbox everybody knows and loves ;D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_282.jpg)
Now here's my idea. As standard you'd have a "negative" ratio with the lever on the shaft beeing longer than the one on the ratchet, which leaves you with quite a long foot lever. So if you changed this ratio, you could mount a shorter lever. And the ratchet and lever go different ways. If you were to mount the lever backwards, you'd have to have both going the same direktion, to stay with your known gear shift pattern.
So I changed the levers to a linkage. To achieve that, I first shortened the parts and turned the rachet 90°:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_283.jpg)
The linkage looks adventurous, but there are quite some obstacles to look out for!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_284.jpg)
First tests were promissing. Next I have to make the top and bottom plate to cope with the turned assembly.
But this gives me some advantages:
-Same shifting force as usual
-Keeping the shift pattern
-Keeping the neutral finder
-No outside linkage
One problem is the spring that pulls back the lever. This way I can't use it as it was before and I have to figure out a different way of doing it, but I'm on that! 8)
So long,
Andreas
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What an amazing mind & skill set...it's like watching Michelangelo build a motorcycle.
Thanks for sharing this project, can't wait to see what's next.
Best regards - ACR -
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Have you seen Grumbern's (RE) Indian Chief restoration? ;D
A.
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Yes, I found it the other day - very impressive. You don't see artistry like this often. I'm happy when I can bolt on a new part that works! Way back in the 70's in Tucson I knew a retired machinist/fabricator that had built his own running Scotch-Yoke motor from scratch. The small consolation is that without the army of us feckless parts-changers for comparison, the truly talented wouldn't obviously appear to be as amazing as they are. The breadth of skills is what I marvel at, let alone the quality of workmanship. I learned a lot from just following the decision tree dialog, which brings up another separate well developed skill set- an ability to impart what you know in a comprehensible manner to others. This a great website, what a resource rich environment.
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Thank you guys, I'm always happy if my work finds appreciation ;D
So here's some more.
The base plate didn't need much alteration. Only the stop was pressed out and relocated by 90°:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_294.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_295.jpg)
Much more difficult was (or still is?!) the centering spring for the ratchet claw. As I didn't find any good alternative I ground two notches into both parts and clamped them together with a spring band:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_296.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_297.jpg)
Due to the off center axis both parts will cross during operation and tension up the spring, which brings them back into position. Works, but still needs to be secured and protected from slipping and falling off...
As expected it got really close for the kick starter spring, but luckily somehow everything doesn't foul just like that ::)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_298.jpg)
Maybe tomorrow I can make the top plate and then it's only details.
So long,
Andreas
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The top plate is finished.
But first the original part:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_299.jpg)
From this the important holes where transfered to the sheet metal and drilled. The one segment is already filed in shape:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_300.jpg)
Cut and the second one done, it's ready for a quick try on:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_301.jpg)
And the final shaping done. The somewhat strange shape results from maximum guidance for the ratchet parts and clearance to the gearbox cover:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_302.jpg)
The linkage just clears the clutch lever and to the bottom the kickstart return spring is the limiting factor:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_303.jpg)
Clutch lever also is free at the top:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_304.jpg)
Gearbox cover and neutral finder mounted:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_305.jpg)
And a quick demonstration:
https://www.youtube.com/watch?v=y68Tk3vONoY (https://www.youtube.com/watch?v=y68Tk3vONoY)
So long,
Andreas
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Andreas never ceases to amaze me with his skills and ingenuity.
Frank
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Inspiring as always! Looks like someone needs to start selling the "kit" to the dirt riding contingent & Cafe folks! Use what you have for a pattern, maybe a nice niche market opportunity for some retiree with a nice shop & some spare time...? Certainly replaces a lot of clunky linkage. Does "Grumbern" translate as Da Vinci in German? :) - ACR -
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Thank you! If this was to be made as a kit, some other improvements could still (and probably should) be made. But I don't know if this would really pay off?!
Oh, actually, grumbern translates to potato ::)
Yesterday I worked on the timing cover. The welding was done some time ago, but it still needed reboring. Using a hand grinder probably wouldn't give a good result and necessity begets ingenuity. So I first removed the Multifix tool holder and set up the timing cover instead. Using a perfectly fitting pipe and metal sheets I could adjust it to the right position and clamp it down:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_306.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_307.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_308.jpg)
After that I changed the three jaw chuck to an MT adaptor and set up a boring head. I had this for a long time now and finally it came to use! ;D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_309.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_310.jpg)
Gruß,
Andreas
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And while we're there we also make the bore:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_311.jpg)
And tap it. Really not a lot of meat there!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_312.jpg)
So long,
Andreas
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https://www.youtube.com/watch?v=3iLK-4EnPnk (https://www.youtube.com/watch?v=3iLK-4EnPnk)
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My filler cap has arrived! :D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_313.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_314.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_315.jpg)
Make: Bonora, Bologna :)
I also finished the second tank side panel - now both need to be matched and then it's time for the top panel 8)
So long,
Andreas
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Now THAT's some bling, Grumbern! :) - ACR -
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That's how the cap looks like on the tank by the way:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_316.jpg)
I think I'll mount it a bit further in the back, but we'll see.
For now I finished the tach-drive flange:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_317.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_318.jpg)
The angle drive shown belongs to the Interceptor and will not be mounted on this bike. Also, a tachometer is more than unnecessary on a trials machine, so the flange will be covered by a plate and only used for setting and checking the ignition timing:)
So long,
Andreas
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Here you can see how I made it:
https://youtu.be/ijYjG3PfCNs
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Grumbern, I have enjoyed following your build threads very much, but, I do have a little concern about your fuel cap.
Going off road, there is a good chance of the bike having a sudden stop, where you carry on sliding up the tank, need I say more !!!
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Haha, you're not the first to mention this ;D
Maybe I should add some armour to my pants for serious riding?! :o
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Ha Ha, good idea, my wife was making some shish kebabs for dinner, so your cap made me wince a bit.
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This update isn't as glorious, but just as important.
Gave the worm nut a new cork seal:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_319.jpg)
And made a new magneto gear nut to fit a tachometer drive:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_320.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_321.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_322.jpg)
So long,
Andreas
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Now the top of the tank is hammered and biggest part of the hammering done 8)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_323.jpg)
Next I've done the cutout for the filler neck. Attention, pofessional tooling! ;D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_324.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_325.jpg)
We're getting closer...
Andreas
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Again, excellent workmanship, though I do wonder, why would you need a rev-counter on a trials bike?
A.
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Absolutely true! I just did it because the works trials bikes sometimes had them and, for a bigger reason, to set up my ignition timing disk ;D
So it really is only a gimmick, just for fun ;)
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And on we go with the filler neck. Starting with a 55x55x12mm piece of AlMg3:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_326.jpg)
Drilled a center hole in the middle on both sides:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_327.jpg)
And put it on the lathe between centers:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_328.jpg)
With this short geometry this set up isn't ideal, but it works, if you only make light cuts.
Second side was done in the calssic three jaw chuck:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_329.jpg)
The finished filler neck viewed from below:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_330.jpg)
...and above:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_331.jpg)
The filler cap fits perfectly:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_332.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_333.jpg)
Now it's really starting to get exciting!
Andreas
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Nice!Gotta love this thread! ;D
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cannot see pictures any more... :-[
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Try a different internet browser. I can see most pictures with Firefox, if that does not work for you then try Chromium, the open source version of Google Chrome.
A.
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I've heard from several people that they have problems seeing pictures hosted on third party servers recently and I suppose it's a software update thas causes this. When clicking in the area where the pictures should be you should be able to "open in new tab". This is a bit laborious but still a workaround...
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cannot see pictures any more... :-[
Not just me then?
I can see other poster's images but not ones on Andreas's posts.
[Using Chrome]
Frank
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Can see them indeed again with an other browser.
Thx.
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Some more updates.
The front wheel is now done an equipped with a tyre:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_334.jpg)
I also did some retouching on the right hand tank panel and now I really like it. I don't say that too often, but I am satisfied with it :)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_335.jpg)
So I tack welded the three pieces:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_336.jpg)
The welding will be taken care of by a professional though. My results don't reach the level of quality that I'd want and trust. With this thin material and vibrations every little error won't be forgiven.
But it doesn't look to bad until now:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_337.jpg)
So long,
Andreas
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The tank should be a classic Bike's crowning glory, I hoper you professional welder gets this.
Meanwhile that headlamp could use a bit of tender loving care, especially the rim. Next on your job list?
A.
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Yeah, he's welding the battery cases for the new Porsche Taycan at the moment, so some good meters of welding Aluminium every day from 1mm to over 20. I guess he's got some experience and knows his trade :)
He also thought the pictures I showed him quite astonishing, so I don't think he'll just do it as a simple side job.
The headlamp should probably be the last thing I am concerned with, lot's of other stuff yet to be done there and a headlamp isn't that necessary for a trials bike ;)
Andreas
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If your welder is convinced that you're as serious about what you're doing as he is about his own work, that is a very hopeful sign!
A.
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Well guys, one (to me) big step is taken: The top of the tank is welded! 8)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_338.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_339.jpg)
With cap:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_340.jpg)
The root of the weld is very strong ;)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_341.jpg)
Thanks to Chris, who did this professional weld, that was beyond my possibilities. I won't sand the welds but leave them as they are.
Despite some concerns, the cap isn't as prone to causing any harm as it might seem:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_342.jpg)
Also the oil pumps and pre filled filter (who ever spent an hour with the kick starter to fill the dry system will know why) are installed in the timing chest cover:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_343.jpg)
So long,
Andreas
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Oh, so NICE! ;D 8)
Glad you got some help on the welding. I know a good weld from a bad one, but until I get some practice with my MIG rig there's no way I can compete with that.
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Yeah, Chris is a welder in our firms prototyping departement and does a lot of crash relevant welds on structure parts for Porsche, BMW and Audi. So he definitely knows how to do that correctly :)
Today I was finally able to do the cut out for the tank tunnel. For that after marking everything I drilled the radius:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_344.jpg)
After removing the excess material I filed the edges, final shaping will be done together with the tunnel:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_345.jpg)
Fits much better, that's the way to go! :D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_346.jpg)
So long,
Andreas
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May the puzzle begin:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_347.jpg)
All parts found and serviceable, ready for cleaning:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_348.jpg)
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This might be of interest, ethanol-resistant floats for the Monobloc carburetor.
http://amalcarb.co.uk/monobloc-series/376-series/floats/monobloc-stayup-float-viton-tipped-needle-valve-kit.html
A.
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Can somebody please give me the name or a description of the handlebar Grumbern has used on this bike? It's the bend I believe I'd like to have on mine.
This build, and Grumbern's skills with both showing and telling about it are utterly inspiring!
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I think he calls them a set of chopper bars very early on. How about a set of Western or semi-Western handlebars from a Brit bike specialist who has spares for the export 70's Nortons or later (Meriden) Triumph twins?
A.
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@Adrian, Yeah, I _think_ it might be a Western bar, but with everything closed, it's pretty hard to get your hands on anything to know the feel for sure.
What I'm wanting is to effectively move the grips forward to where they'd be with a normal trials/scrambles bar if the clamps were over the stem, not 2" behind it. Threadjack done though.
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Our Indian friends have top yokes/triple trees where the handlebar clamps are in front of the stem, which they fitted to the 535 Lightning and 350 Thunderbird (home market) models. If you have jest spent reasonably big $$$ on the alloy top yoke, it's easier to change bars.
A.
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Yeah, those new style clamps are, uh, exceedingly utilitarian looking—nothing like the beauteous curves and distinctive shapes of the casquette or the trials top yoke. No interest there, though I would consider swapping on a set of Ceriani or similar European alloy triples from the '60s if such were to turn up in my feed.
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I'm very sorry, but I have no idea where these bars originated from. These were mounted on the bike I salvaged and took parts from for the Laubfrosch. It just looked right, when I put it on there and so I kept it. I believe there were some Bullets in the early 90s, or even mid-80s equipped with higher bars like this one, but there might be others from smaller Japanese bikes that would come close to this one.
Regards,
Andreas
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Thanks Andreas. No worries, and please keep up the gorgeous work on this beastie!
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Some things happened until now.
Firstly, I set the bike up on my multi purpose IKEA table ;)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_349.jpg)
Then I started working on the foot pegs:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_350.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_351.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_352.jpg)
As I messed up the other one due to gas contamination wile TIG-welding and I wanted to move the pegs a little higher anyway, I made a second pair:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_356.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_357.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_358.jpg)
I also removed the gearbox cluster for inspection:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_353.jpg)
As it showed this was no mistake, as the high gear pinion has a broken tooth:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_354.jpg)
These are still the old pinions with 30-18 gearing, but I ordered a 15/25 replacement that should do as well from India.
Otherwise the gears look fine, but when disassembling the rear wheel for putting in new spokes, I damaged one lockring stud:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_355.jpg)
The previous owner glued the nut with thread lock. Hopefully I'll be able to obtain another one, or else I'll have to make one myself.
So long,
Andreas
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A source of imperial thread fasteners in stainless steel (metric too, as well as Laverda parts).
https://www.motalia.co.uk/stainless-fasteners.html
A.
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Are you going to use this Enfield in competition? Just an observation I think you might find the footrest a bit on the low side, your feet need to be up out of the way of rocks and so on. I trialled an Enfield back in the 70s and rocks, going over logs etc catching your feet were the most reason to bring you to a halt. my foot rest were up by the swing arm pivot.
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Thanks Adrian, this site might be helpful some time!
@Symmo: No, at the moment I have no plans of using it for competition, just for fun, but with a competitive touch ;)
I mean, it should be built so it might be (or have been) used in competition, but I don't need to go into every last detail as it could cost me a point or two otherwise. If that was the case, I guess some other details would have called for different choices as well (for example engine mounts from Aluminium instead of steel).
The pegs aren't that low really, because the suspension is quite a bit higher than original (about 3-4 inches).
Andreas
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Longer rear shock absorbers will mean a bit of extra work dealing with the rear chain run, quite possibly! I you haven't already seen it, this neat chain tensioner set-up was posted on Hitchcocks' forum recently.
A.
https://messageboard.hitchcocksmotorcycles.com/viewtopic.php?f=3&t=11467
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Yes probably. I thought about fitting sliders of any sort, but I'll see once a chain is put on.
Andreas
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As the main shaft bearing was a bit lose, I glued it in place with Loctite while securing it with a somewhat improvised setup:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_359.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_359.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_360.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_360.jpg)
The gars were disassembled, cleaned and found to be ok. With exception of the lmain shaft sprocket which was changed for a new one, as well as the fitting kick starter gear:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_361.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_361.jpg)
A little accident happened when removing the rear wheel bearings :o
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_362.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_362.jpg)
Not wanting for this to happen again, I machined a nice knurl and will give it a drop of Loctite as well:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_363.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_363.jpg)
As I didn't want to turn over the engine by hand, I simply modified an old M10 bolt:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_364.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_364.jpg)
Way better!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_365.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_365.jpg)
Oil pump working!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_366.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_366.jpg)
But I had to whitness this as well:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_367.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_367.jpg)
What the ...? There shouldn't be any oil there, but it keeps coming consistently. I'll have to put a fiber washer under there, the bore of the bolt broke through to the oil pump shaft.
I made a new hole in the kick stater shaft to give the return spring a bit more tension, as the kick start lever will be heavier and less optimal in geometry after it's modified to fit the bike:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_368.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_368.jpg)
The gear change mechanism parts freed from dirt and rust:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_369.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_369.jpg)
And mounted just in place:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_370.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_370.jpg)
And I didn't have a securing bolt for the final drive sprocket, so I made one:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_371.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_371.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_372.jpg)
Link (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_372.jpg)
One step at a time...
So long,
Andreas
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Thanks for the links!
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AS I needed longer studs for the primary housing, I made some from M8 bolts and cut a 5/16-BSC thread to go inside the engine housing:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_373.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_373.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_374.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_374.jpg)
The kickstart lever had to be a bit longer to clear the foot rest, so I forged a new middle part:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_375.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_375.jpg)
The kickstarter: was bent to allow for a different design:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_376.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_376.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_377.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_377.jpg)
Both combined...
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_378.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_378.jpg)
...result in a longer lever:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_379.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_379.jpg)
And after some more bending:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_380.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_380.jpg)
That's how it looks on the bike:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_381.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_381.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_382.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_382.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_383.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_383.jpg)
This might already work. If not I can still make some adjustments. but first I'll have to give it a try like it is.
As the Indian primary cover had quite a tilted bore pattern, as well as too little clearence (litterly none), I had to redo this too.
The primary sprocket would fit, but with the chain it interfered with the casting. So I made a fixture to clamp the housing to my drillpress:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_384.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_384.jpg)
Centered and clamped in place:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_385.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_385.jpg)
Makse some space for the sprocket:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_386.jpg)
>>Link<<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_386.jpg)
The chain tensioner needed to be set back a bit as well:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_387.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_387.jpg)
Close, but will do:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_388.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_388.jpg)
Better!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_389.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_389.jpg)
More to come... 8)
-
Finally I started to work on the tunnel/bottom section of the tank.
First a generous rough cut and bending of the tunnel:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_391.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_391.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_392.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_392.jpg)
Marking the bottom line of the tank, make the cut for the "neck" and folding over the sides for the bottom (works ok with the vise):
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_393.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_393.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_394.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_394.jpg)
After that marking the outline of the tank an cutting it:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_395.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_395.jpg)
After some trying, bending and filing both tank and tunnel go together nicely:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_398.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_398.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_399.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_399.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_400.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_400.jpg)
One needs to stay in tough with current technology and nowadays there's now way past CAD - so I was told!
So I also use the advantages "Cardboard Aided Design" (to quote Paul brodie ;) ):
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_401.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_401.jpg)
After that more cutting, still keeping a bit of reserve:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_402.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_402.jpg)
Using two old bearing rings and the vise to form...
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_403.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_404.jpg)
... the funnel for the petrol tap:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_405.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_405.jpg)
After the "neck" was hammered I could start forming the collar:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_406.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_406.jpg)
As you can see the metal started to crack here, so I drilled a hole at the end of the crack. Started to do so again though...
Some more:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_407.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_407.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_408.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_408.jpg)
My biggest nemesis in this case:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_409.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_409.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_410.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_410.jpg)
And I was right to think so, as it started to crack in one spot as well. I do hope a small spot weld will do to cure this.
All in all I am well pleased with the outcome and one learns a lot by doing this kind of things :wink:
That's it for now.
Andreas
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Going on with the tank.
I made a little tab at the end for a rubber band to hold on:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_411.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_411.jpg)
I allso made and welded two thick washers to strengthen the front mount, as well as a lug for the tap, and tack welded top and botton part of the tank:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_412.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_412.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_414.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_414.jpg)
While already having the welder in action I did the non fitting bores on the primary housing:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_415.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_415.jpg)
The tank was now done to be handed over to Chris to weld it all. Then it happened...
-
The links work well - thanks for that. Amazing as always to see you in action! -ACR -
-
It's just a work-around, but as long it's sufficient... 8)
But on with the tank. I still can't look at these pictures without disgust and pain.
In hindsight I might have been able to weld it myself, as V-joints are much easier to do than butt-joints, with the root being not that important (in this case). Maybe I should have. But I let the welder do it, who formerly did a good job at the joints of the top section. This time he seemed to be in a rush and screwed up, and worst of all sanded down the complete edge (about 15mm) along with the outside:
(http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_01.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_01.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_02.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_02.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_03.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_03.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_04.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_04.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_05.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_05.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_06.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_06.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_07.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_07.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_08.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/Desaster_08.jpg)
I was devastaded, seeing all my efforts of the last months go to waste... :-X
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Aaaagh! Nightmare. :o :'(
What will you do? Get him to put it all right, assuming it can be repaired. Surely most of it should be salvageable. Look for a different welder?
I suppose one thing is never to assume people understand what you want, maybe it's worth spelling it out in painful detail, in writing, though you might already have done so!
A.
-
While still coping with the depressing events regarding the tank, I set it aside and decided to work on the primary housing again.
Not owning an automatic facing head at that moment, I used my boring head to plain the flange in little steps:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_417.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_417.jpg)
Determine the actual positions for the threads:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_418.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_418.jpg)
And bring my Tapmatic into use 8)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_419.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_419.jpg)
Thinking about a way to repair the tank, I tried a little with making a fake hammering. One part is hammered, one part ground with a Dremel and sanded. Can you guess wich is which? ;D
(http://www.provinzkartoffel.de/picture_library/350_Trial/FAKE.JPG)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/FAKE.JPG)
So long,
Andreas
-
Now that I knew this technique would work, I could start to repair and replace the lost material. How? Welding, of course!
First the lug for the tap:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_420.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_420.jpg)
Lots and lots of welding:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_421.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_421.jpg)
The molten away edge renewed:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_422.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_422.jpg)
As can be seen, a lot of sanding wax is cooking out. I would have had to sand it first to remove all of it, but I wouldn't want to remove any more material and weaken the structure any further. With most of it having to be sanded later, the roughness of the welds will not cause any problem.
After even more welding, consuming more than 30m of wire, the outlines were reconstructed as needed:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_430.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_430.jpg)
To have it a little more even, I took a finishing pass to fuse the single layers as well on the outside and the inside:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_431.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_431.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_432.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_432.jpg)
After grinding and sanding to the final shape, I started to grind little and somewhat arbitrary dimples into the surface to mimic the hammering:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_433.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_433.jpg)
Right side completed:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_434.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_434.jpg)
Followed by a finish of 240 grid sanding star and steel wool:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_435.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_435.jpg)
Starting to look quite nice again. Some parts of the repair still seem a bit obvious, but maybe this will change after some "aging".
I have a lot more content here, but you'll have to give me some feedback to keep me motivated- this is not a one man show! ;) ;D
So long,
Andreas
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Glad you were able to save the tank! What an impressive project...
Ludo
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Somehow I didn't think you would let all that hard work go to waste without a fight, which you appear to have won!
I'm certainly still hanging in for the completion of this project, others are too. Aren't you, guys? ;)
A.
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It's not everyday you get to see an actual Renaissance Man in action. Both educational & inspiring - Thanks!
https://helpfulprofessor.com/renaissance-man/#:~:text=A%20Renaissance%20Man%20is%20a,all%20of%20these%20things%20effortlessly.
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I've only just joined this forum and I've been looking back at some of this project. Wow! What a job. Keep up the great work.
I recently finished my J2 project and I understand your feelings. Every now and then I would pack the whole lot up, throw a cover over the bike and vow to take up piano instead because bike resto was TOO HARD!! But, it only lasts a short while before the withdrawal symptoms kick in and I'm back to it.
Everything is a challenge, which means that there are many victories to be had. Get into it mate... in the end, your bike will be awesome.
-
Thank you guys, now I just have to deliver, eh? ;)
I'm certainly no "renaissance man", but I'll go with the "multimath" 8)
As you said I couldn't let go of the tank and with the fake effect proved functional I was back on track!
Beeing a fan of these easy to maintain solutions on the Enfield I wanted to push it even further. So I wanted the tank to be removable without the need of tools. In the back a rubber band is used, but in the front there's a bolt. I could have used winged or knurled nuts, but I came up with a better idea!
But first, I wanted the tank mounted securely and with a big contact area, to spread any forces as wide as possible as well as reduce any vibrations to a minimum. Both would mean death to any sheet aluminium part if not taken care of.
So I made a two piece lug and a set of foam washers, acting as a cushion. These were cut out roughly and then trimmed on the lathe using sanding paper:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_423.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_423.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_424.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_424.jpg)
Mounted to the frame:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_425.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_425.jpg)
And here comes the fun part:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_426.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_426.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_427.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_427.jpg)
Do you recognize, what this is? ::)
This makes any tool obsolete while providing a good clamping force.
Another thing that would have irritated me, was pulling the gas hose. Good thing the tap has a 1/4-BSP thread. Ferrules with nurled nuts are available used for welding gas connectors!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_428.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_428.jpg)
I turned down the second... erm...hook-part(?!) leaving only one in the front and bent the ferrule ~90° to match the carburettor connector, avoiding any loops routing the gas line:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_429.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_429.jpg)
And here's the rubber mount for the rear. This really is just the O-ring seal of a defective water pump and had just the right dimensions:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_457.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_457.jpg)
Now the tank can be removed effortlessly and in a matter of seconds, exactly what I wanted! ;D
So the last thing to do before filling it up with gas, was a pressure test. I gathered some parts I had lying around, to make a simple test rig. The German TUeV (technischer Ueberwachungsverein - "technical supervision society") requests all non pressurized tanks and reservoirs to be tested at 0.3 atmospheres to make sure they're airtight and safe to use in traffic. While that's not my main concern, it's still a good rule to follow for testing. So I pressurized the tank to 0.3 bar and let it set over night. An hour later, no drop in pressure could be recognized. After ~24hours there was still 0.14 bar left. A good value in my opinion, considering some leakage from the (old) valve, rubber plug and screw connections:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_456.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_456.jpg)
So that's it with the tank for now, but there's still more to come. Stay tuned! 8)
Andreas
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The alternative use of the Campag skewer is brilliant, I liking this build right from the start, great engineering.
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Tanks, I absolutely wanted this kind of axle als these have that gorgeous artistic old time look 8)
You might remember that broken securing ring of the rear wheel.
To repair it, I first drilled our the old bolt (worked perfectly on the lathe) and brazed in a new one:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_436.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_436.jpg)
Figured the primary case studs were just the right size and thread. After bead blasting and some paint it's ready for use again:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_437.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_437.jpg)
I allso drilled the broken off piece out of the nut. Whoever wanted to know, how a cleaned out thread looks like, is welcome :D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_438.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_438.jpg)
Back in the rear wheel where it belongs:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_442.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_442.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_443.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_443.jpg)
So long,
Andreas
-
Now it was time to start with the seat:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_439.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_439.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_440.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_440.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_441.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_441.jpg)
Lookin good already. now it needs the edges folded in and some mounting points.
For the rear mount of the seat I made another beam and welded it to the sub frame:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_444.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_444.jpg)
The before made blocks of Aluminium bolted on:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_445.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_445.jpg)
Filed to fit the seat and welded to the same:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_446.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_446.jpg)
Now it needs upholstering, but all at it's time 8)
So long,
Andreas
-
One thing I dind't have in mind, was the main shaft. My gearbox originally was off a 500 twin, with a considerably longer main shaft. Unfortunately I only recognized this issue trying to mount the clutch. Marked on the rod is the length of the twin main shaft, compared with an Indian made:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_447.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_447.jpg)
I still had this indian made main shaft lying around, manufacturer unknown. In hindsight, I should have dumped this one and taken a branded one. These no-name parts are a really bad fit!
That aside, Indian shafts are made for metric bearings, British ones are imperial. I didn't want to change anything on the gearbox housing. So the plan was adjusting the shaft from 17mm to 5/8".
First check runout:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_448.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_448.jpg)
At first turning went pretty well, until the last few tenths. Probably the shaft was too hard. One part of the shaft was within specs, and another still 1/10mm above! So what could I do? Improvise!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_449.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_449.jpg)
One can easily spot the high areas:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_450.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_450.jpg)
No bashing please! This isn't what you might call ideal, but it worked ;D
Taking measurements - they meet the specs:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_451.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_451.jpg)
I also had to adjust the length and the shaft profile. As mentioned before, this was a very bad fit. The clutch center also needed a bit of persuasion to take it's place. Well, let's see. I just hope it won't desintegrate :o
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_452.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_452.jpg)
So long,
Andreas
-
Before you fall asleep:
Did some work on the clutch. It seems I was delivered push rods for the 4-plate clutch and these are too long for the 350 3-plate clutch. So I shortened and re-hardened the rod. For that I heated the tip to aprox. 700°C and dipped it in oil. The file test was positive and asured full hardness. So I tempered it again at about 300°C. Now the fila has some grip again, but you can still feel the hardness. I would guess about 50HRC, which is good against wear 8)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_453.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_453.jpg)
Then the clutch received someimprovements . Besides a new set of friction and steel plaes, allso a needle roller bearing. Together with the two balls there shouldn't be any significant friction and in trial use there will probably be a lot of clutch use ::)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_454.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_454.jpg)
Such bearings are available commercially, but they are about 30€. The AXK0515 is just a thenth in a set of two with the fitting thrust washers ;)
Dimensions with just one thrust washer are the same as standard and are a direct fit. The clutch pad should be hard enough, so no second thrust washer should be needed there.
Everything assembled again:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_455.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_455.jpg)
So long,
Andreas
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Always a learning experience watching you fabricate - Thanks for sharing! - ACR -
-
Received a package from the Netherlands:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_458.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_458.jpg)
So I could fabricate some of the cables and mount the tank. Now I was able to start the Laubfrosch for the first time! In this video the ignition adjustment wasn't active, so it was running at full retard. This way the engine is loud, runs unsteady and spitts flames. Who cares, it runs! ;D
https://youtu.be/AizhZC8Hnkk
So long,
Andreas
-
That special moment... 8) Well done!
A.
-
Still a long way, but an important step has been taken.
Almost as important is the brake.
As the lugs on the fork tubes for mounting the mudguard, as well as the brake cable were missing on this particular set I used (they wouldn't do for a restoration project anyway), I had to get creative.
I let myself be inspired by the J2 Bullet and made a similar bolt:
Planed the first side and turned the outside diametre, as well as the grooves for the brake shoes:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_459.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_459.jpg)
Fits perfect!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_460.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_460.jpg)
And the other side turned with a radius at the end, ready for turning the thread (5/8-BSC):
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_461.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_461.jpg)
Comparison old vs. new:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_462.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_462.jpg)
And here it was: Too short! >:(
I didn't think about the fixing nut, that wouldn't leave enough space for the knurled nut of the brake adjuster...
So back to start! That's why in the next picture it is longer, but with a fittting bore, a flat and the grooves for the knurled nut:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_463.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_463.jpg)
On the other side there's a notch for guidance of the adjuster, made with a dull chissel:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_464.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_464.jpg)
Just perfect!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_465.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_465.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_466.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_466.jpg)
Here it is with the cable:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_467.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_467.jpg)
And since I felt there hasn't been a picture in the whole for a longer time now:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_468.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_468.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_469.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_469.jpg)
So long,
Andreas
-
Last weekend I finally managed to reweld the exhaust pipe.
The reason was, that there was no good way to mount the silencer as it was:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_470.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_470.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_471.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_471.jpg)
Obviously this would have looked ridiculous, especially the end pipe.
So I cut the header pipe and lowered it a bit using a piece of straight tubing.
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_472.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_472.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_473.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_473.jpg)
After I tack welded it, everything looked fine but after welding, it had a downwards kink and fouled the engine housing. So I had to bend it a bit using my Acetylene torch, as you can notice by the dark colour in the bend.
Now I can start working on the real silencer and get rid of the cardboard dummy :D
So ,long,
Andreas
-
I went on a bit more.
First cut some sheet metal:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_474.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_474.jpg)
Not bad for a hand bend ;)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_475.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_475.jpg)
This might do!
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_476.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_476.jpg)
Next will be the internals.
So long,
Andreas
-
So let's first weld the outside of the can:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_477.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_477.jpg)
This time, thanks to thorough preparation with file and Acteone, but especially a more aggressive welding style with more power and speed, even the root turned out nicely:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_478.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_478.jpg)
And allso I did the recess for the filler bolt:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_479.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_479.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_480.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_480.jpg)
Step by step, but the shop's getting uncomfortably hot...
So long,
Andreas
-
Still anybody here? ???
-
I think I'M still here! ;)
Pressing affirmation button in 3, 2, 1, BEEP!
Seriously, it's coming on great.
My own 350 project is still a little while off. It's for my wife, ostensibly, hence the low seat, but if she doesn't get on with it a SUPPOSE I might keep it. ;D Say hello to ASBO45 or Not A Westerner.
(https://i.postimg.cc/g0SH6bHz/DSCF9269.jpg)
Allowing for the addition of lights and a different exhaust, the inspiration was one of Hitchcocks' Instagram archive photos of a genuine 350 Westerner, which I hope they won't remove.
(https://i.postimg.cc/L5Y6NbPc/Screenshot-2022-06-20-at-13-52-34-Hitchcocks-Motorcycles-hitchcocksmotorcycles-Instagram-photos.png) (https://postimages.org/)
A.
-
Thanks Adrian for your reply. I almost thought I was talking to my own again ;D
The Not-a-Westerner's coming along. A Bates saddle might look a bit less clunky thoug, and add to the American style, don't you think?
So here we go with -as promised- the "intestins".
For that I first reactivated my punch and fabricated a second screen pipe. That really was fun and I actually was kind of sad when it was finished :D
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_481.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_481.jpg)
With this and four end plates, the ingredients for the internals were complete:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_482.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_482.jpg)
then combine the two bent Aluminium sheets:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_483.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_483.jpg)
Attach the endplates:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_484.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_484.jpg)
Now you can see how the silencer will work:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_485.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_485.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_486.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_486.jpg)
And a view into the silencer put together:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_487.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_487.jpg)
Appart from some minor constructive errors, all fits together quite well and I am convinced, the silencer will do a good job. But I'll only know for sure, once everything is welded up and taken for a test 8)
So long,
Andreas
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Still anybody here? ???
I am here too, I enjoy reading about your build.
-
i'm here too! just flabbergasted...
Ludo
-
Still anybody here? ???
Yep I've been here since your first post, can't wait to see and hear the finished project. You are some engineer.
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Thanks a lot, that raises my confidence ;D
The silencer is now sealed and fits the bike quite well:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_488.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_488.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_489.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_489.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_490.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_490.jpg)
And now the fun part: It's super silent! At least for my understanding.
I'll probably have to make another recess, as the clutch wire comes dangerously close. And it needs a good mount and head deflector, but the design may be counted as a success! :)
Of course this didn't go without a mishap and at the first test I managed to start the bike with a gear engaged and the lose chainjamed itself between frame and swinging arm. One can imagine, how it looks there now >:(
Well, no that bad. some cosmetic surgery and paint and everything is fine again.
So long,
Andreas
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Yes I'm here too Andreas. Your work is Number 1. That bolt recess is unbelievable mate. I'd be happy if I weld two pieces of metal together neatly. Keep on keeping on.
-
Thanks a lot!
Here's a short proof it works:
https://www.youtube.com/watch?v=Cs1MN31xbOk
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Wow, I’ve really enjoyed reading your thread on the Chief restoration and am enjoying following this thread as well. You are a true craftsman!
Jim
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That silencer/muffler doesn't sound overly restrictive. Looking forward to seeing the final result, which can't be far off.
Back to the Abfanjäger next?
A.
-
Yes, this will be next! ;D
But first there are still some things to do, like rear brake (and lever), chain guard, inner mudguard, front mudguard stays, tail light (well, not neccessarily), chain guide, rear engine mount, seat, sub frame clamps... all those nasty little bits you don't really notice, but are essential.
Thanks Jim!
-
Somewhere I have a photo of my 350 trials Enfield with sidecar that I used to ride back in the 60s, and as far as I can remember the great machine you have just built looks just like the photo of my old 350, but with a modern take on engineering. It was a wonderful competitive machine that got used and abused that just went on and on trial after trial, and great fun. Seeing you build your machine Andreas has brought back many memories of me and my mate (brother in law) from my trialing days. :)
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I'm very happy my project brings back precious memories :D
-
Due to an accident last summer, the following rehabilitation and a cold winter, that made the workshop unpleasant, not much has happened here since.
The last thing I did before that, was modifying the kickstart lever.
For this I first cut the lever and forged a piece to go in between:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_491.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_491.jpg)
After this I welded, forged and bent the lever like I did before.
Now it fits better with the footrest and the available way of travel:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_492.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_492.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_493.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_493.jpg)
Also I took care the lever wouldn't foul the oil filter housing:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_494.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_494.jpg)
It doesn't look as sleek as before, but works better and you wouldn't really notice, if you're now laying on the floor ;)
-
Glad you're back, I hope you're well enough to finish the bike and actually have some fun riding it!.
A.
-
Thanks Adrian,
I'm doing fine. It wasn't a bad accident but still left me unable to do anything for some weeks with a broken hand joint and as stated above, my shop wasn't that inviting in the winter. Also other project took up my time, like finishing my milling machine (an old Elliott Rapidmil - maybe more common in the UK) and making a safety valve for a Norton drag race bike.
And then I was fighting and struggeling with my sewing machine to make the seat cover. It just wouldn't sew reliably. So this took some time as well and I finally decided to sew it by hand.
For this I first slaughtered a leather stool which I picked up for free just for this purpose:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_498.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_498.jpg)
With the salvaged leather I started sewing the cover:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_499.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_499.jpg)
The seams were flipped over and doubled for looks and strength:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_500.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_500.jpg)
As the previously made upholstery was way too soft, I made another one from foam rubber.
Therefor I first cut the sheet on the band saw, glued it to the sand blasted and powder coated base plate and brought it to shape by rough cutting with a knife and refining using a rasp. I bruned the remaining lints carefully:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_501.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_501.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_502.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_502.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_503.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_503.jpg)
The cover obviously wants to resist a bit, but no worries ;)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_504.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_504.jpg)
Using strong clamps and water, it can be pulled down firmly to take the correct shape:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_505.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_505.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_506.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_506.jpg)
That's it for now, but more to come!
Andreas
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That's very good work, knowing your dislike of bulky pattern seats, I reckon this should result in a good fit.
First time I saw this however, I couldn't help being reminded of a pork pie... ;D
A.
(https://i.postimg.cc/QxsK1TXs/350-Trial-500.jpg) (https://postimages.org/)
-
I first had to google this - but yes, there are similarities ;D
-
Well, the cover now is glued on and greased. As predicted it darkened a lot, but this was my plan from the start and I like it.
Unfortunately I managed to lose a bit of tension while glueing and the cover is a bit more slack than I prefered, but I can live with that.
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_507.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_507.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_508.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_508.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_509.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_509.jpg)
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That is a great job. What did you grease it with?
Regards
Tony
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Black shoe polisch ;D
-
I used to help my daughter with her horse tack and we used Dubbin so I used that on my seat. The seat was all dried up and cracked and looked very bad but the local upholsterer told me it was ok and I should restore it.
I used a whole tube of leather conditioner which softened it up a bit then about half a dozen applications of Dubbin. It came up really good. Best thing about Dubbin is it doesn't stain your clothes when they rub on the leather. It's neutral in colour.
-
The seat
-
Looks good!
As the XS650 is almost ready again, we can continue with this one.
The recess for the clutch cable is done. I hope it's enough:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_511.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_511.jpg)
This is how the cable will be routed:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_510.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_510.jpg)
And just for fun a picture from my favourite view:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_512.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_512.jpg)
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Also started work on the brake pedal. Solid it would be too heavy, so I made it from pipe.
It started with a length of electric installation pipe, from wich I cut a triangular piece and bent the rest into an oval cross sectioned cone:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_513.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_513.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_514.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_514.jpg)
Then I heated it with the torch and bent it into it's shape:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_515.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_515.jpg)
At last I filed the ends. Now it becomes visible, how it is going to look like:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_516.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_516.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_517.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_517.jpg)
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I can't remember the German phrase for single-minded, but I doubt if the English would do its German translation justice!
A.
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Thanks Adrian! I don't know if I got what you meant to say, but I'll just go with what I think you meant ;D
For the pedal I clamped a piece of flat steel 45° and milled some stairs. Then gave it a little bend:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_518.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_518.jpg)
Roughly cut the shape with a hack saw:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_519.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_519.jpg)
And after some filing welded it to the pedal arm:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_520.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_520.jpg)
From this angle it looks much rounder than it actually is. I messed up the weld, luckily it's on the bottom ;)
So long,
Andreas
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Amazing! Looks great.
-
Thanks!
Meanwhile I made a clutch cable. Between the silencer and the cable is a hard paper. That'll do. I also changed the routing of the cables. Now they run without narrow curves and half way neatly ;)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_521.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_521.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_522.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_522.jpg)
Also I weighed the frog as it is now and it came out a good 120kg - I think that's pretty good compared to the original ~170kg (according to datasheet, not checked).
So long,
Andreas
-
More to show.
First clamp a piece of mild steel in the lathe and turn it in shape:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_523.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_523.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_524.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_524.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_525.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_525.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_526.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_526.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_527.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_527.jpg)
With the resulting tube I could fit in the lever by filing, so the ribs lie perpendicular to the tube.
Yes, the square could need some attention - it was rescued from the bin...
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_528.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_528.jpg)
After that removed all the excess material from the tube:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_529.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_529.jpg)
Now I could weld both pieces:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_530.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_530.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_531.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_531.jpg)
As I didn't like the visible weld on the back (the pipe kinked in a bit while bending) and everything could look a bit more clean, I brazed and sanded the affected areas:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_532.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_532.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_533.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_533.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_534.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_534.jpg)
That's more like it ;)
So long,
Andreas
-
Some minor updates.
The silencer now has a rear mount:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_535.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_535.jpg)
Also I filed the hadle bar clamp to a more cast iron look. Left is the initial state (the "sibling" to it):
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_536.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_536.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_537.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_537.jpg)
I lowered the back of the seat as well and smothened the welded up holes in the engine mounts.
Then it's time for sand blasting and priming the parts:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_538.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_538.jpg)
Followed by several layers of paint:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_539.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_539.jpg)
So long,
Andreas
-
Moving on:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_541.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_541.jpg)
A little less eye catching: A set of chain sliders for the swinging arm and foot rest arm:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_542.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_542.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_543.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_543.jpg)
And some fringes for the adequate western look:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_544.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_544.jpg)
Ok, I'll admit, this isn't the plan.
It's all about cable management:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_545.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_545.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_546.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_546.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_547.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_547.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_548.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_548.jpg)
The leather was tanken of the same piece as the seat cover, so this adds some continuity
So long,
Andreas
-
Really not much to do now, is there? Will you have the cylinder head bead blasted or vapour blasted to match the cylinder barrel, or will you spray some crud over the cylinder to stop it looking too new? ;D
A.
-
I'll let nature go it's way ;D
There's still a lot of things to do though (chain guard and mudguard on the frame, front mud guard mounts, air filter, generator and electrics, rear brake, bash plate, ...). But I think I may be able to have a short ride this year at least.
-
Bike is looking great. Love that brake pedal...
-
I'll let nature go it's way ;D
The condition known as "new cylinder-itis" is a common sight on Bullet engines which have been tuned or otherwise modified, particularly where an iron barrel has replaced an alloy one, ASBO Bullets seem highly prone to this...
(https://i.postimg.cc/7PVf1Pvv/DSCF9067.jpg)
A.
-
;D
-
A package from HMC arrived and so I could work on reducing the speed by changing the secondary and primary sprockets:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_550.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_550.jpg)
A better view of the chain slider:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_551.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_551.jpg)
There's an obvious difference between the new and the standard primary sprocket:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_552.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_552.jpg)
The chain has a lot of slag, although ordered to specifications:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_554.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_554.jpg)
The adjuster bolt would just fall out with the tensioner in position:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_555.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_555.jpg)
So I took an M8 bolt and converted it to 5/16-BSC (and tried out my thread gauge):
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_556.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_556.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_557.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_557.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_558.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_558.jpg)
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_559.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_559.jpg)
This should work:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_560.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_560.jpg)
And also somethng handy for quick access:
(http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_553.jpg)
>>Link<< (http://www.provinzkartoffel.de/picture_library/350_Trial/350_Trial_553.jpg)
And the provisional result:
https://www.youtube.com/watch?v=t6n9rZIioUc
(comments and votes welcome ;) )
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Congratulations! You have a working trials Bullet. :) 8)
A.
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Yaaay!! Fantastic...