Author Topic: Project "Laubfrosch" - the trials hybrid  (Read 21891 times)

0 Members and 2 Guests are viewing this topic.

grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
on: May 25, 2019, 09:55:11 pm
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:




Quite obviously, there are some areas that wouldn't fit:










So I started by cutting off any parts that might be in the way:






Everything cleaned propperly:






Used a factory made stencil for the radius ;D






Fits much better now:








More tomorrow!
Andreas


mattsz

  • Grand Gearhead
  • *****
  • Posts: 5,525
  • Karma: 0
  • moto-gurdyist
Reply #1 on: May 25, 2019, 10:57:18 pm
Oh, boy, here we go again, just in time!!!



Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #2 on: May 25, 2019, 10:58:23 pm
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.



Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #3 on: May 26, 2019, 08:56:22 am
Trying on the magdyno:




Looking good!




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:






I also have an old Interceptor tank that might be used here - or an aluminium one?!






The donor for some of the parts:




The whole rear section is going to be used here and fits perfectly into the 250 frame:




A quick mock up with the front end put together - gotta love these half width hubs:




The wannabe- Chopper handle bars fit much better on a trials bike, don't you think?




I also got two packages from Austria:




Inside was a ready-to-salvage 350 parts collection:




As I want to use the narrow primary housing, the crank shaft had to be shortend. So first was the disassembly:










More to come...


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #4 on: May 26, 2019, 06:26:26 pm
Quote
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #5 on: May 26, 2019, 07:28:17 pm
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


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #6 on: May 27, 2019, 09:27:49 pm
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? ;)












Next will be the fork stanchions ;)


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #7 on: May 27, 2019, 11:33:31 pm
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.



A.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #8 on: May 28, 2019, 06:27:07 pm
Yes, it will be trimmed a bit.

But first, why would anyone buy a pair of 4" longer stanchions? To shorten them of course!






Only to cut a thread in them to accept the fork nuts!






Also you can clearly see the differences in the types of stanchions. Top to bottom:

-new type
-vintage '50s type
-early Indian type




Turned the lower part to fit the lower bushes used on the old folk legs:




Looking good:




Next I will continue with the crankshaft.
Andreas


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #9 on: May 31, 2019, 11:46:41 am
Still no one interested?

Ok, now here we go...
Completely disassembled the crankshaft:




To make the promary cover fit, I trimmed the end of the driveshaft:




Gave it a centre bore:




And cut a new thread to accept the primary sprocket nut:






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:




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:






Comparing the old one against the new one:




You can see the old one is already damaged:








The new bush is pressed on the crank pin, instead of being a floating one:




Turned the bush to its final diametre, exactly the same as the old one:






Fits perfectly:




And while I was at it, I did a little job on the connecting rod as well:






And finally I reasembled the crankshaft and trued it to just ~2/100mm of runout:




Stay tuned for more...


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #10 on: May 31, 2019, 06:53:46 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #11 on: May 31, 2019, 07:22:22 pm
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. I guess he would know 8)

Doing this wasn't very hard really, I tought it would be tougher.
Some more tomorrow...
Andreas


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #12 on: May 31, 2019, 09:05:45 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #13 on: June 02, 2019, 09:01:08 am
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:








This now is a little too low, but can be kompensated with  sheet metal:




I also made an engine stand (actually, it's five of them):




The broken steering stop was repaired:




Worked a bit more on the front mounting plates:




Also straightened the lower yokes, as these were bent back by at least 5mm!






Now it was time for new bearings, so I put the engine halfs in the oven:




Ready for reassembly:




I fitted the magneto drive gear with a bearing inner ring to give it a hard enough and smooth surface for the seal:




That's it for now.
Andreas


DavidGraves

  • Grease Monkey
  • ****
  • Posts: 292
  • Karma: 0
Reply #14 on: June 03, 2019, 03:22:50 pm
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


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #15 on: June 03, 2019, 05:52:20 pm
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


DavidGraves

  • Grease Monkey
  • ****
  • Posts: 292
  • Karma: 0
Reply #16 on: June 03, 2019, 10:19:51 pm
Thanks Andreas

You are also an excellent photographer and archivist of your work.


Arizoni

  • Grand Gearhead
  • *****
  • Posts: 7,409
  • Karma: 2
  • "But it's a dry heat here in Arizona
Reply #17 on: June 04, 2019, 01:36:35 am
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. :)
Jim
2011 G5 Deluxe
1999 Miata 10th Anniversary


mattsz

  • Grand Gearhead
  • *****
  • Posts: 5,525
  • Karma: 0
  • moto-gurdyist
Reply #18 on: June 04, 2019, 03:37:49 pm
Still no one interested?

What, my little happy dance means nothing to you?!?  :(

;D


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #19 on: June 04, 2019, 08:01:38 pm
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


heloego

  • A 2x4. My kingdom for a 2x4!
  • Grand Gearhead
  • *****
  • Posts: 2,485
  • Karma: 0
  • USA '12 C5, '06 ElectraX
Reply #20 on: June 06, 2019, 03:30:01 am
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.  :)
'18 Bonneville T-100, Blue/White
'12 C5 Classic
'06 Electra X AVL w/32mm Mikuni and Gold Star system.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #21 on: June 08, 2019, 10:18:40 am
Thanks a lot, now I know there's some people reading this ;)
Here's a picture of the primered parts an the rear frame:



Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #22 on: June 08, 2019, 01:24:27 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


mattsz

  • Grand Gearhead
  • *****
  • Posts: 5,525
  • Karma: 0
  • moto-gurdyist
Reply #23 on: June 08, 2019, 07:56:19 pm
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...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #24 on: June 08, 2019, 10:08:07 pm
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


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #25 on: June 09, 2019, 04:15:10 pm
Heres two pictures of the seam of the rear frame. To be able to propperly weld, I turned and pressed in a little lug:






As well welded on the brackets for mounting to the frame and seat:




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:








Gorgeous, eh? I love that structure, very old school! I absolute liked that on the Heinkel "Perle" (Pearl).
In combination with raw aluminium this is ought to look perfect.
So long,
Andreas


mattsz

  • Grand Gearhead
  • *****
  • Posts: 5,525
  • Karma: 0
  • moto-gurdyist
Reply #26 on: June 09, 2019, 10:37:52 pm
Very cool color!  I'm liking this so far...  8)


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #27 on: June 09, 2019, 10:54:50 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


chuychacon

  • Bulleteer
  • ***
  • Posts: 159
  • Karma: 0
  • TEAM BANZAI 88
Reply #28 on: June 10, 2019, 02:43:39 pm
Beautiful job!!

  your cat is drinking your beer?
Moto Guzzi Lemans 1980
Kawasaki 750 Twin Cafe 1982
Honda XL 350 older brothers age 18-20
Honda Dream 50cc hand me down age10-14


symmo

  • Scooter
  • **
  • Posts: 34
  • Karma: 0
Reply #29 on: June 11, 2019, 08:49:59 am
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.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #30 on: June 16, 2019, 09:09:04 pm
@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:




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?!




Andreas


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #31 on: June 16, 2019, 09:11:44 pm
@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:




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?!




Andreas


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #32 on: June 17, 2019, 08:10:03 pm
Try a different tank?



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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #33 on: June 18, 2019, 04:31:40 pm
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:






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


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #34 on: June 18, 2019, 06:57:02 pm
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.

Quote
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.

Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


symmo

  • Scooter
  • **
  • Posts: 34
  • Karma: 0
Reply #35 on: June 20, 2019, 06:23:33 pm
21" wheel surely, a must for an authentic looking replica.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #36 on: June 21, 2019, 09:01:09 am
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?!





Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #37 on: June 22, 2019, 05:03:35 pm
Quote
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.



-

« Last Edit: June 23, 2019, 01:48:57 pm by Adrian II »
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #38 on: July 05, 2019, 09:27:13 pm
Comes close!

The rims were cleaned up a bit and new tyres pulled on:




Tight fit!




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
« Last Edit: July 05, 2019, 09:29:37 pm by grumbern »


symmo

  • Scooter
  • **
  • Posts: 34
  • Karma: 0
Reply #39 on: July 06, 2019, 09:09:39 am
This is such an interesting blog, can't wait to see this machine finished and fired up. Great work.


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #40 on: July 07, 2019, 01:37:51 pm
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.

Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #41 on: July 07, 2019, 03:49:51 pm
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
« Last Edit: July 07, 2019, 03:51:54 pm by grumbern »


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #42 on: July 07, 2019, 04:34:07 pm
Quote
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.

Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #43 on: July 07, 2019, 06:43:24 pm
Yeah, thought I'd allow myself the luxury of an AC/DC-TIG welder - cheap China device though, but it does weld ;)


Bilgemaster

  • Just some guy
  • Global Moderator
  • Grand Gearhead
  • *****
  • Posts: 2,384
  • Karma: 0
  • 2005 Bullet 500ES in "Mean Green" Military Trim
Reply #44 on: July 08, 2019, 02:12:53 am
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.
So badass my Enfield's actually illegal  in India.

(Legal enough to pass muster if they don't look too closely in Woodbridge, Virginia, where the buses don't run at night, holidays or weekends and I'm a contender for 'Village Idiot')


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #45 on: July 08, 2019, 06:09:36 pm
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.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #46 on: July 12, 2019, 01:47:15 pm
Engine plates type "Special" :)



grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #47 on: July 14, 2019, 11:05:51 am
Now, second layer of paint applied:




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:




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:




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.








Today nothing else will happen here, but next week I can start the machining.
So long,
Andreas
« Last Edit: July 14, 2019, 11:08:20 am by grumbern »


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #48 on: July 14, 2019, 02:43:36 pm
Quote
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.

Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #49 on: July 14, 2019, 07:48:57 pm
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.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #50 on: August 08, 2019, 10:01:31 am
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:




The outside is turned to 14,3mm (9/16"):




Finally slotted it using a hand saw, so the axle, simply a piece of 12mm 1.4301 round stock, can be clamped:




Thas looks pretty much like this:




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?




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!








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


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #51 on: August 10, 2019, 11:21:59 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #52 on: August 14, 2019, 02:23:23 am
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.

Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #53 on: August 14, 2019, 12:01:13 pm
Yeah, I thought of this option, but it builds just so big. So I think I'll just go with the trials-type muffler.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #54 on: October 05, 2019, 04:44:37 pm
The view inside the combustion chamber. All nice and new:




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:




First the measuring:




And then cutting new ones from a suiting piece of paper:






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:




And a picture of the rebuilt rotor. Primary and secondary windings, as well as the condensor were professionally replaced:




So long,
Andreas


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #55 on: November 18, 2019, 09:35:47 pm
Next I needed an adaptor for the timing chest. I used a piece of aluminium that was roughly cut and turned:






Fitting the magdyno:




Drilling the taps:




Some spare parts:




Finishing the adaptor:




The rest was done with my highly sophisticated CNC centre - Completely Non Computerized (flat file):




With the shaft seal in place:




And with the pinion. You can clearly see there's still some missalignment:




That's why I put the engine on the mill once more:






Took off another 2mm in width:




As well as 1/10mm in hight, so I could use a 3mm shim, instead of several ones combined to 2.9mm:




The three bores were counter sunk:




After that the positioning holes for the magdyno had to be made. There are two in the right case and the shim:




The magdyno has two coresponding pins locating it on the crank cases:






this gives perfect alignment of the pinions:




The timing chest cover is in bad shape. Some idiot drilled a 1/4" tap, breaking through the pump housing:




But I found a nice small headlamp, that will look gorgeous on there:






So long,
Andreas
« Last Edit: November 18, 2019, 09:56:23 pm by grumbern »


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #56 on: November 19, 2019, 11:24:53 am
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...


Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #57 on: November 20, 2019, 06:39:17 pm
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


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #58 on: November 20, 2019, 09:49:13 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #59 on: November 22, 2019, 08:13:36 pm
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.

Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #60 on: November 23, 2019, 04:27:44 pm
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:






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
« Last Edit: November 24, 2019, 10:20:53 am by grumbern »


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #62 on: November 28, 2019, 08:32:08 pm
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #63 on: November 30, 2019, 10:22:49 pm
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



Bash it!




Getting in shape:




Well, still a lot to do...




So long,
Andreas


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #64 on: December 06, 2019, 05:09:12 pm
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:




And it's getting time to work on the details.
Before:




And after:




About one third is in acceptable condition now and you can see how it might turn out:




More to come...
Andreas


ERC

  • Grand Gearhead
  • *****
  • Posts: 1,809
  • Karma: 0
Reply #65 on: December 06, 2019, 06:51:30 pm
Hope you have a good English wheel to finish that off.  lol  ERC
2-57 Apaches, 2-57 Trailblazers, 60 Chief, 65 Interceptor, 2004 Bullet, 612 Bullet chopped.


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #66 on: December 06, 2019, 07:19:41 pm
Or else it's to match the hammer finish of that green paint!

A.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #67 on: December 08, 2019, 08:58:41 am
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:






So long,
Andreas


Ove

  • Grease Monkey
  • ****
  • Posts: 409
  • Karma: 0
Reply #68 on: December 08, 2019, 03:04:22 pm
Like the Fred Flintstone centre stand.  ;D

The frame colour is spot on. Excellent. Following with interest.


olhogrider

  • 650 Interceptor and C5
  • Grand Gearhead
  • *****
  • Posts: 2,653
  • Karma: 1
  • VEGAS!
Reply #69 on: December 08, 2019, 08:40:33 pm
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:






So long,
Andreas

Beautiful!!


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #70 on: December 24, 2019, 09:16:05 am
Still working on the front mudguard. The surface is getting better and better:




Used a 1-1/2" pipe bend as an anvil:




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/

A merry Christmas to you! I need to join the family for a bit now ;)
Andreas


Boxerman

  • Grease Monkey
  • ****
  • Posts: 303
  • Karma: 0
Reply #71 on: December 24, 2019, 01:01:06 pm
Here's what I mean:
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



grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #72 on: December 27, 2019, 06:02:57 pm
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:




Now it already looks like a mudguard:






Now it only needs the edges folded and some final shaping.
Isn't this finish just gorgeous?




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


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #73 on: December 27, 2019, 06:57:19 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #74 on: December 27, 2019, 07:07:23 pm
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


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #75 on: December 29, 2019, 11:04:30 am
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:






After the first run you can already see a nice crease forming:




As soon as this is done, it is folded down with a hammer:






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


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #76 on: December 29, 2019, 10:10:43 pm
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.




Here its easy to see how the outer edges warped by folding:




After straightening it's not noticable:




Then I started working on the front:




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:






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


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #77 on: December 29, 2019, 10:26:19 pm
Which is most important, form or function?  ;)

A.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


Ove

  • Grease Monkey
  • ****
  • Posts: 409
  • Karma: 0
Reply #78 on: December 29, 2019, 10:37:50 pm
I quite like a good mud flap. This is a labour of love. Thanks for sharing.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #79 on: January 30, 2020, 09:17:05 pm
Two newer pictures:






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


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #80 on: January 31, 2020, 05:58:05 pm
And yet some more with the mudguard, worthy of the name:




After a quick steel whool polish:




And the whole bike:





Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #81 on: February 01, 2020, 12:55:04 am
Quote
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #82 on: February 02, 2020, 08:45:06 am
Nah, that'd be too much, I guess. 8)


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #83 on: February 15, 2020, 06:19:01 pm
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.

« Last Edit: February 15, 2020, 09:50:22 pm by grumbern »


Ove

  • Grease Monkey
  • ****
  • Posts: 409
  • Karma: 0
Reply #84 on: February 15, 2020, 06:49:31 pm
Looks lovely to me, albeit an untrained eye. Only you will ever notice it :)


Mike flanagan

  • Scooter
  • **
  • Posts: 44
  • Karma: 0
Reply #85 on: February 20, 2020, 02:21:38 am
Thats more fab than ill have done in my whole life,very impressive.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #86 on: February 29, 2020, 08:41:15 am
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:




Then, using a fitting piece of round stock driven into it with a hammer, it's widened:




After that I heated the whole tube and the following tool was used:




It's a modified drill press, with a prism and an HSS tool attached:




It allows to create such holes:




If you do that for some time and take a little care about positioning, this is what you get:




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)




So long,
Andreas


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #87 on: February 29, 2020, 08:55:29 am
Also I started the rear subframe. It's made from one single lenght of hydraulic pipe.
First tried on with the shocks fully compressed:






Looking good and there's even enough space left for the tyre.
Then with the shocks fully expanded:








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


Ove

  • Grease Monkey
  • ****
  • Posts: 409
  • Karma: 0
Reply #88 on: February 29, 2020, 05:22:29 pm
Taking shape, going to be a head-turner. That baffle is a work of art. Well done.


mattsz

  • Grand Gearhead
  • *****
  • Posts: 5,525
  • Karma: 0
  • moto-gurdyist
Reply #89 on: February 29, 2020, 06:05:10 pm
Taking shape, going to be a head-turner. That baffle is a work of art. Well done.

+1!


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #90 on: March 07, 2020, 09:46:05 pm
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:




Dismanteled and combined they form this:




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:








Sometimes it can be so easy ;)
So long,
Andreas


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #91 on: March 07, 2020, 10:15:41 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


uhu

  • Scooter
  • **
  • Posts: 32
  • Karma: 0
Reply #92 on: March 09, 2020, 08:36:31 am
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



Stanley

  • Grease Monkey
  • ****
  • Posts: 367
  • Karma: 0
Reply #93 on: March 11, 2020, 04:40:57 pm
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


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #94 on: March 11, 2020, 07:17:00 pm
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:




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:






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:






So long,
Andreas


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #95 on: April 12, 2020, 08:57:26 am
Started cleaning the timing chest cover. Still needs repair and some modification:




Allso I sealed the magdyno against the housing. Not visible, but yet important.
But I fabricated a fixture for the headlamp. Close, but ok!








The rear subframe is coming along as well:




The rear mudguard brackets welded on:




Looking cool:




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:








But now it fits. Both in the rear and on top there's enough space:






And on the subframe I added some plates for stiffening as well as for mounting the mudguard's front and the seat:




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


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #96 on: April 12, 2020, 04:28:29 pm
Quote
Was nicht passt, wird passend gemacht. (What doesn't fit, is made to)

Preach it, brother!

Similar headlamp mount on the Electra-FT.



Coming on nicely, we're looking forward to seeing this one ready.

A.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #97 on: April 12, 2020, 09:39:36 pm
 8)


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #98 on: April 18, 2020, 09:34:39 am
The brackets are welded. Not very beautiful, but it will do  ;)




One can easily see how these brackets strengthen the braces and at the same time provide mounting points for the mudguard and seat:




More to come...
So long,
Andreas


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #99 on: April 18, 2020, 12:36:55 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


Stanley

  • Grease Monkey
  • ****
  • Posts: 367
  • Karma: 0
Reply #100 on: April 18, 2020, 04:28:35 pm
This thread joins  Michael Waller and Tatro Machine as my favorites. Watching a bracket being discussed, designed and produced is my therapy.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #101 on: April 18, 2020, 09:43:43 pm
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 ;)


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #102 on: April 30, 2020, 09:03:55 am
The mag is assambled and does it's job:




And I started with the hammer again:




If you hit it long enough and remove some of the excess, something like this may be the result :D






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


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #103 on: April 30, 2020, 12:57:35 pm
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.

Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #104 on: April 30, 2020, 01:38:28 pm
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 :)


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #105 on: April 30, 2020, 03:15:22 pm
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.

Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #106 on: May 02, 2020, 08:20:59 am
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:




Getting close!




After that I masked the right hand panel using tape:




Peeled off and turned inside out it makes a good but sticky stencil for a mirrored panel:




Excess material marked to be cut:




Here are the three parts for the tank body. At first glance the panels look quite symmetric:




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:





So long,
Andreas


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #107 on: May 02, 2020, 02:56:35 pm
That shape reminds me of the BSA B50MX alloy fuel tanks.

A.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #108 on: May 02, 2020, 10:41:24 pm
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


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #109 on: May 04, 2020, 07:10:18 pm
The following version is now what I think of is best (top has yet to be trimmed to fit):










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?





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
« Last Edit: May 04, 2020, 07:14:05 pm by grumbern »


Stanley

  • Grease Monkey
  • ****
  • Posts: 367
  • Karma: 0
Reply #110 on: May 05, 2020, 06:36:24 pm
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.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #111 on: May 19, 2020, 09:51:03 pm
Thanks, Stanley!

I made some progress again.
First I improved a bit on the lettering. Here's what I started with:




The tools used:




Doing the outlines:






Adding some texture:




Now it might once look like this:





Allso made some welding clamps. Much more convenient than tape:





Then I made a layout for the script:






All the letters cut out twice and sprayed with glue:




Stuck on the tank:




A thin layer of paint:



And the stencils removed:






Now I started the hammering. First panel is half way done:




Just some more hours...
Andreas
« Last Edit: May 19, 2020, 09:54:31 pm by grumbern »


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #112 on: May 22, 2020, 09:35:13 pm
Since yesterday the panel is hammered completely and today I poured in molten tar as support for the chasing:








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


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #113 on: May 23, 2020, 12:31:46 pm
Worked a little on the script. What is seen here took me about 2 hours  ::)









So long,
Andreas


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #114 on: May 23, 2020, 02:15:04 pm
Incredible work, how thick is that ally sheet?

A.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #115 on: May 23, 2020, 10:14:06 pm
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


ace.cafe

  • Grand Gearhead
  • *****
  • Posts: 14,297
  • Karma: 0
  • World leaders in performance/racing Bullets
Reply #116 on: May 24, 2020, 12:14:07 am
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.
Home of the Fireball 535 !


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #117 on: May 25, 2020, 07:19:55 pm
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





grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #118 on: May 27, 2020, 09:43:53 pm
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:




And that's how it looks like now:




So long,
Andreas


uhu

  • Scooter
  • **
  • Posts: 32
  • Karma: 0
Reply #119 on: May 29, 2020, 04:51:59 pm
incredible craftmanship. Great to follow this build. Thanks for sharing.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #120 on: July 17, 2020, 02:23:21 pm
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:




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:




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:




The welded and roughly shaped tach drive flange:




And yes, I did it! ;D




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
« Last Edit: July 17, 2020, 02:25:58 pm by grumbern »


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #121 on: July 19, 2020, 04:27:30 pm
Glad you're still with us Andreas, that wretched Covid 19 isn't finished yet.

A.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #122 on: July 20, 2020, 09:05:22 pm
No worries, I'm fine. Just lots of different stuff to do :)


heloego

  • A 2x4. My kingdom for a 2x4!
  • Grand Gearhead
  • *****
  • Posts: 2,485
  • Karma: 0
  • USA '12 C5, '06 ElectraX
Reply #123 on: July 21, 2020, 01:14:24 am
I'm stunned! Love what you did with the tank!!!!!!!!
 :o ;D
'18 Bonneville T-100, Blue/White
'12 C5 Classic
'06 Electra X AVL w/32mm Mikuni and Gold Star system.


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #124 on: July 21, 2020, 02:08:56 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #125 on: July 21, 2020, 09:22:07 pm
@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... :-[


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #126 on: July 21, 2020, 09:57:53 pm
They're still available!  ;)

A.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #127 on: July 21, 2020, 10:14:12 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #128 on: August 10, 2020, 09:17:49 am
@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




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°:




The linkage looks adventurous, but there are quite some obstacles to look out for!




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
« Last Edit: August 10, 2020, 09:25:08 am by grumbern »


AzCal Retred

  • Chennai Wrencher
  • Grand Gearhead
  • *****
  • Posts: 1,747
  • Karma: 0
  • Laissez le bon temps rouler! Fresno, CA
Reply #129 on: August 11, 2020, 10:03:00 pm
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 -
A brace of 1999 Bullets: 1 Red Deluxe, 1 Green Standard. Also, 1 wee orphan 1956 Fire Arrow project.


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #130 on: August 12, 2020, 05:13:56 pm
Have you seen Grumbern's (RE) Indian Chief restoration?  ;D

A.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


AzCal Retred

  • Chennai Wrencher
  • Grand Gearhead
  • *****
  • Posts: 1,747
  • Karma: 0
  • Laissez le bon temps rouler! Fresno, CA
Reply #131 on: August 12, 2020, 08:07:51 pm
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.
A brace of 1999 Bullets: 1 Red Deluxe, 1 Green Standard. Also, 1 wee orphan 1956 Fire Arrow project.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #132 on: August 15, 2020, 09:01:24 am
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°:






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:






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 ::)




Maybe tomorrow I can make the top plate and then it's only details.
So long,
Andreas
« Last Edit: August 15, 2020, 09:04:28 am by grumbern »


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #133 on: August 19, 2020, 09:15:23 am
The top plate is finished.
But first the original part:




From this the important holes where transfered to the sheet metal and drilled. The one segment is already filed in shape:




Cut and the second one done, it's ready for a quick try on:




And the final shaping done. The somewhat strange shape results from maximum guidance for the ratchet parts and clearance to the gearbox cover:




The linkage just clears the clutch lever and to the bottom the kickstart return spring is the limiting factor:




Clutch lever also is free at the top:




Gearbox cover and neutral finder mounted:




And a quick demonstration:

https://www.youtube.com/watch?v=y68Tk3vONoY



So long,
Andreas
« Last Edit: August 19, 2020, 09:17:25 am by grumbern »


Boxerman

  • Grease Monkey
  • ****
  • Posts: 303
  • Karma: 0
Reply #134 on: August 19, 2020, 10:19:50 am
Andreas never ceases to amaze me with his skills and ingenuity.

Frank


AzCal Retred

  • Chennai Wrencher
  • Grand Gearhead
  • *****
  • Posts: 1,747
  • Karma: 0
  • Laissez le bon temps rouler! Fresno, CA
Reply #135 on: August 20, 2020, 08:09:37 pm
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 -
A brace of 1999 Bullets: 1 Red Deluxe, 1 Green Standard. Also, 1 wee orphan 1956 Fire Arrow project.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #136 on: August 21, 2020, 09:01:32 am
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:








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






Gruß,
Andreas


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #137 on: August 21, 2020, 03:44:55 pm
And while we're there we also make the bore:




And tap it. Really not a lot of meat there!



So long,
Andreas


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
« Last Edit: August 21, 2020, 04:00:31 pm by grumbern »


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #139 on: September 19, 2020, 09:53:12 pm
My filler cap has arrived! :D








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


AzCal Retred

  • Chennai Wrencher
  • Grand Gearhead
  • *****
  • Posts: 1,747
  • Karma: 0
  • Laissez le bon temps rouler! Fresno, CA
Reply #140 on: September 20, 2020, 03:22:27 pm
Now THAT's some bling, Grumbern!  :)  - ACR -
A brace of 1999 Bullets: 1 Red Deluxe, 1 Green Standard. Also, 1 wee orphan 1956 Fire Arrow project.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #141 on: September 23, 2020, 06:15:22 pm
That's how the cap looks like on the tank by the way:




I think I'll mount it a bit further in the back, but we'll see.
For now I finished the tach-drive flange:






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


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #142 on: September 25, 2020, 06:11:24 pm
Here you can see how I made it:

https://youtu.be/ijYjG3PfCNs


Black fingernail

  • Bulleteer
  • ***
  • Posts: 114
  • Karma: 0
Reply #143 on: September 29, 2020, 06:34:13 pm
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 !!!
It's metal, it doesn't understand!

Enfield 500 Deluxe 1998
Benelli 500 LS 1979
Velosolex 3500S 1968
Jaguar X type 2005
not forgetting SWMBO's Z3 2002


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #144 on: September 29, 2020, 09:31:21 pm
Haha, you're not the first to mention this ;D
Maybe I should add some armour to my pants for serious riding?! :o


Black fingernail

  • Bulleteer
  • ***
  • Posts: 114
  • Karma: 0
Reply #145 on: September 29, 2020, 09:49:05 pm
Ha Ha, good idea, my wife was making some shish kebabs for dinner, so your cap made me wince a bit.
It's metal, it doesn't understand!

Enfield 500 Deluxe 1998
Benelli 500 LS 1979
Velosolex 3500S 1968
Jaguar X type 2005
not forgetting SWMBO's Z3 2002


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #146 on: October 06, 2020, 09:25:33 pm
This update isn't as glorious, but just as important.
Gave the worm nut a new cork seal:




And made a new magneto gear nut to fit a tachometer drive:







So long,
Andreas


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #147 on: October 18, 2020, 02:42:32 pm
Now the top of the tank is hammered and biggest part of the hammering done 8)




Next I've done the cutout for the filler neck. Attention, pofessional tooling! ;D






We're getting closer...
Andreas


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #148 on: October 19, 2020, 11:40:38 am
Again, excellent workmanship, though I do wonder, why would you need a rev-counter on a trials bike?

A.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #149 on: October 19, 2020, 02:27:56 pm
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 ;)


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #150 on: October 19, 2020, 03:48:38 pm
And on we go with the filler neck. Starting with a 55x55x12mm piece of AlMg3:




Drilled a center hole in the middle on both sides:




And put it on the lathe between centers:




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:



The finished filler neck viewed from below:




...and above:




The filler cap fits perfectly:






Now it's really starting to get exciting!
Andreas


heloego

  • A 2x4. My kingdom for a 2x4!
  • Grand Gearhead
  • *****
  • Posts: 2,485
  • Karma: 0
  • USA '12 C5, '06 ElectraX
Reply #151 on: October 20, 2020, 11:39:03 pm
Nice!Gotta love this thread!  ;D
'18 Bonneville T-100, Blue/White
'12 C5 Classic
'06 Electra X AVL w/32mm Mikuni and Gold Star system.


uhu

  • Scooter
  • **
  • Posts: 32
  • Karma: 0
Reply #152 on: October 30, 2020, 03:04:10 pm
cannot see pictures any more... :-[


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #153 on: October 30, 2020, 04:00:03 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #154 on: October 30, 2020, 04:32:52 pm
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...


Boxerman

  • Grease Monkey
  • ****
  • Posts: 303
  • Karma: 0
Reply #155 on: October 30, 2020, 05:53:38 pm
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


uhu

  • Scooter
  • **
  • Posts: 32
  • Karma: 0
Reply #156 on: November 02, 2020, 12:57:40 pm
Can see them indeed again with an other browser.
Thx.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #157 on: November 07, 2020, 10:27:30 pm
Some more updates.
The front wheel is now done an equipped with a tyre:




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 :)




So I tack welded the three pieces:




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:




So long,
Andreas


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #158 on: November 07, 2020, 11:04:03 pm
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.

Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #159 on: November 08, 2020, 12:47:58 pm
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


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #160 on: November 08, 2020, 06:23:18 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #161 on: November 20, 2020, 10:41:47 pm
Well guys, one (to me) big step is taken: The top of the tank is welded!  8)






With cap:




The root of the weld is very strong ;)




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:




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:




So long,
Andreas


heloego

  • A 2x4. My kingdom for a 2x4!
  • Grand Gearhead
  • *****
  • Posts: 2,485
  • Karma: 0
  • USA '12 C5, '06 ElectraX
Reply #162 on: November 21, 2020, 06:01:35 am
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.
'18 Bonneville T-100, Blue/White
'12 C5 Classic
'06 Electra X AVL w/32mm Mikuni and Gold Star system.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #163 on: November 29, 2020, 06:03:27 pm
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:




After removing the excess material I filed the edges, final shaping will be done together with the tunnel:




Fits much better, that's the way to go! :D




So long,
Andreas


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #164 on: December 22, 2020, 12:41:01 pm
May the puzzle begin:



All parts found and serviceable, ready for cleaning:



Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #165 on: December 22, 2020, 02:25:06 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


nonfiction

  • Bulleteer
  • ***
  • Posts: 113
  • Karma: 0
  • New Bullet Owner/Longtime Bike Guy
Reply #166 on: March 02, 2021, 08:42:54 pm
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!


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #167 on: March 02, 2021, 09:37:29 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


nonfiction

  • Bulleteer
  • ***
  • Posts: 113
  • Karma: 0
  • New Bullet Owner/Longtime Bike Guy
Reply #168 on: March 02, 2021, 11:46:00 pm
@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.


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #169 on: March 03, 2021, 01:13:33 pm
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.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


nonfiction

  • Bulleteer
  • ***
  • Posts: 113
  • Karma: 0
  • New Bullet Owner/Longtime Bike Guy
Reply #170 on: March 03, 2021, 08:03:09 pm
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.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #171 on: March 04, 2021, 03:23:57 pm
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


nonfiction

  • Bulleteer
  • ***
  • Posts: 113
  • Karma: 0
  • New Bullet Owner/Longtime Bike Guy
Reply #172 on: March 04, 2021, 04:42:38 pm
Thanks Andreas. No worries, and please keep up the gorgeous work on this beastie!


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #173 on: March 14, 2021, 11:05:58 am
Some things happened until now.
Firstly, I set the bike up on my multi purpose IKEA table ;)




Then I started working on the foot pegs:








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:








I also removed the gearbox cluster for inspection:




As it showed this was no mistake, as the high gear pinion has a broken tooth:




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:




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


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #174 on: March 14, 2021, 01:07:03 pm
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.

Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


symmo

  • Scooter
  • **
  • Posts: 34
  • Karma: 0
Reply #175 on: March 15, 2021, 08:39:13 am
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.


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #176 on: March 15, 2021, 04:34:47 pm
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


Adrian II

  • Grand Gearhead
  • *****
  • Posts: 2,630
  • Karma: 0
  • Sharing my ignorance with anyone who needs it
Reply #177 on: March 15, 2021, 04:55:54 pm
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
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #178 on: March 18, 2021, 05:14:28 pm
Yes probably. I thought about fitting sliders of any sort, but I'll see once a chain is put on.
Andreas


grumbern

  • Grand Gearhead
  • *****
  • Posts: 527
  • Karma: 0
Reply #179 on: April 19, 2021, 05:01:59 pm
As the main shaft bearing was a bit lose, I glued it in place with Loctite while securing it with a somewhat improvised setup:


Link


Link


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:


Link


A little accident happened when removing the rear wheel bearings :o


Link


Not wanting for this to happen again, I machined a nice knurl and will give it a drop of Loctite as well:


Link


As I didn't want to turn over the engine by hand, I simply modified an old M10 bolt:


Link


Way better!


Link


Oil pump working!


Link


But I had to whitness this as well:


Link


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:


Link


The gear change mechanism parts freed from dirt and rust:


Link


And mounted just in place:


Link


And I didn't have a securing bolt for the final drive sprocket, so I made one:


Link


Link


One step at a time...
So long,
Andreas


AzCal Retred

  • Chennai Wrencher
  • Grand Gearhead
  • *****
  • Posts: 1,747
  • Karma: 0
  • Laissez le bon temps rouler! Fresno, CA
Reply #180 on: April 20, 2021, 02:26:26 am
Thanks for the links!
A brace of 1999 Bullets: 1 Red Deluxe, 1 Green Standard. Also, 1 wee orphan 1956 Fire Arrow project.