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D1 53 Plunger Lucas restoration
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Martin_uk
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October 21, 2018 - 9:35 pm
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Making progress on my restoration but encountered a problem that I would be interested in views.

Bike was dismantled when I bought.

Checked wheel offsets before stripping and rear was within a couple of mm, but front varied by 4 mm.

I assumed rim bent or badly set up.

Hubs stripped and powder coated, new bearings.

I have fitted Devon Rim Co SS rims and spokes.

Started to true and rim is way out before starting with spokes loosely tightened and noticed run out on front brake drum edge up to 3mm.

Suspect hub may be bent causing drum misalignment, but before I try to find one to replace wondered if anyone else has encountered this and how much drum run out is acceptable.

 

Thanks

1953 D1 Plunger Lucas

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Martin_uk
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October 21, 2018 - 10:32 pm
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Recent purchase of bike that PO had started restoration, but realised would not have time to finish.

Engine seized but many parts brush painted.

 

 

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1953 D1 Plunger Lucas

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Martin_uk
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October 21, 2018 - 10:40 pm
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Trying to decide how far to go and whether to redo the painting.

I have restored a few bikes over the years and more recently a C90 and a CB750 SOHC

I do like to get them right, but will compromise on some cosmetic aspects.

 

 

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1953 D1 Plunger Lucas

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Martin_uk
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October 22, 2018 - 10:19 am
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Rear hub looks like it has had replacement brake drum welded on . Not very pretty 🙁

 

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1953 D1 Plunger Lucas

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Martin_uk
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October 22, 2018 - 10:24 am
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Martin_uk said
Recent purchase of bike that PO had started restoration, but realised would not have time to finish.

Engine seized but many parts brush painted.

 

 

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Assume battery carrier outer clamp has been made?

1953 D1 Plunger Lucas

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sunny
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October 22, 2018 - 10:38 am
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it  would have  been  best  to  rebild  frame  & forks  fit  wheels   to  see if  you  can  get  complet   ALAMENT    with  all the  old parts this  tells you  if the  frame  or  wheels  are   bent    coz  now  you  may  have  new  rims & spoks  that  dont  mach  up      ,i  be serprizd  if  this  get  done  without  you  losing  your  temper   you   need  to  chec  all spoke  lenths   and  angles  of  the  holes  from  your  old  to new rims    then  work out  wich spokes gos with  with  rim   wile  looking  at  the  old  rims & spokes      take  you  time  and  a  big   mug  of  TEA  or  something stronger   it  wont  look  so  bad   

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Mags 1
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October 22, 2018 - 11:20 am
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I tried skimming a D1 bare hub a few years ago on my lathe, I was quite perturbed to notice whole drum actually moving in and out whilst trying to take a light cut, I think they're pressed steel, rather than the cast iron of the D7 and later 'improved' types...I'd look for a better one myself, they're common enough and cheap, couldn't get £10 each for some I tried to sell on ebay last year.

Four now on the road and at least several in bits.

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Martin_uk
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October 22, 2018 - 6:56 pm
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It took a while to get piston free

 

Not so much info on line about Lucas set up

 

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1953 D1 Plunger Lucas

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Martin_uk
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October 22, 2018 - 7:02 pm
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It was a challenge getting rotor off.

Could not find the tool to remove, tried screwing in a 5/16BSF bolt but did not work.

In the end I used a piece of brass bar and screwed 5/16BSF bolt against it.

Have cable tied rotor within generator in view of dire warnings if it is removed.[Permission to view this image is denied]
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1953 D1 Plunger Lucas

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chickensoup
Bolton, Greater Manchester
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October 22, 2018 - 9:05 pm
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Hi Martin,

Great photo's. I have a 1950 Lucas D1, but its running at the moment with a D5 engine, as my Lucas D1 engine needs a lot of time and money spending on it. Keep us all posted with photo's of your restoration.

Nick

                           Kind regards,  Nick     Bolton, Greater Manchester

                              1950 D1 Plunger Frame with 1958 D5 Engine,

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Martin_uk
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October 22, 2018 - 10:23 pm
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I have obtained another hub and checked .

Run out is minimal, so now will get it powder coated and fit bearings before swapping over stainless rim and spokes

Shame as it looked good

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1953 D1 Plunger Lucas

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Martin_uk
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October 22, 2018 - 10:33 pm
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Engine is resisting seperation.

Crank is seized and big end semi seized.

Suspect fly wheels seized in crank case.

I have got the dowels out and have heated cases.

Leaving to soak in parafin for a while whilst I get on with other stuff.

Have dropped off barrel for rebore.

Spark plug sheared when trying to remove.

One broken 1/4 BSW crank case screw.

 

 

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1953 D1 Plunger Lucas

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sunny
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October 23, 2018 - 9:59 am
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hi  DONOT    tack    the  generator   APART   or    you  will  loos   the   strenth    from  the   magnets  

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Martin_uk
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October 24, 2018 - 9:27 am
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Parts ready for powder coating and zinc plating

 

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1953 D1 Plunger Lucas

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cocorico
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October 24, 2018 - 10:12 am
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sunny said
hi  DONOT    tack    the  generator   APART   or    you  will  loos   the   strenth    from  the   magnets    

I think that only occurs after a long period of time. You can separate the rotor from the stator as long as you place a 'keeper' across the magnets. (Again, I think that's the case, I've not seen the Lucas system - it certainly works on other makes.)

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sunny
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October 24, 2018 - 11:53 am
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HORNSBY     00  tran sets  also    aply

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Martin_uk
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October 24, 2018 - 4:33 pm
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I see that the 53 D1 was available in Black so decided to go down that route.

Some bits back from painting and plating.

Most plating was clear zinc but a few bits in Nickel as much cheaper than chrome and looks OK.

I have rotary wire brushed the sprocket to remove coating in contact areas to save clogging chain.

I ground down the gobs of weld with an angle grinder and finished with a file and emery cloth.

Shame the front hub was bent and did not notice until after I fitted bearing, spokes and rim.

I have another one but need to start again, should have checked 🙁

 

A fruit tray is handy to sort out the bits

 

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1953 D1 Plunger Lucas

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Martin_uk
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October 24, 2018 - 4:46 pm
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A few more painted bits

 

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1953 D1 Plunger Lucas

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Martin_uk
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October 24, 2018 - 4:52 pm
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And a few more[Permission to view this image is denied]
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1953 D1 Plunger Lucas

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Martin_uk
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October 24, 2018 - 5:01 pm
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I was concerned that after problem with distorted front hub, I should have checked the rear hub before building wheel.

I have previously rebuilt the wheels on CB750 using a modified paddock stand with wheel balancing adaptor but shaft too big for Bantam .

Luckily PO gave me a wheelstand, but the largest ball bearings I had were too small for rear wheel bearing inner.

Came up with a solution as per image and luckily the hub runs true 🙂

Also included a shot of replacement front hub whilst checking run out[Permission to view this image is denied]
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1953 D1 Plunger Lucas

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