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Hans, 1949 D1 survivor
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Hans Kreuzen
Queensland Australia
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February 18, 2018 - 12:50 am
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Here is my latest project to tinker with, a 1949 D1 rigid, that has been sitting in a shed since 1959 when the registration run out after a front on accident.

The plan is to carefully remove most of the brushed on house paint layers and to make sure it will be safe to ride on the road, I will leave all the bare rusty metal and use a oily rag or a flat clear coat for this survivor restoration.

I have a straight rusty handle bar to replace the bend one, the frame will have to be straightened, the front wheel has been fitted the wrong way around, the engine leaks like the Titanic, etc etc.

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This picture shows all the brushed house paint, before the stripping.

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The original Pastel green paint is starting to show.

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Even the gold pin striping is being revealed.

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The last 1959 registration label.

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It even has the original rear lamp.

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The 49 chain guard, has a rolled edge on the inside, My 1948 D1 has a straight cut edge, ????? maybe a export type??

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The frame has been bend and will have to be straightened, I will make a jig on my welding bench, hopefully I will be able to straighten it myself.

It will be a nice contrast next to my 1948 restored D1 and a challenge to find and use old rusty parts like a rusty worn mirror and tyres. 

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1950 D1 plunger for daily use, Concourse 1948 D1 rigid, Black 1953 D1 plunger nearly done and a 1949 rigid D1 survivor.

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cocorico
Central France
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February 18, 2018 - 8:22 am
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Smashing, Hans. As you say, the contrast between an unrestored and a restored  version of the same model would be interesting at any show.

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ZZ
Murray Bridge, near Adelaide, South Australia
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February 18, 2018 - 8:53 am
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Hans, I reckon the bike must have been parked and got hit by a truck. No way the D1 could go fast enough to hit something at speed and do that damage.freaked-out_gif

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Hans Kreuzen
Queensland Australia
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February 18, 2018 - 9:16 am
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ZZ said
Hans, I reckon the bike must have been parked and got hit by a truck. No way the D1 could go fast enough to hit something at speed and do that damage.freaked-out_gif  

The Bantam hit a tram in Sydney, that's why the frame is that damaged, It should straighten out OK I think.

And Cocorico, I can't wait to park the 2 Bantams together for some pictures after I have finished the oily rag resto on the 49.

I replaced the bend handle bar today with a rusty original straight one.[Permission to view this image is denied]

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1950 D1 plunger for daily use, Concourse 1948 D1 rigid, Black 1953 D1 plunger nearly done and a 1949 rigid D1 survivor.

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BSAdave
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February 18, 2018 - 10:28 am
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looks like an interesting project. I notice that a speedo is not fitted was that the normal for this year ?

I could agree with you, but then we would both be wrong

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Blue Heeler
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February 18, 2018 - 10:29 am
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Wow,that`s going to be a little beauty,I`m sure.Great to retain that "dragged out of the past" look.Is it a closely-guarded trade secret how you remove the brushed-on paint while preserving the original?

Some impact...top tube stretched,bottom tube compressed.I saw one on here,the poor chap had had it stove enameled and was embarking on a rebuild before I pointed out his problem.There`s D7? on ebayUK at the mo with a clearly bent frame,folk are merrily bidding away...

Why aren`t your forks and wheel bent?!

I have a plunger frame I bought loose for the challenge,to straighten sometime,I thought maybe drill holes in concrete floor,epoxy in anchors,place frame on metal plates,level and wang down with U-clamps back and front.Long piece of wooden dowel through the headstock to see what the twist is...they are never hit square on in a smash,wheel alignment when I was an MOT tester showed that phenomenon up.Bikes folk rebuilt after smash,or even sliding off, etc.I`m lucky enough to have another straight frame stripped for reference.Two oxy-acetylene/propane heat guns playing on offending areas,metal bar in the headstock....

...or cheat and take to nearest motoliner shop and hand over a ton or whatever they charge nowadays.

Look forward to see how you tackle her.

Blue

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Hans Kreuzen
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February 18, 2018 - 10:54 am
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BSAdave said
looks like an interesting project. I notice that a speedo is not fitted was that the normal for this year ?  

 It was a optional extra here in Australia and not needed for registration, so not many early Bantams had them fitted.

1950 D1 plunger for daily use, Concourse 1948 D1 rigid, Black 1953 D1 plunger nearly done and a 1949 rigid D1 survivor.

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Hans Kreuzen
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February 18, 2018 - 11:03 am
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Blue Heeler said
Wow,that`s going to be a little beauty,I`m sure.Great to retain that "dragged out of the past" look.Is it a closely-guarded trade secret how you remove the brushed-on paint while preserving the original?
Why aren`t your forks and wheel bent?!
Blue  

Hi Blue

I have tried everything to remove the old house paint, but found using a heat gun and scraper the best, I also use methylated spirits to remove the last bit of paint.

The forks are not bend but have moved a lot in the yolk, Not until I strip it all down, will I find out what the damage is.

1950 D1 plunger for daily use, Concourse 1948 D1 rigid, Black 1953 D1 plunger nearly done and a 1949 rigid D1 survivor.

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Piquet
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February 18, 2018 - 1:16 pm
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I heard that oven cleaner will remove synthetic paint but leave cellulose untouched, ie. removing sign-writing ..... but please test first.

I'm not a complete idiot ............................................ some parts are missing.

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Hans Kreuzen
Queensland Australia
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February 18, 2018 - 8:04 pm
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Thanks Piquet, I will try that.

1950 D1 plunger for daily use, Concourse 1948 D1 rigid, Black 1953 D1 plunger nearly done and a 1949 rigid D1 survivor.

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neddyo
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February 18, 2018 - 9:02 pm
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fantstic find, lucky you, bikes that original are few and far between.

I have straightened several D1 frames, there are a few pitfalls.

when you pull the head lug forward to it's original position

you can end up with double bends in both the to and bottom 

tubes. It seems the sections that are already bent will

resist straightening to the point the unbent sections

yield first. (does that make sense, probably not)

I will post images of a set up i used.

Nick.

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neddyo
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February 18, 2018 - 9:16 pm
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Someting interesting I found in a D1 parts book and may indicate

your bike was not sold in OZ buy imported privately.

The rear carrier on colonial D1's had an extra tube across the carrier

between the two up right tubes. I also found this out when I bought

a new replica carrier in England last year, the seller asked me

was it for England or Australia.

Nick. 

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Hans Kreuzen
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February 18, 2018 - 9:22 pm
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Hi Nick

Pictures of the frame straitening would be great, I had this Bantam dated by Steve, Dispatched for Bennet and Wood Sydney on December 1949, this why it has all the 1950 features .

Thanks, look forward to seeing your pic's, I have 2 frames to straighten.

I Better start work, «censored»

1950 D1 plunger for daily use, Concourse 1948 D1 rigid, Black 1953 D1 plunger nearly done and a 1949 rigid D1 survivor.

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Blue Heeler
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February 18, 2018 - 10:48 pm
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I`m pulling up a chair for the frame straightening 🙂

Good tips on the paint removal from Hans & Piquet.

I always wonder what those no-crossbar carriers are built to carry...a big cake tin that just slots in? Mine`s missing...so no cake for me!

Hans,just looked at that top tube again,it does look waisted(not wasted),might be worth measuring dia of tube in several places.I can see what Nick means by possibility of ending up with double bends when trying to put a stretched section back to normal!

Got any frame builders near you,grasstrack/speedway/specials/chops? I`m thinking they`d cut the brace out & headstock off and go from there...?

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neddyo
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February 19, 2018 - 1:07 am
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With the frame jigging if you look along the square tubes you can see clamps and bands

holding the tubes from bending where not required.

I believe some people heat the tubes where they want the straightening to take place, I tried this but got into

all sorts of trouble which was not reversible.

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neddyo
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February 19, 2018 - 6:07 am
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Image shows 2 carriers in parts book and a more detailed image of the frame straightener

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neddyo
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February 19, 2018 - 6:29 am
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Sorry about the carrier image, it copies as a gif file and converts to a jpg and then

 it wont open in the forum? any image wizards please

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Hans Kreuzen
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February 19, 2018 - 8:54 am
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Hi Nick

Your pictures are great, the carrier pic came up fine also.

I like the jig you build, do you suggest I build the same type of jig for mine? and did it work out in the end? do you suggest to bend it cold?

PLAN B: I was thinking that if the jig wont work, that I will cut the tube on the bend, remove the triangle original plate, straighten and than machine a tube to fit inside the tube and weld it through drilled holes and the cut joints, hope you understand what I mean.

Thanks heaps for your input, any help is appreciated, ha ha., why on earth do I buy these challengers. rantingout-a-here

1950 D1 plunger for daily use, Concourse 1948 D1 rigid, Black 1953 D1 plunger nearly done and a 1949 rigid D1 survivor.

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Hans Kreuzen
Queensland Australia
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February 19, 2018 - 9:10 am
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Another question Nick, Did you knock the cup and cones out of the head stock and machined a bar that fitted snug inside?

I suppose the biggest question is, did the jig work or do cut and shut it?

Thanks, Hans

1950 D1 plunger for daily use, Concourse 1948 D1 rigid, Black 1953 D1 plunger nearly done and a 1949 rigid D1 survivor.

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neddyo
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February 19, 2018 - 8:35 pm
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One of the problems is the tubes are actually bent

right down to the engine and back to the sadle.

If you are going to cut out the head bracket it's better to

start by making up a bar to go through the head bracket

and roughly pushing the head bracket out to it's original

position before cutting it out.

you need to do this with the engine in place and bolted up

tight, this will get the tubes roughly back into position.

Befoe I had a portapower I used a length of 16mm all thread.

It's less fluffing about and quicker to cut and shut but you need to

ruin a good donor frame, frowned upon by my fellow Bantamites.

I will post more detailed images of the. bar and how it fits the head cups

Nick

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