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Colin's D1 rebuild
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cbranni
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October 7, 2020 - 9:44 pm
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Hi everyone,

I am a bit late starting this rebuild diary but the one good thing is you only missed the dirty part and we have all been there but it has to be done, the basic plan is my friend Leon and I get together on a Friday and Saturday and mess with old bikes in my shed, middle of last month we finished a Matchless 650 twin and we then rolled the BSA Bantam D1 1959 into the shed and work commenced.

rsz_p1050802.jpg

 

The condition of the Bantam was quite good considering it had been in a garden shed since 1969 but it fared much better than the Matchless which had holes in the petrol tank rusted from the outside in, the condition of the Bantam may be due to the fact that it had two coats of paint first a coat of mist green and the maroon and black, to me this was done in the factory, I know maroon was an option in 59 so if you ordered that colour they painted all the previously green components maroon and black before assembly.

The petrol tank on the bike has some dents by the forks why I don't know, anyone any ideas? there were two tanks with the bike and I am using the other which after cleaning and rubbing down looks okay.

rsz_p1050842.jpg

The mag was in a mess and I thought of replacing it all with electronic kit but it all seemed to working on the test bench I made

rsz_p1050854.jpg

I made a dummy crankshaft to suit the motor shaft and bolted the rotor to it, I then made a flange bolted to motor frame to hold the coil and points cradle and spun the motor and I got a good spark and plenty of volts out of the lighting coils.

rsz_p1050943.jpg

 

The engine was stripped down and cleaned fitted with new bearings and seals, bore was honed and new set of rings, new set clutch plates were fitted and new bearings bushes and seals to the gearbox and all rebuilt.

rsz_p1050853.jpg

It turned out looking good.

rsz_p1050924.jpg

I will fit an A reg to control the volts and fitted new ignition coil, condenser, points and cam.

rsz_p1050934.jpg

With the engine all done the frame and all the metal work was stripped of paint, I use a good quality paint stripper that actually works, the name of which I can't remember at the moment. The main stand legs were worn out so these cut off and new bits made and are ready to be welded on.

rsz_p1050900.jpg

This is the first batch of black paint done, we use 2K, it's the frame, stand, headstock and rear plungers just so we can start to mount stuff back in the frame which will be this weekend coming, photos aren't very good but you can make out the frame and other stuff.

rsz_p1050925.jpg

rsz_p1050928.jpg

 

To be continued.............

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cbranni
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October 7, 2020 - 10:37 pm
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I am a little confused on why am I losing photos, can someone help please, they are getting less and less what am I doing wrong and now their have all vanished.

Colin

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Alan.Moore
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October 7, 2020 - 11:06 pm
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Colin

the images need to be under 1MB in size

If you click on the Attachments button at the bottom of the window you type the text into another smaller window opens with Select Files top left

You can drag the images from your folder on your computer into the box or click the Add files button bottom left and select the images from within a folder window

I add one at a time into the Select Files window. I then click in the box you are typing the text into and then click the button Start Uplaod in the Select Files window. The image should then be inserted into the window you type text into.

Hope this makes sense

Cheers

Alan

1939 Ariel VH, 1942 Ariel WNG, 1951 Triumph 6T Thunderbird, 1970 BSA Bantam B175, 1980 Honda CB250N, 1986 Yamaha SRX600

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cbranni
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October 8, 2020 - 6:59 am
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well I think I got the hang of it, the following photos may not be in the correct order but the rest will, thanks for your patience.

rsz_p1050802-1.jpgrsz_p1050842.jpgrsz_p1050853.jpgrsz_p1050900.jpgrsz_p1050854.jpgrsz_p1050924.jpgrsz_p1050925.jpgrsz_p1050934.jpg

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Stoo63
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October 8, 2020 - 8:10 am
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Very nice, Colin. Looking forward very much to seeing how you get on. 

 '55 D3 Battery; '58 Square Four (project); '59 D1 direct lighting plunger; '59 Tiger Cub; '60 5TA;  '76 FS1-E; '97 Honda Sky SGX50.

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cocorico
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October 8, 2020 - 9:59 am
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Smashing. Those 'dents' look to be symmetrical. I wonder if the bike was originally modified for a service of some sort, which required the fitment of a 'hoop' of some sort either side of the tank?

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GlenAnderson
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October 8, 2020 - 12:55 pm
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I’ve seen dents on n the tanks like that before, either on bikes “modified” for trials work with the steering lock stops removed, or after an accident where the forks have been forced past them. 

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cbranni
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October 8, 2020 - 6:58 pm
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Thanks for the kind comments, I thought the dents in the tank were for some sort of clearance but what I ain't got a clue, I'm not using that tank so it will be confined to the attic. I do have a question which is have I got the correct tank transfers for D1 59, I have added a photo and the size is about 90mm x 50mm.

rsz_p1050944.jpg

I thought the BSA Bantam and lines should be red where these are almost brown but they are not black, any advice would be appreciated.

Kind regards Colin

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Alan.Moore
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October 8, 2020 - 7:02 pm
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Looking good Colin. Your rate of progress puts my slow burn restoration to shame smile

I've considered using 2 pack paint but the potential health risks have put me off as I don't have the proper kit so have stuck with cellulose and enamel type paints.

Did you have the cases vapour blasted? they look brilliant.

Cheers

Alan

1939 Ariel VH, 1942 Ariel WNG, 1951 Triumph 6T Thunderbird, 1970 BSA Bantam B175, 1980 Honda CB250N, 1986 Yamaha SRX600

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cbranni
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October 8, 2020 - 7:34 pm
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Hi Alan

Leon does all the paint, I'm only allowed to touch up scratches, he does use proper 3M's breathing kit, and the engine cases were aqua blasted in fact anything alloy gets blasted but I don't polish or buff I leave it matt and it gets a wipe over with petrol or panel wipe and it stays looking good.

Regards Colin

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sunny
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October 9, 2020 - 9:54 am
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hi Colin  the transfers   are rit  19 50   to  63     dark red    

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JamesB
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October 9, 2020 - 1:50 pm
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Hi Colin,

You are right they should be red, you can get them on line as a full set with tank gear selector, battery box etc.. As I don't need all of them and don't need them yet I have decided to wait and hopefully save some money if the straightforward tank decals become available again.

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Stoo63
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October 9, 2020 - 3:59 pm
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Hmmm, those look very red to me and don't look like any in the pics of old bikes I've seen. ** Please log in to view ** look more the thing to my eye. Shame they're not in stock 🙁   Someone will have them

 '55 D3 Battery; '58 Square Four (project); '59 D1 direct lighting plunger; '59 Tiger Cub; '60 5TA;  '76 FS1-E; '97 Honda Sky SGX50.

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cbranni
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October 9, 2020 - 4:47 pm
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Thanks for all the advice guys, I bought these from VMCC as Classic Transfers are out of stock at the moment, I will email Marcia at Classic Transfer Monday to see when they will be back in stock.

Kind regards Colin

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cbranni
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October 9, 2020 - 5:11 pm
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Well it's Friday morning and the workshop is clean and a new white towel was laid on bench and work began assembling the Bantam, the stand and footrest bar went together but we did make a mistake, ten points to who ever spots it.

rsz_p1050945.jpgrsz_p1050946.jpg

Next up was engine in frame again all going well, too well if you ask me.

rsz_p1050947.jpg

rsz_p1050950.jpg

Leon had some black spraying to do so I left him carry on with that while I dry fitted the tool box and rectifier.

rsz_p1050955.jpg

As you can see I am housing a modern reg/rect in the tool box but keeping the original rectifier in place with dummy leads for show

rsz_p1050967.jpg

By dry fitting I can drill any holes I want before the box is painted, stop Leon from moaning.rsz_p1050956.jpg

We assembled the headstock and put a few shiny bits on plus the speedo.rsz_p1050960.jpg

rsz_p1050961.jpg

You can't really see the error in the stand but the stand pivot clip was under the stop plate not on top but managed to correct it without too much hassle.

So we had a really good day.

Kind regards Colin

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mike p5xbx
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October 9, 2020 - 5:26 pm
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you can get that transfer in black, gold, or red
which one is correct for year I dont know but gold or red looks better to me

BSA-fuel-tank-01.jpg

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D? - D10- D14 Bantams 350 AJS -500 Triumph http://bsanotru.....lfire.com/

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cbranni
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October 9, 2020 - 5:43 pm
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Hi Mike,

Thanks for that photo, the dark red on your tank is the same shade as my transfers in the flesh, I am a few weeks away from having to fit the transfers so I won't panic yet.

Cheers Colin

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Alan.Moore
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October 9, 2020 - 7:01 pm
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Lovely workshop Colin. Looks like you've made good progress today. 

Cheers

Alan

1939 Ariel VH, 1942 Ariel WNG, 1951 Triumph 6T Thunderbird, 1970 BSA Bantam B175, 1980 Honda CB250N, 1986 Yamaha SRX600

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Stoo63
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October 9, 2020 - 8:29 pm
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Great stuff, Colin. Some days everything just goes to plan. Others.......freaked-out_gif

 '55 D3 Battery; '58 Square Four (project); '59 D1 direct lighting plunger; '59 Tiger Cub; '60 5TA;  '76 FS1-E; '97 Honda Sky SGX50.

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cbranni
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October 10, 2020 - 9:05 am
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Alan,

It's a good workshop, it could be bigger but we all want a bigger one, all the cupboards came from MFI closing down, doors are just chipboard from Homebase cut to size, I do use a lot of seed trays for storing parts for rebuild and there is an attic space full bike bits which need sorting out badly, maybe over this coming winter.

Stoo,

Yes you dead right, some days flow but then other can be a right *&^%$£, lets hope today isn't one of them.

Kind regards Colin

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