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Colin's D1 rebuild
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larryc
burnley lancashire
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October 10, 2020 - 7:04 pm
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Look a great resto , I am jealous of your garage, I struggle with my 2 sheds, your centre stand spring looks new or is it an original cleaned up? they are hard to source, the D7+ springs are too long, if it is a new one where did you get it from?

regards Larry

Riding a D1 springer with a D3 engine, 2 x more D1's being built from bits one will be a GPO lookalike the other I am just collecting bits for at the moment

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cbranni
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October 10, 2020 - 7:16 pm
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Hi Larry thanks for the compliments, the stand spring is the original one from the bike I just wire brushed the rust off, thinking about it maybe I should have sprayed it silver.

Cheers Colin

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GlenAnderson
Dover
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October 10, 2020 - 10:20 pm
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Nice work. 

I thought the “mistake” was fitting the footrest rubbers before putting the brake pedal on...

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cbranni
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October 11, 2020 - 9:42 am
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Well spotted Glen but the reason the lever couldn't be fitted somebody who shall remain nameless forgot to paint it, and then when it was painted on Friday he wasn't happy with the finish and re-painted the items on Saturday(you know what these arty farty people are like) but be fitted next weekend.

rsz_p1050977-1.jpg

The mudguards were given a tidy up all the dents beaten out a spot of filler to hide the small ones.

rsz_p1050971.jpg

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cbranni
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October 11, 2020 - 10:15 am
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More photos of the mudguard work

rsz_1p1050968-1.jpg

rsz_p1050974.jpg

rsz_p1050976-1.jpg

The inside of the mudguard gets coating of some stone chip spray we have, as you can see the mudguard is in great condition, this is the rear mudguard so oil leaks and chain lube help to stop corrosion but even the wire loops are still all there which is rare.

As I couldn't fit the brake lever I got busy on the wiring loom, I wanted to keep the original switch and plug but also fit as you have seen before a 6v A reg re/rect. There are two wires which are dark red and green which run from the genni to the light switch these wires not be be used as far as I can tell because also there is a translucent resistance wire which is not needed so these were cut out (too late).

I added two black wires to the loom, one for horn push and one for engine cut out, I won't add the brake switch supply and rear light till later.

rsz_p1050973-1-1.jpg

That's it for this weekend but Leon may send me some petrol tank progress photos..........(if he remembers)............he "needs to be alone" when he's being creative.

Take care all Colin

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Number6
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October 11, 2020 - 4:46 pm
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As I couldn't fit the brake lever I got busy on the wiring loom, I wanted to keep the original switch and plug but also fit as you have seen before a 6v A reg re/rect. There are two wires which are dark red and green which run from the genni to the light switch these wires not be be used as far as I can tell because also there is a translucent resistance wire which is not needed so these were cut out (too late).

Translucent should be the earth wire for the headlamp back to frame and battery, so shouldn't have any resistance ... http://livinginthepast-audioweb.co.uk/imagex/misc/th_scratchhead.gif

Green wire is the low power charging winding, this is connected all the time to rectifier and thence battery.

Dark red wire is from the lighting coils, both this and green go to the light switch so that when turned to 'H' (headlamp on), the lighting coils' output goes back down the green wire to rectifier.

At least, if wired up as standard ...

 

 

-

Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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cbranni
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October 11, 2020 - 7:38 pm
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Hi Number 6,

The bike has a Wipac set up as standard and yes the translucent wire is earth and runs to the headlamp shell, but there is another translucent earth wire linked to the earth point by the battery this translucent wire runs to the lighting switch terminal number 4 and has a resistance winding along some of it's length, green to number 5 and red to number 6. As I am not wiring it as standard I don't need them so I cut them out.

The  A reg 1 will replace the Wipac rectifier which will rectify the volts (AC to DC) and limit the output to 6v, it will also monitor the battery and keep it charged, it's a very good bit of kit, when I work on an alternator bike I always fit an A reg 1 and if working on a dynamo bike I fit a DVR2.

Kind regards Colin

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cbranni
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October 12, 2020 - 3:45 pm
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Leon sent me some photos of the progress on the tank, it was prepared at the same time as the Matchless tank and that tank was the worst tank we have repaired, this tank was only used for one year so we did our best to save it, (well Leon did), the Bantam tank was in good condition.

He has applied the Old English White.......

rsz_p1020022.jpg

Then the gold pin line masking.........

rsz_p1020024.jpg

Then spray on the gold pin line...............rsz_p1020025.jpg

Ready now for the Maroon.

Kind regards Colin

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cbranni
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October 13, 2020 - 10:08 am
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Leon has done more work to the tank, no point explaining it all easier with a photos...............

rsz_tank2.jpgrsz_tank3.jpgrsz_tank4.jpg

Leave it harden off for few days then flat it off apply transfers and lacquer.

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Number6
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October 13, 2020 - 8:17 pm
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Seriously impressive. http://livinginthepast-audioweb.co.uk/imagex/misc/th_worshipper.gif

But I'd be too frightened to use it now .. http://livinginthepast-audioweb.co.uk/imagex/misc/ohmy.gif

Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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cbranni
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October 16, 2020 - 6:51 pm
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Thank you Number 6,

So tank has now been flatted off and ready for transfers.........

rsz_p1050984.jpg

That went to plan and I think it looks fine, and some of the maroon parts are primed ready for top coat tomorrow.

rsz_p1050987.jpg

The hubs are ready for wheel building when I get the rims, the battery holder has been repaired.

rsz_p1050983.jpg

The resize photo thing I use has stopped working so I will stop here in case I lose it all.

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cbranni
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October 16, 2020 - 9:06 pm
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Resize is working again but it could have been me.

rsz_p1050988.jpg

Battery carrier has had new hinge clamp made, looking good

rsz_p1050991.jpg

I drilled and tapped both handle bar lugs one side is for horn the other for cut out.

rsz_p1050990.jpg

Be more tomorrow.

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Blue Heeler
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October 16, 2020 - 9:48 pm
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Superb work, loving the quality finish on everything!

Was the n/s rearward fitted side stand bracket welded on...looking at the bike pre strip-down, post No4?

Blue

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cbranni
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October 17, 2020 - 3:08 pm
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Hi Blue,

Thank you for those kind comments.

The side stand is a clamp on type and MCA cast into it so they must have made it as an after market part.

Kind regards Colin

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cbranni
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October 17, 2020 - 3:20 pm
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Today Leon painted all the maroon parts except the mudguards which needed extra work and then he applied the primer.

rsz_p1050993.jpg

rsz_p1050995.jpg

I finished assembling the horn after a total rebuild, it looks okay to me.

rsz_p1050997.jpg

All coming along nicely.

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cbranni
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October 24, 2020 - 3:59 pm
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Friday came around again and due to Covid rules this will be the last day working on the Bantam for a few weeks as Wales is now in lockdown again, Leon gave the tank a top coat in the week and it looks very shiny...........

rsz_p1060019.jpg

 

On Friday he painted the mudguards while I fitted the toolbox and battery holder all went together nicely.

rsz_p1060018.jpg

rsz_p1060010.jpg

 

We then fitted the forks and headlamp.

rsz_p1060007.jpg

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cbranni
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October 24, 2020 - 4:18 pm
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rsz_1p1060005.jpgrsz_1p1060006.jpg

So that's as far we've got and it will be on stop now for a few weeks but no big deal as we are still waiting for rims and for the re-chrome parts, okay guys take care and stay safe.

Kind regards Colin

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Alan.Moore
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October 25, 2020 - 12:15 am
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Looking really nice Colin. Q: Are all the fasteners new or have you had the originals re-plated?

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 25, 2020 - 10:14 am
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Hi Alan,

All fasteners are new zinc plated from Nooky's nuts and some like the dome nuts I have made from stainless just to brighten the bike up, Leon likes a bit of bling !!!rsz_p1060008-1.jpg

Kind regards Colin 

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GlenAnderson
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October 25, 2020 - 11:35 am
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Do you two fancy doing a repaint on my D1 when you’re finished with this one and you’re bored? 😃

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