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D1 53 Plunger Lucas restoration
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Martin_uk
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November 12, 2018 - 1:38 pm
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Unfortunately.Glen's comments were prophetic and tank leaks 🙁

At first I thought it was the tap, but on closer inspection there are a number of small pin holes !

 

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1953 D1 Plunger Lucas

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cocorico
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November 12, 2018 - 3:43 pm
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Martin_uk said
Unfortunately.Glen's comments were prophetic and tank leaks 🙁

At first I thought it was the tap, but on closer inspection there are a number of small pin holes !

  

I recently used a sealer 'Slosh' on a tank with pin holes (some a bit more than that after poking about a bit). Make sure it's clean inside by following the instructions and it's not a difficult job - though I had to wait until spring for some warm, dry weather to do it. The holes that I'd enlarged were sealed from the outside with epoxy to give the sealer a better chance.

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Just my own experience with this product.

1956 D3 awaiting a new magneto. 7 other bikes in the Barn, 6 runners and a still in progress Morini 250

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Martin_uk
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November 12, 2018 - 5:43 pm
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cocorico said

I recently used a sealer 'Slosh' on a tank with pin holes (some a bit more than that after poking about a bit). Make sure it's clean inside by following the instructions and it's not a difficult job - though I had to wait until spring for some warm, dry weather to do it. The holes that I'd enlarged were sealed from the outside with epoxy to give the sealer a better chance.

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Just my own experience with this product.  

I used a tank sealer on my AJS 350 tank, probably 15 years ago and was fine until they started adding Ethanol to petrol and it caused sealant to break down and block carb.

I have been trying to remove with nuts and bolts shaken inside and various solvents but still resisting 🙁

I know latest sealants are meant to be resistant to Ethanol, but is a concern, especially if the government decides to increase %.

Non resistant plastic carb floats can also be affected.

1953 D1 Plunger Lucas

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swalsh58
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November 12, 2018 - 6:01 pm
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Martin_uk said

I used a tank sealer on my AJS 350 tank, probably 15 years ago and was fine until they started adding Ethanol to petrol and it caused sealant to break down and block carb.

I have been trying to remove with nuts and bolts shaken inside and various solvents but still resisting 🙁

I know latest sealants are meant to be resistant to Ethanol, but is a concern, especially if the government decides to increase %.

Non resistant plastic carb floats can also be affected.  

Acetone will remove most tank sealants. Best way to repair pinholes is with lead solder wiped into the holes, the same way plumbers used to wipe lead pipe water joints. It has to be scrupulously clean before starting though, and use a strong flux.

Current bikes......1958 D5, a 77 Suzuki GT250 and a 77 Honda CB125S. I have a 74 Kawasaki S3 400 and a B175 waiting for restoration. A 1980 Honda CB400N waiting for MOT.  Everyday ride is a 2011 Harley Davidson Sportster. 

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GlenAnderson
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November 13, 2018 - 5:33 am
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I think any repair to that tank is going to have to be considered temporary. I’d be looking for a better one. 

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cocorico
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November 13, 2018 - 8:19 am
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swalsh58 said
... Best way to repair pinholes is with lead solder wiped into the holes, the same way plumbers used to wipe lead pipe water joints. It has to be scrupulously clean before starting though, and use a strong flux.  

Plus a big torch, you'll need plenty of heat. 

1956 D3 awaiting a new magneto. 7 other bikes in the Barn, 6 runners and a still in progress Morini 250

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johnsullivan
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November 13, 2018 - 12:58 pm
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This holing can be done with low  melt solder and the hot air gun.Cleanliness vital of course .I have an JB weld repair on a mower doing well...

67 D10. and a D7    2007 Honda Hornet FA. Honda CD200 81 93 Yamaha TTR 250 Raid, Sinnis SC 125.   75 Montesa Cota 247 an electric scooter of Famous make.

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Martin_uk
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November 15, 2018 - 5:39 pm
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I have found Lucas part number 516597 and see link for image, item 14

 

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1953 D1 Plunger Lucas

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Martin_uk
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November 16, 2018 - 12:08 pm
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I bought new fork bushes and waiting for one to be replaced as undersized.

Trying to decide whether to replace sliders as chrome poor at bottom, worn and slightly distorted by a fraction.

 

Draganfly have new Stainless ones they had made, (Tomahawk style)  they are £65.94 each.

Decided to go for it and ordered with a couple of other bits means another £150 !

I'm finding that a lot of small items that used to be pence, like springs, lock tabs,grease nipples, bolts etc are now several £s.

Trouble is that I cant bring myself to refit worn old parts if replacements are available 🙁

Bought used top and bottom yokes, but had to send back as top yoke distorted 🙁

Still waiting to hear back from specialist welder verdict on crank cases.

1953 D1 Plunger Lucas

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Martin_uk
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November 21, 2018 - 4:13 pm
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New fork sliders arrived.

Need a little finishing for burrs and will polish lower part

 

Also got the pilot lamp holder, didnt realise it was remanufactued in stainless.

Thanks to suggestions on here, warmed fork gaiter in hot water and pushed over similar sized cylinder to seal holder to make fitting a bit easier.

 

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1953 D1 Plunger Lucas

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Martin_uk
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November 21, 2018 - 4:19 pm
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Started looking at Lucas generator wiring.

The loom I bought comes with a new section that needs soldering on.

 

Anyone know a source for the contact breaker terminal  and fibre insulation?

 

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1953 D1 Plunger Lucas

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Martin_uk
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November 23, 2018 - 2:11 pm
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Sliders look better after polishing

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1953 D1 Plunger Lucas

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Martin_uk
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December 5, 2018 - 10:13 pm
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A bit more progress.

Chrome rear plunger covers fitted. I did try with original painted silver but did not like.

Waiting for new  rear wheel chain adjusters and a handlebar lower spacer to arrive from Bournmouth Bantams who managed to find.

Front mudguard temporary fit to work out which stays go where 🙂

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1953 D1 Plunger Lucas

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Martin_uk
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December 21, 2018 - 12:03 pm
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It was too cold to work in my shed so have brought bike into my attached garage.

Making some progress and also managed to find an original Lucas Delux headlamp.

As I suspected the original bulb holder plate for underslung pilot is much thinner than the repro stainless part from Draganfly.

Now need to find the pilot lens rubber surround 516395.

Does anyone have details of the correct cable routing on 53 D1 inc speedo cable?

 

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1953 D1 Plunger Lucas

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Martin_uk
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December 26, 2018 - 1:14 pm
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Martin_uk
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December 26, 2018 - 1:16 pm
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A bit more progress on the ignition/lighting switch.

The fixing for the Lucas switch with spring and locking plate does seem over complicated

1953 D1 Plunger Lucas

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December 26, 2018 - 1:30 pm
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Martin_uk said
A bit more progress on the ignition/lighting switch.

The fixing for the Lucas switch with spring and locking plate does seem over complicated  

Doesn`t look very complicated to me! 🙂

If you have a friendly biker postman as I have,they should be able to supply you with suitable strength replacement lacky bands? 😉

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Martin_uk
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January 30, 2019 - 8:09 pm
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Got the crankcases back from welders

Need some machining and the petroil feed hole to bearing which may be tricky to get it correctly aligned.

 

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1953 D1 Plunger Lucas

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