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D1 1954 Plunger frame Build
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Kirkbybil
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January 2, 2016 - 11:11 am
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o-m-g I had a colonoscopy a few weeks ago, it looked exactly the same!! 

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BSAdave
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January 6, 2016 - 2:29 pm
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Yesterday a lot of parcels turned up (eight in total) . I now have more or less every thing I require to finish this, the only thing stopping me is the weather. One of the parcels contained the missing front centre mudguard support. Has you can see from the picture a centre cross bit had been added, I cut this off and flapped the welds back and re drilled the fixing holes and sanded it down and gave it a coat or two of primmer.

Then it was onto the wheels I removed the tyres and with the aid of a wire wheel removed all the rust this was then treated with Krust and once that was dried it was sprayed with etch primmer and once that cured it was given a coat of primer. Now every thing is in primmer just waiting for some decent weather to give it its top coat, I have one litre of Vauxhall leaf green paint for this.

Before:

support.JPG

After:

mudguard-support.jpg

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BSAdave
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January 6, 2016 - 2:39 pm
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The D3 engine waiting to be rebuilt:

D1 engine casings:

 

D1-engine-casings.jpg

Frame:

Frame.jpgFrame-1.jpg

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BSAdave
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January 6, 2016 - 2:41 pm
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The other bits:

20160106_140855.jpgHandle-bars.jpg20160106_140609.jpg20160106_140559.jpg

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BSAdave
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January 6, 2016 - 2:51 pm
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After getting a quote for £250 to re chrome the handle bars I have decided it is just not worth getting them done. So the plan is to strip them and paint them. But having said that Kempton is on on the 23 January so I will go and see if I can find a better set, I also need foot rest, gear change and kick start rubbers two tyres and inner tubes and rim tape along with the luggage rack an exhaust lock nut various nuts and bolts a petrol tap tank transfers a set of engine bolts. I have a running total of what I have spent and this is getting expensive. Including the price of the frame and other bits it is at £730 

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

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Derek's D5
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January 6, 2016 - 3:17 pm
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Dave, if the handlebars are straight it would be worth getting them rechromed. I'm sure you can get a better price. I paid £25 to get mine done 20 years ago, and that included the levers. They did a great job and they haven't rusted or flaked. I know you won't get them done for £25 nowadays, but I would have thought £50 might be a reasonable price. I can't remember where I got them done, but it would have been somewhere in the Derby / Nottingham area.

if it's only standing you at £700 then you've done well. I might come up to Kempton too, need a few bits. Petrol tap with an intact filter would be nice. Might be able to help you with an exhaust nut, will check if I have a spare one.

got my tyres from Tyrefinder. Came with rim tape, tubes and a small plastic bag of French chalk that could have looked extremely dodgy if an officer had stopped me on the way home!

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BSAdave
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January 6, 2016 - 5:26 pm
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Thank you for that Dookie,

I will take a look about for another quote ,Jess pm ed me about a supplier of handle bars for £30 so might look into that.

If you are going to Kempton let me know and we will meet up , two minds and all that. Last time I went I got some good stuff at a very good price. There is normally a bloke who sells tyres there as well , having said that i found an on line supplier who sells the Mitas H-01 2.75 X 19 tyre for £30 including delivery or the Mitas H-02 2.50 X 19 for £27

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

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Bournemouth Bantams
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January 6, 2016 - 7:14 pm
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I have to come up to London for a meeting in the afternoon of the 23rd so will also be at Kempton.

The guy that sells tyres at Kempton is Mick from Tyrefinder, if you give him a ring he will reserve the tyres for you to collect, makes sense you using him Dookie as he is based in Waterlooville.

"H"

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Derek's D5
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January 6, 2016 - 8:46 pm
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Yes, Mick was very helpful. I went to his house on a Saturday to collect the tyres, saving the couriering charge. Got two Mitas tyres. They were about £30 each. I think he knocked a few quid off the inner tubes and tapes. Had a nice chat about tyres, bantams and about his life in Ballarat, Victoria. Would certainly get tyres from him again.

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CharlieCeng
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January 7, 2016 - 1:53 pm
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That's a good idea Dave. I have a new tank for my SQ4, and one of those cameras. I'll poke it inside and take a look.

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BSAdave
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January 12, 2016 - 4:10 pm
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Not much done lately due to the weather, But today I had a good tidy up of the shed and the postman brought me a new tyre holder, I have a cunning plan for this.

Finally got round to sorting all the tools out and then went on the hunt for the wheel adjusters that I know 100% I have, but do you think i can find them, they are some where safe.

I did find a  tyre that I forgot I had along with an inner tube so that is a bit more money saved.

Wheel-stand.jpg

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BSAdave
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January 23, 2016 - 1:29 pm
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I have got back from Kempton and managed to buy:

The parcel rack

One tyre and two tyre rim tapes:

Footrest, gear lever and kick start rubbers:

Stainless steel exhaust clamp:

I paid a visit to the chain man and purchased a chain and two spare links, he is quite a character.

A tin of etch primmer.

Ten cutting disks

Engine mounting bolts and nuts

All in all a good morning out.

There was a lot of Bantam parts for sale, but none i needed.

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

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BSAdave
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February 3, 2016 - 4:19 pm
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Today I got round to sorting out the hospital bed, Well pleased with how it turned out. I also managed to get some more prep work done on the rear mudguard and wheels.

The bed was a straight forward job, what I did in the end was to cut away the main frame but leaving the wire grill between the two lifting arms and bolt a bit of 18mm ply to the lifting arms, This was then giving a coat of paint, I then cut down the main rails of the bed frame and bolt this to the front of the frame on the other end I bolted down the front wheel holder, then because I just happened to have it I screwed down and bolted a bit of alloy five bar plate. The upright bare metal bar you can see under the lifting arm is a fail safe with this in place the bed can't be accidentally lowered, on the opposite side I cut off the two operating levers as these take up valuable space. In the bottom picture it looks like the wood is bowed but that is just an optical illusion. Just has soon as I can get the welder fixed I will weld up the front stays to the lifting arms, but to honest it is solid so not sure if this is required. I left the two wheel side bits on has I can store it on its end when not in use and these make moving it around a lot easier.   The whole project has only cost me the initial £20 purchase price. all the other bits I had laying about. The bed is now 24 inches wide and 69 inches long the width can not be reduced with out manger cutting and welding of the lifting arms the length was determined by the bit of ply I had, not very scientific but just happened to work.  The space under the bed towards the back I intend to make a metal box to store tools etc.

This should help save my knees.

https://farm2.staticflickr.com/1452/24498944360_f8dfed7363_z.jpg

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

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jess steele
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February 3, 2016 - 6:56 pm
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Thats a very neat job Dave,well done.........

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The Bushman
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February 3, 2016 - 7:40 pm
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looks the business dave and saves your back lol

thumbs-up

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Hans Kreuzen
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February 3, 2016 - 8:40 pm
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Looks great, well done.

PS: Do you feel like a Doctor now, when you work on the bike?out-a-here

1950 D1 plunger for daily use, Concourse 1948 D1 rigid, 1949 Aus. PMG replica D1 project and a 1949 rigid D1 survivor.

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BSAdave
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February 9, 2016 - 4:20 pm
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The Bed

I needed to build some sort of ramp to get the bikes onto and off the bed , so with the remaining bits of the bed I took a look at what I could use, in the end I cut off the end bit as it was wide enough and channelled so had plenty of strength, this then needed to be attached in such a way that it could be removed once the bike was on the bed, I then cut up the side of the old bed frame as this had a welded on lug and this was bolted onto the end of the bed I was lucky that at one end of the frame was a welded on lug so I had one fixing point and on the other end was a hole just in the right place so with the aid of a long bolt I now had two fixing points, to stop the ramp from sliding off I used a long bolt which drops into the lug. Simple but effective. 

20160208_133946.jpg

2015-12-16-14.50.21.jpg20160208_133906.jpg

20160208_133913.jpg

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BSAdave
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February 12, 2016 - 10:18 am
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Yesterday I had a go at welding , I am definitely not a welder, Although it didn't need it and for no other reason but it was lying around, I had a go at welding an 90 degree angle to the rear of the bed, The welder was playing up and when i finished it looked a right mess so I also bolted it into place , then it sill looked rough so I made a cover plate has I had also burnt the paint in my attempts at welding and also to make it a bit more pretty and for no other reason  other than it was all i had to hand I sprayed it black.  , being has the whole thing owes me very little money I am going to splash out on some red paint and spray the whole thing red. With some more time on my hands I continued on the prep work on the frame and mudguards.

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

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BSAdave
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February 15, 2016 - 4:03 pm
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Too cold still to spray, so I started on the engine rebuild, I removed the old bearings and started to fit the new bearings, then I hit the dreaded bearing too tight problem and not liking the idea of sanding the crank down i took a different approach , the bearing that was causing me the problem is the one that sits on the outside of the crank cases on the primary side the other two where not a problem, I have in my possession two D1 early crank cases , I found that one of the cases had the correct fitting bearing and in good condition, I removed it very carefully and put it into the D3 cases, I then fitted the generator side oil seal, the crank now fits in there very nicely. So missing the generator side oil seal i got on the phone and spoke to Rex and that is now winging it's way to me. I had a tidy up in the shed and found I still had one side of the hospital bed rails left over, It would have been rude to have thrown it away , What to do with it ?

I decided to make some sort of engine stand, with the welder out of action and my inept welding skills any way, I soon come to the conclusion that the only way I was going to make one was to make it in such a way that it would have to be bolted together. It is not the prettiest but it works, the rear support has two bolts on the other side that bolt to the inside of the up right. it is very solid.

I had the wire grill bit that was on the centre of the bed lying about so this was cut up to fit the shed windows and fixed into place to make a very nice security grill.

That hospital bed is a gift that keeps on giving, I still have parts left over but have run out of ideas as to what to do with them.

20160215_153026.jpg

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BSAdave
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February 18, 2016 - 2:10 pm
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Today I turned my attention to the engine, with help from Jess and others I now knew where and how to fit the clutch side oil seal, this was quickly fitted, The next job was to clean and polish the cylinder head, first i gently scraped off the carbon build up in the dome area where the spark plug protrudes, then using my very fine wire brush in the drill polished out the remainder it came out very well, Then onto the top part, I used the same method but using a long thin wire wheel , it is not perfect but it is clean and tidy.

Next up the barrel, using the same process, on the out side to get rid of the rust and debris, Then I dug out my Dremmel and with a very small grinding stone I cleaned out the exhaust outlet and finished it off with a polishing mop, I lightly gave the two ports the same treatment, once all this had been done I gave the barrel a clean, I used the air line first of to clear out any particles then sprayed WD40 just to make sure all was clean, I then blocked off all the openings and sprayed the outside of the barrel black.

I'm awaiting a delivery of the gears and parts for the clutch as soon as these arrive I can finish off the engine. My budget has crept up to over £1000 , Today I also purchased a new spray gun, when looking back on the 1949 build I did last year I had started spraying the bike in March so the weather must have been good, so lets hope it is the same this year. On Friday i had an interview for a new job, if i get the job it will mean the end to my dodgy shift patterns and a more normal 8am to 4pm , but there is a down side it will mean less time for Bantam work.

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

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