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D1 Rebuild by No.6
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Roadracingtog
Cheshire UK
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June 8, 2020 - 4:33 pm
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Hi Mike 

Did you have any success sourcing some bottom yoke pinch studs? I’ve searched everywhere I can think of without finding any. One of mine is probably ok but the other needs replacing. Thanks in advance. Andy

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Number6
Lincolnshire
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June 8, 2020 - 5:44 pm
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Hi, assuming ours are identical, I got 5/16 x 1" BSF hex bolts, from wjperryjaguarspares on eBay

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3 separate orders of different lengths of 5/16 I've had from him, they've all been OK.

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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Number6
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June 8, 2020 - 5:53 pm
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Funny how something you've been planning for ages doesn't turn out as you expected – I expected the paint on the insides (!) of the brake drums could be simply and quickly wire-brushed off with a rotary brush in the Black-&-Decker, nope! The brush is too "aggressive" – scratching the metal! http://livinginthepast-audioweb.co.uk/imagex/misc/ohmy.gif

So weeks of anticipating exactly how the "procedure" would go went out the window – had to resort to the Dremel – just as well I've got one! I used the "fine" sandpaper wheel in the end.

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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Roadracingtog
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June 8, 2020 - 6:13 pm
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Number6 said
Hi, assuming ours are identical, I got 5/16 x 1" BSF hex bolts, from wjperryjaguarspares on eBay

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3 separate orders of different lengths of 5/16 I've had from him, they've all been OK.  

Cheers, order placed 👍

I’m not far off beginning to build up the chassis, which I need to do if I want to use the dining room, as a dining room, anytime soon 😂😂😂

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Number6
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June 8, 2020 - 6:24 pm
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I'm a bit further ahead than you, I can now use the sofa in the conservatory for sittng on again (had a tidy up)

The floor is still largely occupied tho

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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Number6
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June 24, 2020 - 7:01 pm
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Can't believe it's over 2 weeks since I last did anything. http://livinginthepast-audioweb.co.uk/imagex/misc/ohmy.gif

Currently rebuilding the wheels, I decided not to cut the spokes in the end but see if they would unscrew, they did, so have retained the old sets which look like could still be usable.

Before ...

IMG_3125.jpg

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After ...

IMG_3131-1.jpg

 

Next I want to clean up the hubs, press in new bearings then repaint them. Weather's too damn hot to do much at the mo tho .. http://livinginthepast-audioweb.co.uk/imagex/misc/th_hot.gif

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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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Number6
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July 6, 2020 - 3:56 pm
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Anomalies

In photo below, left, new needle from Burlen, part of Amal 361/1 overhaul kit. Right, what came out of the carb ...

'The Book' says clip goes in second notch (from the top). If you follow across to the other (left to right), due to the spacing being wider (left), this position corresponds to the middle notch on the right one, and indeed this is where it was when I first took it apart.

I thought I should get technical and compare the diameter of each needle at some equal point (black marks) relative to the clip positions, so I got the micrometer out.

At the black marks, left (new needle) is 2.5mm, right (original needle) is 2.45mm. About half a gnat's eyebrow's difference so not worth worrying about. So yeah middle notch for the right seems correct.

So was this original needle for a G.P.O. bike? (A chart I've got says it would be a completely different part number and the clip in the 3rd notch). The needls are quite different ...

IMG_3144.jpg

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Got a new cable adjuster but had to ream it out a bit (3.5mm drill) to clear the (new) cable nipple ...

NB: locknut was missing from original cable adjuster so I'm glad I did lash out for a new shiny one after all, which came with the nut.

IMG_3145.jpg

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Nipple now just about goes through ...

IMG_3146.jpg

 

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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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Number6
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July 6, 2020 - 4:01 pm
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I was trying to unsolder it at first (the nipple), to put the cable through then solder the nipple back on afterwards, but it seems to be crimped on as well as soldered, it weren't going to budge!

IMG_3147.jpg

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Proper job!

IMG_3148.jpg

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Also got a replacement screws kit, just about all the originals are chewed up, plain wrong (come out of somebody's spares box) or, where has a hexagon head, getting rounded off. Cable adjuster wasn't too bad, but rusty.

IMG_3150.jpg

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All ready to go back on now, or seems so.

Video to follow shortly ...

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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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Number6
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July 7, 2020 - 4:53 pm
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As was threatened, http://livinginthepast-audioweb.co.uk/imagex/misc/biggrin.gif , video, assembling 361 carburettor

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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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Number6
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July 12, 2020 - 6:00 pm
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Doing Things With Hubs #1  (Bantam D1 Rebuild part 12)

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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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Number6
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July 15, 2020 - 6:19 pm
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Yesterday – me coils arrived! http://livinginthepast-audioweb.co.uk/imagex/misc/hyper.gif

Coils-2-1.jpg

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To quote George at Villiers Spares, on his web page he says even if you got hold of genuine unused NOS (New Old Stock) it's still been sitting in storage for literally decades, so has most likely "gone BAD", cos things degrade over time. These are brand spanking new and made with all modern materials. I've already got the magneto winding ditto, again plastic former and sealed in modern resin.

Data:

The two outer lighting coils are labelled: "03243"

DC resistance: 0.6 Ω

The middle charging coil is labelled: "02710"

DC resistance: 1.1 Ω

IMG_3166.jpg

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So I now got a 'charging coil', and what has now become 'Plan C' is looking like virtually identical to the original battery charging schematic, I had to have a rethink and concluded I can't easily isolate the other two coils just to do AC for the headlamp, so as per original battery lighting, it's all coming off the battery, with the 2 lighting coils bunged in in parallel when the lighting switch is turned to 'H'. NB: the battery is a small 4 A/h SLA, and will reside in the toolbox, along with a rectifier and regulator.

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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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Number6
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July 15, 2020 - 6:28 pm
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Then late yesterday afternoon, I took off the contact breaker and went down another rabbit hole ...

I thought it would probably be OK to use, but had bought a spare anyway, just in case. (And also, just so I got a spare.)

Now it looks like I'll be putting the new one (in photo, the one at the back) back on ...

IMG_3164.jpg

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On the 'original' the cam heel is very worn, and the spring looks tired (permanently bent). I'd never know any of this if I hadn't got a new one to compare against! http://livinginthepast-audioweb.co.uk/imagex/misc/ohmy.gif

Also there's some corrosion.

On the Genimag, I've got two shims to go at the back of the pivot shaft, but nothing at the front. So I've got some 8mm fibre washers on order.

It turns out the Genimag does already have 3 coils! Depite what the engine number says. http://livinginthepast-audioweb.co.uk/imagex/misc/ohmy.gif

It was 'converted' to direct lighting by the white wire being connected to the condenser screw, leaving only terminals (1) and (4) to actually do anything, with wires attached; I mistakenly thought one of these was an earth back to the harness, on the basis that the P.O. didn't trust the engine mounts to provide electrical continuity to the frame. Pure supposition on my part. They're actually charging coil and lighting coils outputs! I'm still putting my new coils set in tho.

Also on order, 3BA grub screws, thanks to SuperSun64 for verifying that, 'cause I need at least one other grub screw for terminal (3) (missing). In addition, 3BA countersunk and cheesehead screws (in stainless), as the originals looked a bit chewed up and tired; the outer cover screws (countersunk) suspiciously not fitting very well, and been cut down from something longer, don't know what that's about yet.

Another weird one, the round cover is slightly too large for the hole it has to go into, it won't seat in the groove of the Genimag 'ring'. Der ... http://livinginthepast-audioweb.co.uk/imagex/misc/screwloose.gif

It could have the edge filed down I suppose, but even so, what in the name of blinking flip ...

. . .

Finally – the condenser (top of photo below) is junk – just in case it was, I previously acquired a Thorcap to put in (below) ...

IMG_3165.jpg

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The scabby original measures as 4.35 µF, definitely awry.

The Thorcap is 0.225 µF. Guess which one I'll be using ...

. . .

Press onwards rewardless!

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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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Number6
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July 15, 2020 - 7:48 pm
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Even More Previously ...

 

In other news (kind of related), the prototype rectifier / regulator is working ...

IMG_3157.jpg

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IMG_3159.jpg

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IMG_3161.jpg

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IMG_3162.jpg

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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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Number6
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July 27, 2020 - 11:19 pm
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Pressing In New Wheel Bearings

Not as straightforward as you might think...

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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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mike p5xbx
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July 28, 2020 - 5:28 pm
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I was puzzled as I thought the 3 Switchmode Rectifiers were transistors
you have not used the zener diode (zd1) or the transistor driver for the
Mosfet transistor ?
I have used a really simple shunt circuit in the past on the early wipac generators just two resistors and a Zener driving a 2n3055
just really to stop bulbs blowing
but now prefer to convert to 12volt neg earth with LED bulbs and use a cheap 55 Watt Chinese rectifier/regulator which you can usually get for under £5, difficult to make anything for that price.

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

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Number6
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July 28, 2020 - 7:29 pm
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I changed the circuit, that's why 'ZD1' is now a resistor. The theory is, the MOSFET gate threshold kind of makes it act like a Zener so only need to set the required Voltage, which is what the resistors do.

Next I need to make a real AC input test, have got a transformer earmarked ready to mimic the charging winding but I keep being distracted by other stuff.

I think too there is some variable margin, so similarly it will mostly serve to save bulbs, not be fabulously accurate.

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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Number6
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August 2, 2020 - 6:53 pm
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Repainting the hubs, and fitting shiny new grease nipples. Which are completely non-functional, because the new bearings are modern sealed type. Ditto the new felt washer seals, only included just "for show".

 

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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Number6
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August 5, 2020 - 4:44 pm
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Went down another rabbit hole and took off the fuel tap. Surprisingly clean inside! However the filter screen, although whole, is badly squashed and mangled, can't imagine how that happened. What do people do with these things? Also two fibre washers and wellied up to 'X' Newton metres to make the pull-push bit point in the desired direction, viz, rearwards. I had to put it in the vice and rotate the tank around it to start unscrewing it! Also the cork is "tired". New tap on order, money no obstacle. 😀

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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Number6
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August 7, 2020 - 2:51 pm
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Fun with taps

 

IMG_3186.jpg

 

The vagaries of the nomenclature for BSP (British Standard Pipe? Aka, 'Gas') is doing my biscuit in. This is why I like metric, everything is on the same scale.

Turns out I now need a 1/8" to 3/8" adaptor, (OD 3/8" or 9.6mm to OD 5/8" or 16.5mm) also smaller fibre washers for the 1/8 BSP. On order!

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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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FrankG
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August 7, 2020 - 11:37 pm
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Hi, BSP  is measured by the I/D bore of the tube/pipe so the external thread of 1/8" BSP  would be approx 3/8" O/D.

Frank

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