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D3 Rebuild by No.6
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Blue Heeler
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January 28, 2020 - 11:56 pm
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Number6 said

Bantam_2989.jpg

..... yet two more of these horrible rubber "zip-ties" I keep finding.

Hey, they`re Brit-bike standard issue class item, I`ll have you know. Use them on some of my Bantams 🙂 

What would you prefer, the thin alloy ones? Better looking eh -  just checked...couple of my bikes have them.

You appear to be a man of good taste, so not black plastic cable ties?  😉

Blue

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cocorico
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January 29, 2020 - 7:45 am
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All loking normal for an old Bantam. wink

As far as I recall, the speedo cable on my '56 D3 runs up the back tube and along the top tube. I'll check later.

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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Number6
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January 29, 2020 - 9:35 am
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cocorico said
All loking normal for an old Bantam. wink

As far as I recall, the speedo cable on my '56 D3 runs up the back tube and along the top tube. I'll check later.  

Apparently depends how long it is, has to be shorter to do that. My old '55 D3 of years ago had a long one like this too and it went underneath. Originally it was squeezed between engine and frame, can you believe it. In fact my dad said "why have you done it like that", I said "that's how it was", and anyway he should know he'd been tinkering with it before me!

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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January 29, 2020 - 9:56 am
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Hey, they`re Brit-bike standard issue class item, I`ll have you know. Use them on some of my Bantams

Go on? smile They're a bit sad, and limp.

 

You appear to be a man of good taste, so not black plastic cable ties?

I have zillions of the things, so highly probable.

http://livinginthepast-audioweb.co.uk/imagex/misc/4chsmu1.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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Number6
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January 29, 2020 - 11:17 am
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The vagaries of old British fasteners is doing my biscuit in. I'd forgotten how bad it was. I have what I think is a fairly useful and normal range of both imperial spanners and sockets, but none of them fit anything. Well a very few times. Frame nuts and bolts appear to be BSF (according to some new nuts I've got, bought as BSF) but need 13mm socket or spanner. Some spanners I had carefully put aside to compile a travelling toolkit are looking like useless now. I had to buy a double-ended 18mm especially for the drain and filler plugs (18mm is a perfect fit).

Most of the fasteners are pretty rough, and I'm not at all sure are original or absolutely correct anyway. To hell with it. I've decided the whole lot will be changed to metric, where practicable. Sacrilege. The world will end. There will be a great wailing and gnashing of teeth etc. Time and space as we know it will cease to exist. But needs must when the devil how's-your-father. It's what I'm used to. It's what the Ural's got. You get much more choice for one thing. Going for A4 stainless. Socket cap Allen screws and nyloc nuts. On order. Button cap Allen screws for the mudguard stays, rear rack, number plate holder. I remembered originally these were supposed to be shallow dome-head slotted screws anyway (what my other bike had), not the hex bolts this one's got. Which don't look right at all.

 

I should clarify this is not a "resto", this is a make-good-and-mend, get it useable.

Onwards...!

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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cocorico
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January 29, 2020 - 11:35 am
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Number6 said
Apparently depends how long it is, has to be shorter to do that...

There you have it - mine was just too short to take the low route.

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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Stoo63
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January 29, 2020 - 11:47 am
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I found these super handy, Mike.

** Please log in to view **

'52 D1 direct lighting plunger, '58 Square Four (project), '59 D1 direct lighting plunger,  '59 Tiger Cub, '60 5TA,  '76 FS1-E

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toppo46
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January 29, 2020 - 8:44 pm
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Hi mike,I know what you mean about the spanner sizes,I had a few old bsf and whitworth spammers kicking about but have picked up various other ones from the stickney auto jumble for about a pound a each

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January 29, 2020 - 9:39 pm
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Yep, I`ll vouch for Stickney having plenty of old spanner sizes. Many car-boot sales do. 

If in doubt, take your nuts with you.....

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Number6
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January 30, 2020 - 3:34 pm
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New chains have arrived.

Primary is endless, no spring link. Do we not use them now?

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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January 30, 2020 - 3:43 pm
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Number6 said
New chains have arrived.

Primary is endless, no spring link. Do we not use them now?  

Not used one myself ever on a Bantam, but not frit to.

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Number6
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January 30, 2020 - 3:45 pm
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I now have two new exhaust pipes. Neither fit. Well one nearly does, but then the end is pressed against the frame so silencer won't go on. It's too long anyway so would need to be cut. I do not have a large pipe bending machine to try to make it fit better. Also flange is too big for nut. OK It could be ground or filed down maybe ...

I'm lookng at 'Plan C' which is get the old one rechromed. Actually the gear pedal and kickstart could be done as well TBH.

This has become a project which I'm doubting will be finished before April ...

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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swalsh58
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January 30, 2020 - 4:00 pm
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Number6 said
I now have two new exhaust pipes. Neither fit. Well one nearly does, but then the end is pressed against the frame so silencer won't go on. It's too long anyway so would need to be cut. I do not have a large pipe bending machine to try to make it fit better. Also flange is too big for nut. OK It could be ground or filed down maybe ...

I'm lookng at 'Plan C' which is get the old one rechromed. Actually the gear pedal and kickstart could be done as well TBH.

This has become a project which I'm doubting will be finished before April ...  

That sounds like a Bantam rebuild. I have rebuilt Japanese, Austrian, and others and most have been straightforward. Not Bantams. I have done a couple of D7’s, a D5 and I’m currently doing a B175 and everyone of them has been a complete pain. Fit everything at least three times to get it right. Parts don’t fit, bolts wrong size, electrics are a complete nightmare and don’t even mention Bantam forks. I will not be doing another after this one, I’m going back to Japanese, or German, or American.....anything but a Bantam! I will keep my D5 though, she was my first and I won’t ever sell her.

Current bikes......1958 D5, a 77 Suzuki GT250 and a 77 Honda CB125S. I have a B175 in the workshop and a 76 Honda C90 waiting its turn. A 1980 Honda CB400N waiting for MOT.  Everyday ride is a 2011 Harley Davidson Sportster. 

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NeilB
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January 30, 2020 - 7:13 pm
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Wow, that looked great before you started taking it apart and found all those problems! 

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Number6
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February 1, 2020 - 11:03 am
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Yes!

That sounds like a Bantam rebuild. I have rebuilt Japanese, Austrian, and others and most have been straightforward. Not Bantams. I have done a couple of D7’s, a D5 and I’m currently doing a B175 and everyone of them has been a complete pain. Fit everything at least three times to get it right. Parts don’t fit, bolts wrong size, electrics are a complete nightmare

Thanks, nothing unusual then! I feel better smile

What I did with my old one was get everything rechromed, which meant same things fitted back on easy-peasy.

Electrics are the least of my problems, my other hobby is building Hi-Fi valve amplifiers, I have also made a complete replacement loom for my '76 Moto Guzzi Le Mans; still have a lot of the wire and connectors left over, so Bantam doesn't stand a chance! It WILL be sorted ...

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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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February 1, 2020 - 11:16 am
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Just noticed this just by chance this morning – number plate is on the p!ss ...

Bantam_3002.jpg

 

Fairly par for the course, nearly everything I look at has some silly issue, hence why project is stalling. This is not going to be a quick fix-up, put petrol in it and ride, as I first thought. This bike is in the conservatory for the duration. Whatever that will be!

It's obviously a new one. I could straighten it by filing one hole out. Will have go up right side because bottom edge is resting on the reflector, so can't go down.

Fortunately no-one has tried doing any actual mechanical maintenance, like replacing worn things, so they couldn't c0ck that up. Only new bits it's got as far as I can see is tyres and possibly spark plug (it's a new looking NGK).

 

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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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February 1, 2020 - 11:44 am
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Now got a new headlight...

Bantam_3001.jpg

Here I am trying out a BA9S white LED bulb, from Classic Car Leds, to see how it looks. These seem really good; they are specially made for classic vehicles, including 6V and AC. (!) I also have a warm white, and an orange (for dash panel lighting etc.)

So now the latest idea is LED's for all the 'side' lights, and so will include a BAY15D version for the Lucas lamp at the back. Classic Car Leds say this is best done with a red LED version, which has the best spectrum to actually shine through the red 'lens'; the hard white don't have enough red light, if any, and so shouldn't be used, so they also do a 'warm white' if you must also have it illuminate a number plate. I also have the warm white BAY15D (also available as 6V AC). I might try the all red version if I can figure separate number plate lighting.

Anyhoo, it means it can all run off a small SLA battery, like as is used in alarm boxes, power failure backup for electronics and suchlike. The current draw of the LED bulbs is stupidly small, like the brake 'filament' is only 310 mA.

Consequently, the plan thus far is that the main P36D bulb in the headlamp can remain running off the drect AC, and the rest is LED's running off the battery. Also means I get parking lights! The lighting switch has electrically separate 'banks' of contacts to accommodate this. It would also be nice if there was a bit of rectified DC to keep the battery topped up. I also have other ideas hatching ... it's all very fluid at the mo.

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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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February 1, 2020 - 11:54 am
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And earlier, my engine screws kit arrived!

Bantam_2998.jpg

 

This should be good, should mean no more beating seven shades of ** Please log in to view ** out of it with an impact driver and hammer, because the slots are bu99ered, like as in the old days! Ah the memories ... Honda CD175 engine case posi screws, that seemed to be made of licorice and yet at the same time been done up to 100 Nm ...

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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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February 1, 2020 - 4:04 pm
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Speedo cable is totally dry, no lube whatsoever ...

IMG_3004.jpg

 

Never seen one so dry before, unless it was a new one! Fortunately only surface rust, so still bends. (!)

 

Earlier, nice shiny new screws arrived for the headlamp shell ... I also have rubber washers ...

Bantam_3003.jpg

 

Below is example of the socket cap Allens that came in it, photo doesn't do justice to the full extent of the rust. I like Allens, but the socket cap head is unsuitable in this application. Did look quite odd. This is button head instead.

 

PS: the speedometer has no lamp, just a hole when it should go into.

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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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February 4, 2020 - 8:55 pm
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Been a bit quiet due to stuff and things going on. Can't believe it was only 2 weeks ago I bought this thing, feels like 2 years already.

 

One of the things that has happened is I had the speedo apart for a lube job, thanks to the excellent topic on this forum.

 

Bantam_3005.jpg

 

Smiths_3005.jpg

 

It came apart really easy! A per the instructions, small dabs of WD40 were applied in strategic places by a small artist's brush. Proper job.

 

The odometer was seized up, so the little finger couldn't push it around. Hence it was permanently stuck on "3". I was afraid the finger had worn the teeth down in one spot, or had damaged itself. The WD40 freed up the odometer so I could turn it with a small screwdriver. After that, the finger managed to turn it several revolutions of the wheel without any hiccups; I used my Bosch electric screwdriver to save a bit of time, and watching it, I couldn't see any damaged or worn teeth on the gear wheel. So it might have got away wiith that. The bike not being ridden much if at all since it seized (I'm just guessing) would have helped enormously. Hence it now reads 8 miles, instead of 3 miles. Bit of Vaseline on the worm gear, seems good to go!

 

The bulb holder is missing, thus leaving a gaping hole for dirt and rain to blow in (if the bike had actually been used). Nevertheless is all quite clean inside. Vague signs of a bit of corrosion around the cable entry area, otherwise OK. Actually, might just be because the bulb holder was missing. I've ordered a new one from Bournemouth Bantams and we'll see how that goes with a LED bulb. I have a selection, I can try hard white, warm white or a sexy orange, for an antique wireless dial type effect. Maybe.

Onwards ...

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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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