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D1 Rebuild by No.6
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Number6
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April 28, 2020 - 12:17 am
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Good point about the paper – at least there weren't any petrol soaked rags! laugh

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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April 28, 2020 - 8:03 pm
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Bantam D1 Rebuild Part 7, 28/04/2020

 

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Gaiters are eBay item 184116969071, in the drop-down list select: "27mm dia x 35mm dia x 120mm length".

I am not associated with this seller in any way nor profit in any way by mentioning it here. This is not an advertisment.

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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April 29, 2020 - 12:22 am
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Sorted.

Thanks for the gaiter details, I may give that type a go when it`s my D1`s turn. Very tight were the ones I fitted to my D3 and they cover all the leg down to the mudguard bracket, so don`t need to slide....but will be interested to see how you get on with your set-up. 

Blue

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Number6
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April 29, 2020 - 1:44 pm
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Actually they will stretch the other way as well if you want to make them tighter at the bottom – this will probably get you a total travel of about 3 inches – but I figured as it is at the mo the forks compress anyway soon it's off the stand, so not much in it, but only one way to find out! laugh

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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April 29, 2020 - 2:08 pm
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Handy Tip No. 361

I changed all the grease nipples to hydraulic type (HR DIN 71412 etc.) – the previous rebuilder had already started doing this but not completed – this style is for a grease gun having a coupler or locking tip (which is what I've got. I used to have a pressure type that belonged to my dad but I got a feeling I scrapped it.)

When pumping grease into the plunger slider tubes for the first time, i.e. they're empty, just contain air, it turns out it takes about 40 pumps of the lever (on mine), with no resistance, then it suddenly goes stiff. I deduce this is the point where the grease has reached both bronze bushes, therefore the hollow slider tube is full. I supposed you can do it some more to make it ooze out the ends but I would have thought that is enough to lube the bushes, which is the main thing.

Footnote – the original columns (or centre rods) show signs of significant wear and corrosion at the top, although the corrosion had been cleaned off. The right side is particularly bad in fact looks like it has been filed! I can only imagine there was insufficient greasing, that starved the top bushes.

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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Number6
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May 1, 2020 - 6:36 pm
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Odd jobs today.

Started with looking at seat spring mounting and cutting the studding down to fit – dome nuts look like a good idea:

 

IMG_3085.jpg

 

Below: finished modifying this spanner in the foreground, a 27 – 30mm bottled gas spanner, the 27 end I folded the tips over so it would work on the fork seal holders. Today I squared them off flat to make it properly finished. Also at the 30mm end I enlarged it to 31mm (1.25" ?), should fit gearbox sprocket nut.

Centre, 25mm bicycle cone nut spanner, enlarged to 1 inch so fits rear wheel nuts.

Top, 21mm bicycle cone nut spanner, fits front spindle nuts as is.

IMG_3086.jpg

 

Below: wire-brushed and Dremeled!

IMG_3087.jpg

I might show it to some primer, then I've got some so-called "chrome paint" for the top, we shall see!

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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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May 8, 2020 - 6:36 pm
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Stalled due to stupid little distractions, e.g. got involved in fitting the new seat, spent a lot of time making plates to extend the seat front mounting, and getting it wrong twice, and having to do it over. Twice!

The second pair, cut, drilled and painted, holes too close together. Misread the scale on the calipers! http://livinginthepast-audioweb.co.uk/imagex/misc/banghead.gif

And so my postman Dave said, "didn't you try fitting it before you painted it?" And I said,"Yes, and it looked alright" http://livinginthepast-audioweb.co.uk/imagex/misc/idunno.gif

Couple more videos in the pipeline, e.g. number 5 is still not finished yet.

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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May 9, 2020 - 3:10 pm
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Fitting the rear mudguard (which was finished much earlier, new number plate LED rear bulb and new wiring, only needs a connector to be added), and a new Wassel Lycette style solo saddle.

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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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May 10, 2020 - 3:26 pm
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Playing with panniers ...

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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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wildun
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May 10, 2020 - 4:34 pm
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Panniers look good, and useful. You could experiment with inner formers, maybe hardboard to maintain the available shape for full capacity.

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May 10, 2020 - 4:46 pm
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What-ho, cucumber sandwiches & lashings of ginger beer! 😉

Looking good, I think the Plunger models lend themselves to soft panniers. Wicker baskets too.

Blue                     

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Number6
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May 11, 2020 - 5:38 pm
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Oh yes awfully spiffing, what? laugh

@ wildun I'm going to have to design some sort of lower supports, as it is, there's a great risk of catching the tyre. Am hatching a plan to make brackets to extend up from the plunger top bolts, and a flat bar across the back of each bag.

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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May 12, 2020 - 6:25 pm
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Got the brake plates assembled at last. With new springs!

This was delayed due to having to get a "new" rear brake plate, then I got sidetracked into other things ...

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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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May 12, 2020 - 9:41 pm
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Removing front hub bearings

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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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May 13, 2020 - 6:38 pm
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I went down another rabbit hole and took the carburettor apart. And I'm looking at the air cleaner thinking "does it need cleaning or not? Suppose I should go through the motions..."

Left it to soak in petrol for an hour, and the petrol turned dark brown. With black bits. OK so deffo could do with a clean then.

Then I blasted it with carb cleaner, and a coating of black crud came off of the inlet side mesh.

Much more betterer ... can actually see the metal now ...

IMG_3103.jpg

 

After leaving it to dry for a while, I then turned it upside down and gave it some taps with a screwdriver handle, and a load of grass fell out! And more black grit. So I shoved the vaccuum cleaner on it, to make sure

 

Finally, a dunking in SAE 40, then letting it drain back into the can ...

IMG_3104.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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cocorico
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May 13, 2020 - 8:13 pm
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Number6 said
...After leaving it to dry for a while, I then turned it upside down and gave it some taps with a screwdriver handle, and a load of grass fell out! And more black grit. So I shoved the vaccuum cleaner on it, to make sure...
  

You were lucky (another quote from Monty Python) - I once found some grubs in the carburettor inlet...

resize-carb-1-1.jpgresize-carb-2.jpg

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1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine now running.

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May 14, 2020 - 12:21 am
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cocorico said

You were lucky (another quote from Monty Python) - I once found some grubs in the carburettor inlet...

I bet it flies now....or does she just beetle along?....

No6...I`m waiting with Bateman`s breath for you to strip the engine. The last "restored" Bantam I was asked to "give a quick look-over", revealed an equal number of horrors within the motor. It was a D1 & a real "tart", as The Trade refers to prettied-up vehicles hiding a multitude of nasties. Hope your engine has avoided the hand of bodge.

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Number6
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May 15, 2020 - 3:08 pm
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EW!! freaked-out_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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May 15, 2020 - 3:11 pm
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Stainless Fork Sliders, what are they like – Draganfly came through with one lefthand one (so far) ...

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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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May 22, 2020 - 7:23 pm
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Removing Bantam D1 rear sprocket, which is rivetted, so heads had to be ground off then the rivets punched out. What a PITA!

I wanted to do more than this today but just doing this took up most of the time! (Plus "interruptions")

Not much to see here hence very short video would just comprise of grind, bash, grind, bash, nine times (for nine rivets).

The last two would not be persuaded to come out so I had to get drilling, until the punch would work.

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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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