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Kelvin's D3 rebuild...
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kelvinjouhar
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July 30, 2012 - 11:02 pm
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OK - I introduced myself on the relevant forum a few weeks ago, and there was some debate about the identity of the Bantam that I had bought. Well, the bike arrived about a week ago, and although from the pictures it looked in reasonable shape, I have decided to take it to pieces and start again.

The bike has an MOT, although clearly it had not been run for a while. The battery was flat, and some of the wiring was disconnected, so I didn't even bother to try to get it started. The engine has compression, which is good.... I think the bike is a D3 (which seemed to be the consensus on the other thread) ..... It has the "shoulder" in the fork tubes, the 70mph speedometer, the "Bantam Major" transfer, and it is grey.

I have not yet examined the engine - I was told it was a 125 cc, but I will investigate that in due course. I will post pictures on here, as I progress.

 

 

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Anderzander
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July 30, 2012 - 11:13 pm
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Wow - that paint is in great condition. It even has a transfer on the head tube and an nice original side stand !

Very nice.

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baker man
..llandudno conwy wales
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July 30, 2012 - 11:14 pm
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Hi Kelvin, welcome back, i well remember your introduction..hope you enjoy your D3...ask away if you need help..( the sidestands a bonus!...)...thumbs-up

....D5..D7.......2X tiger cubs..2x 3ta..t120 bonnie..t140 bonnie..350 enfield..500 enfield..excelsior consort..bantam bleeder ( leader engine )

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Munchkin
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July 30, 2012 - 11:14 pm
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Be interesting what you do to it and the finished article.Good luck and have fun.

1951 D1 Bantam. 

1983 Kawasaki 440 Ltd USA

There is now room for more bikes!!

 

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dave
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July 30, 2012 - 11:45 pm
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D3's a-go-go! looks great...looking forward to seeing more of it...

dave

'57 Swing-Arm D3 on the road to recovery/ruin/quite possibly both...

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Sprung Chicken
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July 31, 2012 - 10:59 pm
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o-m-g  Tin ware and frame in timewarp condition as they say.

Dougie;Glasgow ;Scotland.
1955 D1, 1970 B175

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iand
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August 2, 2012 - 10:00 pm
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Great base to start from, are you redoing everything or leaving stage paint original?

IanD

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kelvinjouhar
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August 3, 2012 - 11:48 am
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iand said
Great base to start from, are you redoing everything or leaving stage paint original?

IanD

My intention is to re-do everything - ther parts in the picture are going to be powdercoated black tomorrow.  I will buy some new parts where needed (eg Fork seals) and re-condition the engine - I will post pictures as I go...

 

Regards

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baker man
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August 3, 2012 - 12:40 pm
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Hi, it's just my opinian but to my way of thinking the grey paint work on your D3 mayjor sets off the bike mutch nicer than black will, plus the fact you will loose the originaity of the bike....it's your choice of course, but you dont often see D3 bantams in grey...good luck with the project.....thumbs-up

....D5..D7.......2X tiger cubs..2x 3ta..t120 bonnie..t140 bonnie..350 enfield..500 enfield..excelsior consort..bantam bleeder ( leader engine )

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Anderzander
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August 3, 2012 - 12:47 pm
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cry

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kelvinjouhar
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August 3, 2012 - 5:00 pm
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My bike is somewhat of a "bitsa", because it has a 125cc engine and the left-hand filler cap on the tank (and the dealer that sold it to me describes it as a D1, and it was only the forks, speedo and colour that suggested that it was a D3 when I posted the pics on here).... Its either a D1 with D3 forks, colour and  speedo....... or it's a D3 with a D1 engine and tank (albeit with a D3 Bantam Major transfer)

So, although I get the sense that I have slightly dissapointed some forum members with my choice of black for my bike smile , I like the look of the black with  Ivory panel and chrome wheels, and although my bike is a 1955, I note that black was an option on the D3 in 1956.

 

Regards

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baker man
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August 3, 2012 - 5:11 pm
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tumbleweed

....D5..D7.......2X tiger cubs..2x 3ta..t120 bonnie..t140 bonnie..350 enfield..500 enfield..excelsior consort..bantam bleeder ( leader engine )

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kelvinjouhar
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August 5, 2012 - 6:34 pm
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Good news - my bike has a 150cc engine - so its a pukka D3 !

I measured the bore and it was 56.85mm which I think must be 57.00 mm less 0.15mm of crud round the top of the bore.

I don't know what the numbers on the top of the piston mean... any ideas ?

 

 

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bart
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August 5, 2012 - 6:55 pm
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probably just a part number

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Anderzander
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August 5, 2012 - 6:56 pm
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It is !

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kelvinjouhar
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August 9, 2012 - 9:13 am
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Update

Metalwork - All of the parts are now at Trestan Finishers in Southampton for powdercoating. I have used them before, to powdercoat the wishbones, when I rebuilt my Westfield race car. Very helpful people and not expensive I would say. I expect to get the parts back in the next couple of weeks. I have quite a few scrappy looking chrome parts so I will get those re-chromed as well - I am investigating to find somewhere local to get those done.

Wheels - I want these to be chrome, so I guess I have to dis-assemble them in order to clean and paint the hubs, then get the rims and spokes chromed and then re-assemble... alternatively, depending on the condition of my exisiting wheels when I look more closely, I am considering new stainless wheels and spokes. I haven't decided on that yet. The fun part of doing my first bike is learning some new skills - I have, for example, fitted data-logging and traction control to a race car...now I have to learn how to lace a motorbike wheel...!

The rear wheel sprocket looks badly worn to me - it is rivetted on, so I guess I need to drill out the rivets to get it off (?) and then a new one can go on...I think the new one will need to be bolted on, as I don't have the right equipment to rivet it on.

Engine - People talk about a "D1" engine and a "D3" engine, but I think it's the case that both are identical except for the different sized barrels and pistons, which are a straight swap onto the bottom end, to give 125cc or 150cc (?) -  I measured my barrel (57mm) so it's a 150cc displacement, so I have been in touch with Howard and he is going to get it rebored for me and supply a new piston. I will also check the other engine parts to see whether anything needs renewing.

Electricals - the wiring on the bike was really scrappy so I am going to replace it. I removed the old wiring and marked it all up but I didn't test it before doing that. My current thinking is that I will fit the Rex Caunt ignition system and a 12-volt battery. I have read some good reports on here about it's reliability. I know it's not inexpensive, but I tend to go by the mantra .."If you buy cheap, you buy twice"... 

Speedometer - this was not working (there was no cable drive attached) and the glass was broken and the needle looked a little bent - I haven't looked at this yet, but I am hoping it is serviceable - I saw a NOS speedo sell a few days ago on E-bay for about £180 !!  I am going to Sammy Miller bike jumble this coming Sunday - I will keep my eyes open for a second-hand one as a spare, in case mine in knackered.

Thats all for now.

 

Regards

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kelvinjouhar
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August 27, 2012 - 10:44 am
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I got most of my parts back from powder coating - they look good, but some of the parts (mudguards, toolbox, headlight bowl) are going to be painted in 2-pack rather than powdercoat so I don't have those yet.

I have started to re-assemble a few things . I put the headstock on , including the fiddly job of getting the 24 ball bearings into the top and the bottom ! Plenty of grease to stick them in position and all's well !

I need to get some parts re-chromed - I saw an advert in Classic Bike magazine for a firm called Alderney Plating in Poole and that is not too far from me so I might go with them.

Kelvin

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Munchkin
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August 27, 2012 - 10:59 am
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kelvinjouhar said
Update

 

The rear wheel sprocket looks badly worn to me - it is rivetted on, so I guess I need to drill out the rivets to get it off (?) and then a new one can go on...I think the new one will need to be bolted on, as I don't have the right equipment to rivet it on.

 

Thats all for now.

 

Regards

I had the same problem, but took the bike to someone who could do the job, I supplied the parts theyre doing it.

Have fun its part of the enjoyment of owning Bantams..

1951 D1 Bantam. 

1983 Kawasaki 440 Ltd USA

There is now room for more bikes!!

 

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kelvinjouhar
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October 22, 2012 - 7:04 pm
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IMG_1769a-1.jpgIMG_1771a.jpgIMG_1813a.jpgIMG_1815a.jpgIMG_1817a.jpgOK - I am making progress on the re-assembly of my D3.  The barrel went to Howard to have a re-bore. It turns out that there was an amount of pitting on the inside walls - as though a piston had been left in there to rust for a while, so it has been taken out +40 and I will be collecting the barrel and the new piston from Howard in a couple of weeks.

All of the parts are back from powdercoat/paint and it is all gradually going back together. I noted from the current MOT on the bike "Daylight use only", and that is what I am going to start with. I will be wiring up a brake light , and that is all - until I get it running. I don't know what the engine will be like - the only wire that was connected was the ignition coil to sparkplug. The wiring was a complete mess, but that will be re-done in due course.

I have replaced the clutchplates (very thin and stuck together) and the springs. I have not split the casing - if the engine does not run satisfactorily, I will have to do a full rebuild... we will see. Carburettor has all been cleaned up. Fuel tank is being painted.

Here are a few pictures to show the progress :-

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Sprung Chicken
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October 24, 2012 - 9:19 pm
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Its coming on,Kelvin.
As for the rear sprocket,I've tried to re-rivet a new sprocket on and its a right PITA. I ended up using
Allen bolts and nylok nuts.

Dougie;Glasgow ;Scotland.
1955 D1, 1970 B175

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