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My D7 Restoration Thread
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steve2young
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December 9, 2011 - 8:50 pm
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For those that didn't see my introduction in the new user bit I'm Steve and I recently purchased a 1960 Bantam D7 Super via a certain well know auction website for the princely sum of £205.

Bruxa as my little Bantam is now called, which I'll explain later, has been in the back of a shed for 15 years and is in need of a certain amount of TLC and money to get her back to a working and roadworthy condition, but come hell or highwater I'm determined to get this little gem going again and back on the streets where she belongs.

I've decided to start this little thread to share with the other members, who are interested, my trials and tribulations as I work on my little bike.

At the moment I'm still doing a general sus out of what I'm going to need to do to her. The chrome on the tank is shot and is beyond saving so she's going to need a respray at some point although at the minute I'm still cleaning the years of rust and accumilated secretions out of it. The bore was on it's max rebore and had a broken fin but I've managed to acquire a new barrel still at it's standard bore that looks like new which is going to go on to her. She has an Amal 376/313 carb fitted which is good condition even if it is the wrong one for her, she needs a fair bit of de rusting and the odd cable and seal. The front forks have no oils seals and one was fitted correctly and one wasn't and the list just goes on and on.

I'll update my little thread as I go along, with pictures, so you can all tell me where I'm going wrong lol.

Steve

P.S. I forget to say why she's called Bruxa, well I'll explain. The day I went to collect her from her previous owner I somehow managed to cut myself on her whilst loading her on to the van I'd borrowed to pick her up in, which at the time seemed like something that had a high probability of happening so I thought no more of it but ever since every single time I've done anything to her she's managed to draw blood from me which is starting to get a bit suspicious. Anyhow Bruxa is a female vampire that can change in to the form of different animals, insects, and birds and somehow the name just seems to fit. Ok I'm a bit of an old goth and horror movie nut so I kind of know stuff like that alright!!

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Anderzander
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December 9, 2011 - 9:44 pm
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Great stuff looking forward to following your progress.

http://i4.photobucket.com/albums/y113/Anderzander/smilies/worthless.gif

Oh yes - lots of pictures please.

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Sprung Chicken
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December 9, 2011 - 11:07 pm
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Steve,the carb I D is nearly right, 375/31.
Good luck with the resto.

Dougie;Glasgow ;Scotland.
1955 D1, 1970 B175

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Brunow
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December 10, 2011 - 8:14 am
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Anyhow Bruxa is a female vampire that can change in to the form of different animals, insects, and birds and somehow the name just seems to fit. Ok I'm a bit of an old goth and horror movie nut so I kind of know stuff like that alright!!

whahahah 🙂 good luck with her!

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steve2young
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December 11, 2011 - 3:48 pm
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Ok so time for an update.

This is how Bruxa looked at the start of Saturday.

http://img52.imageshack.us/img52/5069/photo001ql.jpg

http://img855.imageshack.us/img855/3161/photo003ll.jpg

As you can see I took the front end off last weekend and my hope this weekend was to get her totally stripped down.

By late afternoon Sunday this is what I ended up with.

http://img412.imageshack.us/img412/958/photo010og.jpg

http://img21.imageshack.us/img21/3931/photo011ek.jpg

http://img3.imageshack.us/img3/6183/photo005lz.jpg

I've now hit a bit of a stop on the engine until I get a clutch compressor and a few other special tools. In the meantime I'm waiting for some POR 15 to turn up so I can get the inside of the tank sorted out and then I have to make decisions on what to do next.

Steve

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Anderzander
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December 11, 2011 - 4:03 pm
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Great stuff !

The paint work looks good in the photos. Will you just be respraying the tank and getting the paint colour matched ?

Stephen

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steve2young
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December 11, 2011 - 7:09 pm
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Quote from Anderzander on December 11, 2011, 16:03
Great stuff !

The paint work looks good in the photos. Will you just be respraying the tank and getting the paint colour matched ?

Stephen

Some of the paint work is absolutely immaculate, the side panels and rear mudguard especially although one of the side panels has a small dent in it, but the front mudguard could do with a bit of a touch up. At the moment I'm undecided if to just do the tank and the touch up or if I should go the whole hog and have it totally redone. Having the tank re chromed and painted is just to expensive for me to justify, been quoted £650, and I'd at least like to keep the tank 2 colours even if one isn't chrome and I can't think of a colour to go with the blue which is pushing me in the direction of a total respray. I'll have to make up my mind before to long which way I'm going to go with it.

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Anderzander
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December 11, 2011 - 7:33 pm
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Seems a shame to do a total respray then - I'm rebuilding a D7 at the moment and encountered the same tank issue, but I did go for the one colour on the tank. You can see pics in my ** Please log in to view **.

For two colours, with one blue, I always thought the Triumphs looked good with blue and silver - maybe you could consider a design based on that?

http://www.burtonbikebits.net/t140%20Tank.jpg

http://www.burtonbikebits.net/T140%20Tank%20Blue%20Silver.jpg

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steve2young
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December 11, 2011 - 8:49 pm
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That gives me a bit more to think about. Apart from that last pic as it just isn't opening.

Anyhow, bit more of an update that I forgot to add on my update and it's more news on it's past. At some point someone has split the crank with the help of a screwdriver. It hasn't done massive damage to anything that I can see and I'm sure that when I have a go with a dremmel the damage that is there will just be a distant memory, or at least that's my hope. Also the paintwork on the frame is very very very soft and all you have to do is touch it and it chips, or more kind of rubs off and leaves red showing. As a lot of the nuts have been painted in whatever it was to this is a real problem as everytime I get my spanner out I know I'm going to lose paint. I'm as yet to decide how to get over this without the hassle of having the entire frame powder coated and a lot of new nuts.

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steve2young
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December 20, 2011 - 9:06 pm
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Thought I'd keep you all up to speed of how I'm getting on but not much to update at the minute. Works Christmas party and buying presents, especially the wifes, got in the way of me even getting out to the shed last weekend, and I don't think I best dare go out there this weekend coming or I'd never hear the end of it lol. So the time of year has stopped me in my tracks, but I do get 10 days off work so I can crack on with what I can over the break.

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steve2young
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December 27, 2011 - 1:28 pm
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Time for a small update. Did get out in to the shed yesterday and started a little bit of rust cleaning and took the rear wheel apart a bit more but didn't really get much done. Today I'm having a bit of a break from being out there as my chest is feeling a bit tight at the minute and it doesn't hurt to have a rest every now and again. I should really explain that even though I'm only 46 years old, 3 years ago next March I had a massive heart attack which I was the lucky enough to be the 1 in 10,000 (I think that was the odds the doc said) to survive a main artery blockage attack after a bit of emergency surgery to have a few stents put in etc, so these days if my chest feels a bit tight I just take it easy. Hopefully back out there and cracking on with her again tomorrow. I know I'm determined to get her up and running even if it kills me, but there's no need to push it lol.

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Anderzander
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December 27, 2011 - 1:41 pm
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Take it easy Steve! No pressure from this side of the screen 🙂 I've lost a lot of my health too and I just work when I can.

I'm looking forward to seeing things progress.

Take lots of pictures!

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steve2young
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December 27, 2011 - 1:55 pm
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Quote from Anderzander on December 27, 2011, 13:41
Take it easy Steve! No pressure from this side of the screen 🙂 I've lost a lot of my health too and I just work when I can.

I'm looking forward to seeing things progress.

Take lots of pictures!

Thanks Anderzander I will. Wish I got to work on my bike in a nice warm house like you though. lol

This seems a good point to add my other hobby in to this. I occasionally paint hockey masks from the Friday 13th films.

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steve2young
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December 28, 2011 - 5:40 pm
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Managed to get out to the shed for a while today and got a few bits done.

Thanks to a tip from Mikef I've managed to seperate the stanchions from the yokes.

http://img835.imageshack.us/img835/5139/photo013yx.jpg

Don't know if this will show up the kind of shape they're in.

http://img694.imageshack.us/img694/1622/photo014qs.jpg

I've decided to have a go at cleaning these up rather than just buying new ones as I believe even though they show signs of pitting and a few surface scratches I don't think it's anything that can't be cleaned and polished off. I had a quick go and so far they're showing signs of encouragement.

http://img683.imageshack.us/img683/6646/photo020f.jpg

This will end up being a job for my bench grinder polisher conversion when the bits to convert it turn up.

At this point it was starting to get near time to eat, and time to have to go out with the wife and lose the rest of my day in the shed, but I still had enough time to take the old oversized piston off as I'm replacing the cylinder barrel and piston with one still on it's standard bore. Look how massively oversized it is next to this ordinary spanner for comparison.

http://img18.imageshack.us/img18/4577/photo017mg.jpg

This is now going to be cleaned up and kept on my desk at work just for fun.

That was really all I got up to today. I did take a long hard look at the paintwork on everything though and who ever did it last cut corners and basically painted over a not very well prepped surface and it's all rather very rough. This is going to involve me having a lot more bits powder coated than originally anticipated which is a pain, but also gives me a few more options
As the tank needs painting anyway and I've finally decided on my colour scheme which is going to be silver grey and black in honour of my late fathers old crash helmet that I always remember from my childhood. With this in mind I had the thought of maybe doing a bit more with the some of the parts of the bike that are just black like the headlight or maybe even the frame. I'm still thinking about this and seeing if I could get it to work.

So that's all I did today. I'm hoping to finally get around to cleaning out and sealing the inside of the petrol tank tomorrow, as long as the weather is ok, but if not I may just take a big overview of what I need to buy and do to her and in what order. Until my clutch compressor etc turn up I can't start on the engine, and with all the factories shut I can't take stuff to be blasted and powder coated so in a lot of ways I'm just kind of doing odds and sods at the minute to pass the time.

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Anderzander
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December 28, 2011 - 8:43 pm
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That last photo is fantastic 🙂

Great inspiration for the colour scheme too!

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lazybandittattoo
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December 28, 2011 - 9:18 pm
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How big exactly is that piston?

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steve2young
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December 29, 2011 - 8:13 am
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Quote from lazybandittattoo on December 28, 2011, 21:18
How big exactly is that piston?

It's actually a +060 piston and doesn't look like it's ever been used.

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Brunow
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December 29, 2011 - 12:32 pm
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Nice work!

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Cornish Rooster
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December 29, 2011 - 12:36 pm
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Cracking on then ! this time of year the best place to be seems to be down the garage or shed doing some bike jobs, BSA A65 fork seals for me today, enjoy.

BSA Bantam D1 "150" in use regularly often as general purpose transport, quite a few other bikes as well. Cornwall Area Rep. 

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steve2young
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December 29, 2011 - 4:01 pm
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This morning my clutch compressor and flywheel extrtactor arrived in the post so today was spent in the shed taking the engine apart.

It took about 5 hours, I only had to destroy 2 screws and Bruxa lived up to her name and managed to draw blood but my engine is now in 2 halves.

http://img46.imageshack.us/img46/7206/photo021wo.jpg

The boring half of the crank

http://img829.imageshack.us/img829/9096/photo022rm.jpg

And the box with the bits in

http://img683.imageshack.us/img683/2833/photo023a.jpg

It actually came apart quite easily and splitting the crank was the easiest part of it as there was no gasket to break and it basically just slid in half.
The clutch was a bit reluctant to come off but not as bad as the flywheel which just didn't want to budge for quite a while.

So having now opened her up as far as I can tell it all seems fine. There's a bit of gunge in there but there's no sign of anything being damaged or worn badly and after a good clean out she should be fine.

So tomorrow is a trip out to over expensive Halfords to buy some gunk engine cleaner stuff and it'll be a day doing the cleaning and then I just have to start putting it all back together.

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