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1957 D3 build
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Piquet
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July 3, 2015 - 1:39 pm
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cocorico said

bsadave said
A bit more progress,..... along with the fork gaiters (which I can not get to go over the seal holders),..

Same here - the gaiters seem to be a standard size, but I don't see how to get a 25mm gaiter over a 40mm seal holder (sizes approx). I've tried using silicone grease, some shim to form a cone, brute force, but no success. Any advice welcomed.

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I'm not a complete idiot ............................................ some parts are missing.

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Hans Kreuzen
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July 3, 2015 - 1:41 pm
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On my D1, I managed to get my rubber gaiters on by heating them in boiling water, and using gloves (hot) and soap and eventually managed to slide them onto the end caps, I could not fit them with the forks in place, so I pulled them out again just to fit the gaiters.ranting

Maybe for you a heat gun and soap might work?dunno

1950 D1 plunger for daily use, Concourse 1948 D1 rigid, Black 1953 D1 plunger nearly done and a 1949 rigid D1 survivor.

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cocorico
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July 3, 2015 - 2:23 pm
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Piquet said

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Seek and ye shall find - thanks Piquet and Hans.

1956 D3 running, lights to sort. 7 other bikes in the Barn, 6 runners (when I get time!) and a still in progress Morini 250

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Maddog Leary
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July 3, 2015 - 3:13 pm
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bsadave said
Hi MD.

Don't worry it is not standard, it is to hold the exhaust up, you have good eyes.

P7020730.JPG

No, just paranoid.... Lol.  Dad and I missed so many things back in the eighties (no internet or decent drawings or owners groups to speak of for info exchange back then) when we did our part restore/part oily rag resto......

MD cheers

Maddog - 56 Swingarm D3 Major -  Major Works in progress! Machine is fighting against me every which way!

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cocorico
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July 4, 2015 - 7:14 pm
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Well I got the gaiters fitted (eventually), but the method that worked for me was to lubricate the insides with silicone grease, slip onto the stanchion, fit the seal holder, then turn the upper part of the gaiter inside out, hold the stanchion between blocks of wood in a vice so that the seal holder could be against a good stop, then work the gaiter up over the seal holder.

The first one took me several hours, on and off: the second took about 5  minutes!

Thanks for the suggestions anyway. thumbs-up

1956 D3 running, lights to sort. 7 other bikes in the Barn, 6 runners (when I get time!) and a still in progress Morini 250

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Hans Kreuzen
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July 5, 2015 - 4:48 am
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Makes you wonder why they don't make the rubber gaiter a bit bigger and save us all some trouble.

At least you managed to them fittedthumbs-up

1950 D1 plunger for daily use, Concourse 1948 D1 rigid, Black 1953 D1 plunger nearly done and a 1949 rigid D1 survivor.

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cocorico
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July 5, 2015 - 6:48 am
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Hans Kreuzen said
Makes you wonder why they don't make the rubber gaiter a bit bigger and save us all some trouble.

At least you managed to them fittedthumbs-up

Seems a bit like the way Citroen used to fit the fabric roof to a 2CV - bloke sat on top with big boots to kick it into place!

1956 D3 running, lights to sort. 7 other bikes in the Barn, 6 runners (when I get time!) and a still in progress Morini 250

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BSAdave
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July 5, 2015 - 10:40 am
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I tried again with the hot water and all I managed to do was split the rubber, will try your method when the new ones turn up, this is getting expensive. I can not see any reason why they are made so small in the first place.

 

Just found out the 49 bantam didn't have them fitted in this year.

I could agree with you, but then we would both be wrong

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cocorico
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July 5, 2015 - 12:25 pm
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bsadave said
I tried again with the hot water and all I managed to do was split the rubber, will try your method when the new ones turn up, this is getting expensive. I can not see any reason why they are made so small in the first place.
Just found out the 49 bantam didn't have them fitted in this year.

Perhaps it helped that it was 30 deg or so in the workshop (I use the term lightly). I also pushed the second gaiter over a tapered dolly of a larger diameter overnight (actually, a bulb dibber). Worked for me.

1956 D3 running, lights to sort. 7 other bikes in the Barn, 6 runners (when I get time!) and a still in progress Morini 250

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Hans Kreuzen
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July 5, 2015 - 12:27 pm
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Your right Dave, The first production run in 1949 did not have the gaiters fitted, The parts catalogue for 1949 douse not mention the gaiters either.

They used smooth fork tube end caps in 49 without the recess grove, You can see the difference in the picture below, left is of my 1948, right 1953

fork-end-caps-2.JPG 

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1950 D1 plunger for daily use, Concourse 1948 D1 rigid, Black 1953 D1 plunger nearly done and a 1949 rigid D1 survivor.

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BSAdave
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July 5, 2015 - 5:14 pm
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Thank you for the replys, but I still have to fit them to the D3 , so I have not got away with out fitting them.

I could agree with you, but then we would both be wrong

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jess steele
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July 5, 2015 - 7:04 pm
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I found fitting the gaiters easy enough to fit once i'd cut a triangle piece of soft-ish plastic (out of an ice cream tub)rolled up into a cone shape and used insulation tape (or sticky back plastic)so it held that shape,i sat the seal holder half way in the top of the cone and lightly smeared the cone with swarfega,whilst the gaiters were in a tub of hot water (does'nt have to be boiling)then with my right thumb in the seal holder to hold in place, i slide the gaiter up the cone and thus on to the seal holder,the cone is then squeezed out the bottom of the gaiter.......

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BSAdave
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July 18, 2015 - 1:21 pm
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Thank you Jess for the tip, I will give it a go.

A bit more progress, The petrol tank stripped treated with Krust filled etch primed and painted , still not sure to leave it all black or to spray the white panel on?

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I could agree with you, but then we would both be wrong

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BSAdave
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July 23, 2015 - 2:07 pm
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Well I'm pleased to say it goes,

Just got carried away with the shake down ride on the newly rebuilt 1957 D3, It goes well, when I say well, it did up until the carb got blocked with rust from the tank. And I thought I had that checked off of the list of things to do. Just has well as my daughter was shouting at me that I have stunk her bedroom out with the smell of two stroke , some people hey,

To spray the white panel on the petrol tank or not ?

Now it is time to sort the paper work out. should be fun.

I could agree with you, but then we would both be wrong

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BSAdave
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July 23, 2015 - 2:13 pm
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I forgot to add the pictures,

four.jpgone.jpgthree.jpgtwo.jpg

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I could agree with you, but then we would both be wrong

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Derek's D5
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July 23, 2015 - 2:36 pm
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Very nice Dave. That exhaust guard looks familiar. We've got something like that hanging in the shed. I think it's for cooking fish on the bbq. Don't think we've ever used it!

Try starting up the bike when the washing's hanging out to dry. See how that goes down.

I failed to spray the white panel on my tank because I was too scared of messing it up. But I will do it... one day.

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BSAdave
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July 23, 2015 - 2:42 pm
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Thank you Dookie ,

Shhhhh She never noticed that the washing was hanging out.  I like it all in black,  but it would look more authentic with the white panel but like you I'm no good at spraying. Might give it a go tomorrow.

Can I ask why the user name Dookie ?

I could agree with you, but then we would both be wrong

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Derek's D5
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July 23, 2015 - 3:28 pm
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It's the dog's name. I have used it on other forums before and it was the first one to spring to mind when I joined here. It's a stupid forum name but I'll have to stick with it now.

A 'dookie' is west coast USA slang for a poo, or so my American friends tell me. It's also the title of a Green Day album.

If you saw my dog you'd understand. He's long and brown. He was already called Dookie when I got him, so I can't be blamed.

Dookie-at-Compton-Bay-Nov-2010.JPG

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dimitris
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July 23, 2015 - 7:56 pm
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Very nice Dave!!!
If it was mine, i would not spray the white panel. The bike looks so different from others, has a character of it own, and don't see why it should have the normal" tank...

Just stick a yellow or red "BSA" decal on both sides...my opinion...

BSA D1, 125cc (1952)---BSA D10 Sport 175cc (1967)---Triumph Cub T20 (1960)

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Sprung Chicken
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July 23, 2015 - 9:34 pm
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dimitriscy said
Very nice Dave!!!
If it was mine, i would not spray the white panel. The bike looks so different from others, has a character of it own, and don't see why it should have the normal" tank...

Just stick a yellow or red "BSA" decal on both sides...my opinion...

I agree... If you like it, stick with it. If you muck up painting the panel, it will be back to square one..

Dougie;Glasgow ;Scotland.
1955 D1, 1970 B175

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