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USA Shopguy's Trail Bronc
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shopguy
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May 31, 2019 - 1:22 am
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In a moment of weakness, I purchased a 65 Bantam.  It happens to be a Trail Bronc.  Missing some fasteners, and a piston in fact....but there isn't much on these anyway.   Problem here in the US is:  very few bantams and little to no parts (new OR used) !

I'm a secondary HS teacher, and will allow the kids to do the chassis work and get it up and running.  The engine?  I don't know if I should farm it out or do it over myself.   Its over the heads of the kids I have, as they are not vocational, but just general education 14 - 16 yr. old minds of mush  - - who mostly have never held a screwdriver in their paws!   They are good kids, but just really really green!

Ill throw up some picts of what I find along the way.......and probably ask for alot of help, as this is my first Bantam.

Stupid question #1:  are all the fasteners British Standard??   I would assume the DKW would have been metric......   And did the Harley Hummer use US fasteners in the same DKW design?

 

Now for the thinking out loud bit:

I'll have to resist the temptation taking away the originality, in getting her going again.  At this point, I might even sell it off and get a less rare Bantam for the kids to "restore".   Tempted to install a AX100 (clone) engine into a bantam.....but NOT something I'd do to the bronc.....

left-side-1.jpg

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Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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cocorico
Central France
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May 31, 2019 - 7:50 am
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Hello again Shopguy. There are no stupid questions (well, there are, but we don't say so...) so to try to answer your questions:

The fasteners used are Imperial - but not all one type, ie you may have BSW, BSF and Cycle Threads in different places (plus a left hander thrown in to hold on the gearbox output sprocket) - and also one of the previous owners may have changed to a Metric thread if he lost , say, an engine mount screw. From what I can see on the photo, it has had very little use, so you should be OK. If you check the state of the slots in the crankcase screws you may find that the engine has never been apart.

As you say, you have a problem obtaining any spares over there. You can get most stuff over here, but add in the cost of postage and things could get expensive. However, everything on the bike is pretty simple to overhaul, you may find problems caused by age or corrosion, depending how and where it's been stored. I would say that the engine is the best place to start as it is well documented, relatively common and not specific to the Trail Bronc. The chassis is somewhat different though - not in actual shape or form, but certainly in identification. The tinware, too, is hard to find.

I would say that your option of selling the Bronc in order to buy another Bantam (though they must be pretty rare around you, too) is a better way to go considering your description of the potential mechanics. I will bet that you could find an old Honda, Suzuki, Yamaha, etc, in a similar condition, with easier access to spares, for less than the Bronc might fetch - and as several members have said, it's too rare (to Bantam enthusiasts) to spoil.

Rule one of the forum, though, is "It's your bike to do as you want with" - maybe one of our American members can help out option-wise?

hope-that-helps

1956 D3 running, lights to sort. 7 other bikes in the Barn, including a Morini 250 now insured and on road testing.

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sunny
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May 31, 2019 - 8:58 am
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hi   Shopguy     here s  your  problams      the  first  is  my  speeling         as  you  cope  with  15  year  olds    NOT   a    bigern     then    " that s cokny  spek "  any  how  if  you  farm  it out for  repair   nobody   will  have  the  extractors   needed     thers  a  lot of  knowhow  to  doing  bantams  the  cranshaft  and   gearshafts  can  be bent   doing  up  the  nuts up  tite   you  and  the  kids ,  mite  find  the  histoy   interesting      if  you  keep  the  work   in  house      dont  forget   to  ask  if   needed

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cocorico
Central France
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May 31, 2019 - 9:14 am
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Well said and well put Sunny.

1956 D3 running, lights to sort. 7 other bikes in the Barn, including a Morini 250 now insured and on road testing.

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shopguy
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May 31, 2019 - 3:54 pm
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pulling it down......20190531_104348_resized.jpgkicker-abuse-1.jpg20190531_080559_resized.jpg20190531_080621_resized.jpg20190531_080656_resized.jpg

Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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Sponge
Lancashire (A chip shop somewhere near Preston)
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June 1, 2019 - 2:36 pm
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Although I am no longer the SME for these rare Bantams I have the pleasure to offer some thoughts on the lovely little BSA Trail Bronc that we see here: 

Two things strike me, straight away and this is GOOD :

It has an almost perfect condition original dual seat in the correct colors (US Spelling) - very rare 

It has the original factory supplied 80 tooth rear sprocket fitted - this is also extremely rare. If you check the rear drive chain you may find 2 x split links ( I would be interested if you do ?) .    

Interesting is the rear fender which has been chopped off ( as most always are) but the stays are fitted wrongly, seemingly to the end of the swinging arm damper (shock absorber) mounts ) could be dangerous.  Of course I could be wrong. 

The chain tensioner is still there - also good and very necessary with the 80 tooth sprocket. 

Side stand correct ( R/H side).  Colours and decals correct (except for the STP stickers of course).  

Cannot see teh exhaust system from teh photographs but if its there and complete it is also a very rare find. 

Its a nice little bike and will be relatively simple to restore - seeing as all the rare bits are already there I would forsee no particular problems with a restoration - be it oily rag or complete total. 

Sponge 

  

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shopguy
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June 4, 2019 - 7:05 pm
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20190604_114831_resized.jpg20190604_114912_resized1.jpg20190604_114926_resized1.jpg

I have the correct pipe.   The muffler can is beat up.   I'll need a used replacement.    What yrs are The same?      

You can see the barrel where there is damage.  Piston is missing, maybe it broke up?   Head damage too.

Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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Sponge
Lancashire (A chip shop somewhere near Preston)
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June 5, 2019 - 12:47 pm
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I believe the muffler for the East Coast model is a standard D1 item with a fishtail instead of the straight cone.  The West coast model was the same externally but had more stuffing in it and tended to choke the bike. 

If you can swap the fishtail onto a new D1 muffler then you will be good to go. 

The pipe is the rare part - if yours is OK then happy days and well done.   

Regards

 

Sponge

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shopguy
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July 20, 2019 - 12:15 am
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I've decided to fully do up the Bronc. It WILL get use.....but I couldn't stop the teardown once started!

Frame is painted.  Engine stripped awaiting parts.  R.fender repaired, needs filler work yet.  Tank / fender / stays primed - color will go on next month or so, no rush.20190718_212823_resized.jpg20190718_212832_resized.jpg20190718_212740_resized.jpg20190718_212744_resized.jpg20190719_185426_resized.jpg20190719_102323_resized.jpg20190719_103312_resized.jpg20190719_185510_resized.jpg20190719_185459_resized.jpg

Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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shopguy
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July 20, 2019 - 2:29 am
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cleaning up the carb - may or may not use it.....we'll see.

375/36,  3 1/2 slide, main 110 (seems awfully small.......), needle jet 105, pilot 25.

Birthday!  12.6420190719_211140_resized.jpg20190719_211159_resized.jpg

Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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sunny
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July 20, 2019 - 9:02 am
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the  parts  book  says   110   cc  main  jet   for  the  west coast   USA        140   for  the  rest     ,,the  carb has    2  bypass  holes  1  in  each  of  the   2   carb body   parts  

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cocorico
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July 20, 2019 - 9:35 am
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Looks like you've found a way to restore those castings to 'as-new'! And the rear 'fender' looks like a factory extra too. I'm looking forward to seeing the progress. You may find you need to adjust the jetting to suit modern fuel, I know some other makes do.

1956 D3 running, lights to sort. 7 other bikes in the Barn, including a Morini 250 now insured and on road testing.

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shopguy
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July 20, 2019 - 12:47 pm
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Carb was missing needle and clip.  Anyone have the needle part number please???    TIA.   

Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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Aquarius
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July 20, 2019 - 4:10 pm
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Amal still list them.

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Francis Lineberry
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August 3, 2019 - 11:44 pm
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Great to see a Bantam project stateside.  Rock on!  Nigel

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shopguy
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August 5, 2019 - 12:01 am
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color!!!IMG_9755.jpgIMG_9753.jpg

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Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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cocorico
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August 5, 2019 - 8:01 am
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That looks good - you need to switch your spellchecker on though! stick-poke roflroflrofl

1956 D3 running, lights to sort. 7 other bikes in the Barn, including a Morini 250 now insured and on road testing.

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shopguy
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August 5, 2019 - 6:28 pm
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colour.....sorry....    😉

Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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swalsh58
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August 5, 2019 - 7:57 pm
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Lovely paint job, I like the colour too!

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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shopguy
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August 5, 2019 - 10:34 pm
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thanks swalsh....    the fender came out pretty good.  The original was chopped.  I took part of a 71 Triumph front fender and welded it on at the rivet point. 

Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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