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USA Shopguy's Trail Bronc
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shopguy
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August 14, 2019 - 3:52 am
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Moving on to the wheels.  Front wheel has a new 6203 sealed bearing on 1 side, the other is that UK special imperial measure one.... no sealed option, so that was repacked and reinstalled.  Rim was polished with 0000 steel wool.  Pitting and discoloration if you look close, but at least its the original Jones WM1 rim.  Rear (Jones WM2)20190813_223931_resized.jpg20190813_223953_resized.jpg20190813_211105_resized.jpg gets 2 new 6203 sealed.  You can see the axle stack in the picts.  Lots more pitting in the rim on this one.  I'm thinking it might get the silver paint treatment.  Still working on the rim.  Tire is a Duro.   3.00x19 front and rear.

Powdercoated the front and rear backing plate and sprocket.  Just a home hobby kit and a spare electric oven. 

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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November 10, 2019 - 5:44 pm
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some updates:  engine 90% done.  I need to buy a tensioner for the primary side before I button it up.  Frame is done.  Wheels too.  Mix of paint and powdercoat depending on size.image0.jpegimage1.jpegimage2.jpeg

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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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shopguy
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November 15, 2019 - 2:49 am
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back as a roller!onwheels1.jpegonwheels2.jpeg

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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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November 15, 2019 - 7:37 am
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A credit to you and your students.

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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shopguy
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November 16, 2019 - 3:06 am
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seat recovered with an ebay item.  special request 2 tone grey rather than reg. black.  1 wrinkle needs a little heat....and that will disappear.

installed the piston and barrel today too.   .040 over.piston.jpgimage0-1.jpeg

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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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November 16, 2019 - 7:50 am
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Thinking about your primary chain tensioner request. Could you make a slipper to sit under the lower run? You look to have the workshop facilities. I'm thinking maybe some hard nylon, or similar, attached to an L shaped bracket held by the two outer casing screws. Or a chain roller, using the same mounting points, for the top run. Might need some more thought on fixing it and the outer cover at the same time!

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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shopguy
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December 5, 2019 - 3:47 pm
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getting closer!  graphics on (slightly different..but close enough).   installed new primary chain, so I'm not going to install a tensioner.  awaiting hardware to button up the sidecovers.tank.jpggastank.jpeg80percent.jpeg

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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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swalsh58
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December 5, 2019 - 4:04 pm
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Nice paint job! That’s coming along nicely 

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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December 5, 2019 - 5:30 pm
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Thanks.  I need 1 part that I can't find or make here.....

I need the round points cover and 2 mounting screws.       Anyone have one?   scarred up is fine....  but needs to fit the D7 engine.

Also posting in wanted section.....

Thanks!

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

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stubaker58
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December 5, 2019 - 7:39 pm
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I have got a cover in my garage, I’ll look it out for you tomorrow.  As for the screws I can order them here in the UK and include them in the package. I’ve no idea what postage will be though.

regards

D7/14 hybrid (4 speed with D7 crank etc.) on the road, D10 Bushman awaiting rebuilding.

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jolon1
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December 6, 2019 - 10:02 am
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shopguy said
getting closer!  graphics on (slightly different..but close enough).   installed new primary chain, so I'm not going to install a tensioner.  awaiting hardware to button up the sidecovers.tank.jpggastank.jpeg80percent.jpeg  

Looking really good, Mike.

D7 & D1 Racer

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shopguy
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December 7, 2019 - 9:30 pm
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I reworked the baffle a bit and fit the D1 cannister.  I'm not going to bother to install the trail bronc tip, I'll juts keep it in a box....

Fitted up the seat and tank together - looking pretty good.  Now....Ive got another problem...  That darn gas cap is looking pretty ratty!   lol

are they available new? or do I need to just find a good used one.    Next task;  controls cables.   Awaiting points cover and new chain from the Chain Man (Jason) before the left side is buttoned up.

TIA!closeRS1.jpegcloseRS2.jpegcap1.jpegcap2.jpeg

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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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shopguy
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December 7, 2019 - 9:33 pm
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looks like the original trail bronc test bike that Hap Alzina road.  My seat top could be a bit darker...but hey, close enoughz.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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shopguy
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December 15, 2019 - 1:35 am
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step forward....step backwards!   Progress halted!  finished the new carb cable and clutch cable!  cruising right along!!!  installed the chain, eye-ing up the progress, something looks "odd".

Sure enough....rear swiing arm has a bent arm!  how did I miss it?????????  darn it.    pulled off the swingarm, stripped the paint, held it in the press, heated the bent area and persuaded it back into alignment.  Cleaned it down, painted er up.  waiting for the paint to dry before reassembly.

this is what makes them fun, right???/

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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December 15, 2019 - 8:48 am
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shopguy said
step forward....step backwards! 
this is what makes them fun, right???/  

well, that depends on your definition of fun. I have restored a few bikes in my time and every Bantam has been like that. Unlike the Japanese bikes which went together well, apart from one GT250 which I think has some Bantam parentage.......

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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cocorico
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December 15, 2019 - 9:50 am
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shopguy said
...this is what makes them fun, right???/  

Just keep telling yourself that. Eventually it works... Speaking strictly for myself, I find them fascinating mechanically and great to work on, but I prefer my more modern bikes for riding.

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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bantammad
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December 18, 2019 - 2:37 pm
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Hi bantammad ere l think you know your way around mechanics and practical engineering nice job by the looks of it by the way a fender is what goes in front of a fire over here have fun regards LES

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shopguy
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December 20, 2019 - 3:21 am
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Got the swing arm (rear fork) straight and reinstalled.   Proper chain too.   Only need fuel line, front brake cable and inner points cover to have it done.

It 27 deg. F today...no riding.   🙁

Overall build?  pretty simple if you take your time.  First 2 stroke engine I've ever rebuilt - simple enough.  I hope it runs!

Departure from stock?   Mikuni carb, electrex ignition, handlebars not OEM and seat cover color slightly off.  I have the original trail bronc cast alloy tip, but I'm keeping the D1 tip on 'cause I'm lazy and its already there!      But I"m really happy with it.  I'm posting the before and after too.

 

Question:   With the Mikuni and Electrex.  Jetted to Rex's suggestions (130 main to start).  I'm planning on 30:1 fully synthetic....then switching to 50:1 after break in.......  (planning anyway....)

What spark plug would one suggest?????????

 

Thank you all who help with your wisdom, encouragement and even parts!    Mike in NJ   (aka Mic)

left-side-1.jpg

finishrs2.jpg

finishcarb.jpeg

finishrs.jpeg

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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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shopguy
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December 20, 2019 - 3:31 am
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bantammad said
Hi bantammad ere l think you know your way around mechanics and practical engineering nice job by the looks of it by the way a fender is what goes in front of a fire over here have fun regards LES  

LOL.   Hey Les....no front fender on the Trail Bronc.  Making it LIGHT and CHEEP for us Yanks!  Here is Hap Alzina's rider on a Trail Bronc in  Zion Nat'lPark in Utah, USA.   That's Hap Alzina's station wagon that made it into the BSA advertising pamplet.  Notice how the machine shrunk in the promo advert.  There's no way its getting into the back of a big ole USA made iron station wagon.  Deceptive Advertising??? you bet!  LOL

BTW:  looks like a silver painted exhaust system, not chrome...

z-1.jpgbronc-on-car.jpg

 

b.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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Mick W
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December 20, 2019 - 10:53 am
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I use Rock oil and I would suggest 25:1 semi synthetic to run in. 33:1 semi synthetic after first few hundred miles. Keep it well lubricated at first to prevent any chance of nipping up. But everyone to their own and would not like to open a can of worms on your thread.
Non resister cap.

looking excellent by the way. You and your team have done a cracking job. 👏👏👏

Mick

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