thou shed grime to shine

[mirror man]

strip of the donor motor begins, god knows how long its been standing
the head was reluctant to come off & needed a heavy hand


this looks a little bit rough


had to drill out the engine mount bolt which sheared off, rusted in place
having got this far it was noted that these cases had previously been repaired but still needed further welding works and to be honest were in worse condition than my original cases, so i decided to go with my orginal cases, the crack was grooved out ready for a weld repair

[pertonpc]

Fair play to you for keeping on with it and not getting too down when the donor motor didn't deliver all you wanted. I found these pics real interesting - a few of the early ones have stopped working - could you re-do the links cos I would like to catch up on what you covered earlier.
Thanks and good luck from Mark

[mirror man]

hi mark sorry about the disappearance of the pics, i was trying to thin out some of the pics in photo bucket, should now be reloaded [just testing] good to see your following the highs & lows of the rebuild cheers alan

[mirror man]

ali welding repairs now carried out




also had some other odds & ends welded, the tacho cable fixing mount was gone, plus the engine casing had a little road rash & was'nt oil tight


weld repair cleaned up

[mirror man]

repair works carried out to the crank, i managed to find a knackered crank with a bent conrod, the rotor end was pulled off & pressed & balanced onto my original damaged crank [ps this was sorted before the donor motor turned up]

[mirror man]

the front fork set up came with a single front disc[front caliper] which im upgrading to twin disc [rear calipers], the fork stanchions are badly pitted, so i now have a set of replacement forks
original forks fitted with aluminium top nuts, 465mm spring + spacer

replacement forks have a steel top nut with a plastic cap



new forks marked up k 207 l, fitted with 530mm spring, does anyone know what these forks are off alan

[pertonpc]

Thanks Alan
I'm up to speed with the early pics now - a bit of a horror story there with all the splits in the motor. looks like you are getting past the main hurdles now. Will you be able to run a normal tacho drive off that head or will it have to become an electric one??

I reckon you should stick the donor bike on ebay as a project once you have gathered together all the left overs (that's what DK in Staffs seem to sell half the time )
From Mark

[mirror man]

Will you be able to run a normal tacho drive off that head or will it have to become an electric one??

I reckon you should stick the donor bike on ebay as a project once you have gathered together all the left overs (that's what DK in Staffs seem to sell half the time )
hi mark the tacho should be fine more pics to follow, as for the donor bike i'll hang onto it for now but it will probably end up on ebay down the line alan

[mirror man]

weld repairs have now had a bit of a tidy up






cases sorted, crank sorted, time to build the bottom end, new timing chain fitted, i decided to clean the engine/cases with the wire brush/spit & pollish treatment for a clean used look, not that keen on the clinical clean look

[mirror man]

at last some shiny bits, frame & odds now powder coated

new tapers to go on, nut & bolts re plated by mikey

engine in

good clutch basket salvaged from the donor



spent a good few hours cleaning up the original spokes [i dont think they will like the wet]


front mudguard is shot, not even mikey could save this, still looking for a relacement

still got some ropey old dunlops fitted, not sure what tyres to put on

[paul doran]

great progress there well done

[kev edwards]

well done that man, looking good

[Pigford]

Stunning - great effort - keep it coming

[mirror man]

thanks for coments guys, now starting to make some progress, the dark days are over i can see light at the end of the tunnel chreers alan

[Z1parR]

Keep up the good work Alan , i'm glad its finally going in the right direction