69 BSA bobber project...or...the cure for wintertime madness!

Discussion in 'Some Assembly Required' started by YZman, Feb 8, 2009.

  1. dlrides

    dlrides 1:1.618

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    Great job on the project ! :thumb

    I have found that trying to do at least one item every day helps keep it moving, even if it is a 10 minute job.

    Keep the build photos coming !
  2. YZman

    YZman Bouncing off Trees

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    Ya know having moved the project into my house (where its warm) vs at my parents has really helped move this along.

    I have been trying to bring something to work every day to clean up on the wire wheel here (bench top grinder ie free to use)

    Its been getting kinda... I dont know boring working on this lattely as all I have been doing is disasembling and cleaning. Dosn't really feel like I am getting anywhere. So Saturday I cleaned out the rear wheel bearings and re-installed the rear wheel assembly on the swingarm (minus brake shoes) and gave it a spin. It spins so nice now. I really like how the sprocket rotates around the polished drum cover. that just looks cool.

    Ya know the coolest part, and ya probably have to be on the rebuilding side of this project to really understand. When I spin the wheel I can actually hear the new Belray greese in the bearings smacking away. I dont know why but that just hits me as cool.

    So now every time I walk past the bike I give the wheel a spin (even though the wheel and swingarm have to come off soon) I give a spin anyways and listen to the greese smacking away. It makes me smile knowing that progress is being made. And I continue on to work on some other discusting part of the bike.

    More pictures will be up tonight. Parts have started to be painted :D
  3. Ruud109

    Ruud109 ADV rookie

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    Looks like a nice project! I love those BSA's !
  4. YZman

    YZman Bouncing off Trees

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    Well I pulled the front brakes apart. Came apart pretty easy. Knocked the bearings out and was greated with this.

    [​IMG]

    Kinda cool knowing that those bearings havent seen the light of day in 40 years and they still look like this.

    Started painting some misc parts. Bottom fork caps, steering head cap, and top tripple clamp.

    [​IMG]

    Then I dove into the tank and hit it with some etching primer and started working on filling 2 small dings.

    [​IMG]

    [​IMG]


    Time to get back in the shop and do a little sanding on the tank and lower tripple clamp in prep for more paint.

    Till then.
  5. shearboy2004

    shearboy2004 KIWIINUSA

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    Great project Mate although i would lean towards original but everyone to their own.

    This motor is prone to main bearing failure on the timing side .
    It as you know is a plain bearing and the bike doesn't have an oil filter this was the main reason for many of the failures.

    I only say this because there is a great upgrade in fitting a Norton oil filter to them .



    http://www.norbsa02.freeuk.com/goffyoil.htm


    This was the first place that came up for the kit but i'm sure they are available here in fact i know they are because my local shop has them.

    Consider a "Pazon " ignition rather than the "Boyer", I burnt up 2 Boyers in my Commando and had trouble with them all through switched to Pazon and it starts first kick every time and runs much better.
  6. YZman

    YZman Bouncing off Trees

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    An oil filter of some sort has been on my to do/want list. Yea the lack of oil filter on these bikes is a little un-nerving. Granted they ran for years like that so maybe its not that big of a deal.

    What I dont want is some big orange fram oil filter hanging around. I would like something slimer and a little more asteticly pleasing. Havent figured that out yet. Thats like step 623 and Im only on like #36. Ill get there :D



    Oh and I pulled the rear wheel back of last night. Kinda liked it on there. Made it look like progress..lol

    Anyways I pulled the swingarm and center stand off last night. Swing arm came off crazy easy. I expected a battle with the bolt. but it actually had greese on it and slid right out.

    The center stand pin was another thing. I had to beat the hell outta that to get it out.

    Next up is break out the grinder and start taking off all the tabs that wont be used and.... gasp ... cut off the sub frame in prep for my new ridged rear that will be coming soon.
  7. YZman

    YZman Bouncing off Trees

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    New tool came in the mail today.

    [​IMG]

    And just as soon as I had it unboxed it was on the fork

    [​IMG]

    And that pesky seal holder was outta there

    [​IMG]


    This fork is locked up pretty solid. But I did manage to hammer the upper tube down a little so it will move. Its soaking in PB right now.
  8. vtwinvin

    vtwinvin Adventurer

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    Lookin good. I had a 500 Royal star in high school. Miss that bike.

    Did ya get the package??...........Vince
  9. YZman

    YZman Bouncing off Trees

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    Yes I did thanks. Havent had a chance to really go thru it more than look to see what was in there. Hopefully Ill be able to use the cam.

    Thanks again
  10. YZman

    YZman Bouncing off Trees

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    Mocking up the front end a little while I wait for the big bird to be done :huh

    [​IMG]

    Trying to figure out what to do about the headlight ears. Looks like some body work is in order to the tune of some sheet metal and a welder.

    [​IMG]

    [​IMG]

    Im likeing the looks of things though :evil

    [​IMG]

    So does my little buddy, She likes to watch me work

    [​IMG]

    Happy Turkey day everyone..... Im gonna go get me some grub :clap
  11. jeep44

    jeep44 junk collector

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    Are you going to go with the whole stock front end? I've seen some stock-looking headlight ears that are chrome at local swap meets-a Britpart vendor has them,along with Emgo repo headlight shells-those old shells just seem to blister up too badly to mess with.
    Hopefully, your ammeter is still good-I'm not seeing any needle-real Lucas ones are expensive,and just about non-existent at swap meets. I got a couple of repop ones from Steadfast-they don't really look like the Lucas ones,but they have a long,thin needle that really shows whether or not the bike is charging much better than the short,fat needle on the original one.
  12. YZman

    YZman Bouncing off Trees

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    Yea Im using the entire front end. I think I want to go with black headlight ears. Chrome would be...well too much chrome. :rofl


    I thought about grafting on a diff front end. But I dont know. I kinda like the old school look of this one. I really like that twin leading shoe brake assembly.

    Ill replace the headlight shell at some point. Its not high on my list at this point. Ill probably get a bulb for this one and run it as is till I get the $ for a replacement. Gotta put my $ where its going to gimme the most bang at this point. Tires, oil tank, seat, handlebars.....etc etc

    Thanks for the EMGO name drop. I didn't realize they made so many brit parts. Ill have to have a chat with my local dealer (ie my man on the inside) to see what kinda deals he can swing me.

    Man I ate waaaay too much today. I really need a nap
  13. Pigford

    Pigford British

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    Good to hear that - Too much chrome is a big No - No :wink:

    Polished alloy is good though :evil
  14. YZman

    YZman Bouncing off Trees

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    Well I got the forks apart today. The one that fell apart wasnt bad at all. Just jerry rigged a slide hammer and plucked the bushings out.

    The other fork was not so fun. I drilled the inner tube and pressed a tube thru it so I had some leverage. Then slid it into a vice and kinda slide hammered the inner tube out of there. I had to really crank on it as you can see by the bent T-tube.

    Then the slide valve wouldnt come out even after taking the retaining nut off. So I cut the fork tube in half, the t-handle wasnt going to come out easy after I bent the hell outta it, and using a tube inside the fork tube poped the valve out.

    [​IMG]

    [​IMG]

    So now the question is. The plastic bushing in between the brass ones. Anyone have a pn# for that as one of them is trashed. I have a feeling it is part of the valving as there is a recess turned on the inside.

    [​IMG]

    I might have a machine shop make me those 2 bushings. I am going to need longer ones anyways as I have to lower the forks about 2-1/2 inches. Longer bushings and cut down springs will acomplish that. Heck we have a lathe at work. Maybe Ill just try to make them myself. Cant be that hard.



    Oh, I won an ebay auction for a continental front tire. Saved a few dollars on that.

    And bought some fork boots.

    And got an email from lowbrow customs that my order has shipped...I cant wait for this one to show up. Once that is here progress will begin!

    Need to order up some fork seals also.


    parts parts parts....it just keeps going and going :D
  15. jeep44

    jeep44 junk collector

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    We're talking about a '60s BSA here-they were covered with chrome.:deal
  16. 305racer

    305racer Fossil Rocket Pilot

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    Yeah but that doesnt mean it was a good thing:D
  17. jeep44

    jeep44 junk collector

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  18. YZman

    YZman Bouncing off Trees

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    Hey Jeep what is it about the 69 that makes it such an odd year for parts? Every parts listing goes up to 68. Some list the 69 seperate. And some list 69 on up. Its like the 69 is cought in the middle of some changeover in design or something.

    I have a parts manual for a 69 A50 Royal star. And it has no info at all on my forks. Doesn't even show them. I have the slide valve fork. THe ones they show in the book are damper rod types.

    Mine has the twin leading shoe front. But most listings dont show it as an option.

    Something about the clutch cable for that year is diff also. Mine has some kind of adapter at the clutch actuator arm.

    For some reason that year seems to be cought up in the middle of no mans land. Not that I havent been able to find the parts I need. It just seems to be an odd year for them.

    Got my fork seals outta the holders last night. I thouth they had a snap ring holding them in. Turns out ya just gotta drive them out.
  19. jeep44

    jeep44 junk collector

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    There's always the chance that yours was involved in a crash years ago , and it was fixed with forks from a different year. There are many subtle differences in BSAs each year from '68-70,even though they look identical. Mine here is a '69, but the gas tank and sidecovers seem to be from '70-'flambouyant blue' was not a color option in '69. Unless I decide to have it repainted,that's the color it will stay.
  20. YZman

    YZman Bouncing off Trees

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    Ya know. Looking at your front fender. Thats what my manual shows for my bike. But my fender has seperate struts that bolt to the fender in the front where yours has that loop over strut. Not that it matters as Im not running a fender. My fenders are going to go onto ebay soon along with other parts if anyone needs something.