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Gary E
Gary E
Medford, Oregon
Posts: 2,704
Joined: January 2006
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Re: Hornet, Wasp, Spitfire Hornet, Cyclone (Restored)
Two Alpha #806128 04/21/20 1:26 pm
Joined: Jan 2006
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Since it is larger, and the fill neck is taller, it is more difficult to to install than the standard oil tank. Installation can be done from the right side, and it needs to go in before the rear fender is installed.


1967 BSA Wasp
1967 BSA Hornet (West Coast Model)
1967 BSA Hornet (East Coast Model)
1968 BSA Firebird Scrambler
1968 BSA Spitfire Mark IV
1965 Cyclone Competition Build
1 member likes this: Allan G
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Re: Hornet, Wasp, Spitfire Hornet, Cyclone (Restored)
Two Alpha #806247 04/22/20 4:18 pm
Joined: Aug 2001
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Thanks Gary

1 member likes this: Gary E
Re: Hornet, Wasp, Spitfire Hornet, Cyclone (Restored)
Two Alpha #807739 05/04/20 12:47 am
Joined: Jan 2006
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The '65 Cyclone Competition build includes the restoration of the fiberglass side covers. I have this right side cover that looked reasonable to restore. But you never know what lurks underneath someone's re-painting. It looks innocent enough with the usual issues to repair.

[Linked Image from i.postimg.cc]

[Linked Image from i.postimg.cc]

The paint stripping included a combination of chemical paint removal and bead blasting. After the paint stripping, all kinds of gremlins show up.

[Linked Image from i.postimg.cc]

[Linked Image from i.postimg.cc]

The break at the top oil tank filler cutout will require some glass work on the back side.
[Linked Image from i.postimg.cc]

This broken out corner will have to be glassed up from behind.
[Linked Image from i.postimg.cc]

The person I bought the cover from conveniently didn't include an image of the cut away pieces. I'll have to make a pattern from another cover and glass up the cut aways to bring that area back to the original shape.
[Linked Image from i.postimg.cc]

All of the gelcoat stress cracks will have to be ground out and filled. The upside is that two mounting holes are in good condition, so will require little repair.
So, Phase 1, the paint stripping to see what's needed, is complete. Phase 2 will be the fiberglass repairs.

I'm in need of a left side cover if anyone has it.


1967 BSA Wasp
1967 BSA Hornet (West Coast Model)
1967 BSA Hornet (East Coast Model)
1968 BSA Firebird Scrambler
1968 BSA Spitfire Mark IV
1965 Cyclone Competition Build
Re: Hornet, Wasp, Spitfire Hornet, Cyclone (Restored)
Two Alpha #808375 05/09/20 8:30 pm
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The engine case for the '65 CC had a hard life at some point or more.

The oil sump cover threaded stud holes had two of them that were in poor condition. The studs had been broken off, so someone had drilled next to the broken stud, at an angle and installed studs to be able to install the sumo cover. They had drilled all the way thru to the outside of the case on one, and all the way thru to the case interior on both of them. It was a real bodge job.

In addition, the bottom case thru hole for mounting the engine to the frame was significantly broken out with the case piece completely missing.

After cleaning the case, this is what I had to repair.

[Linked Image from i.postimg.cc]

The broken studs were ground out with a carbide bit and the holes were enlarged a bit in order to weld them closed. The repair areas were prepped for welding. The stud holes were welded shut from both the exterior and interior of the case. The case-to-frame thru hole area was welded up with extensive build up for later re-shaping. All repaired areas were re-shaped close to the original case shape. The sump cover surface was re-matched and the stud holes were re-drilled and re-threaded using a sump cover as a pattern. The case-to-frame mounting thru hole was re-drilled to its original size. The case was then thoroughly cleaned inside and out.

[Linked Image from i.postimg.cc]


1967 BSA Wasp
1967 BSA Hornet (West Coast Model)
1967 BSA Hornet (East Coast Model)
1968 BSA Firebird Scrambler
1968 BSA Spitfire Mark IV
1965 Cyclone Competition Build
Re: Hornet, Wasp, Spitfire Hornet, Cyclone (Restored)
Two Alpha #808421 05/10/20 7:45 am
Joined: May 2013
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Great job on the repair!


Now let’s all have a beer beerchug

68’ A65 Lightning “clubman”
71’ A65 823 Thunderbolt (undergoing restoration)
67’ D10 sportsman (undergoing restoration)
68’ D14 trials (undergoing transformation)

1 member likes this: Gary E
Re: Hornet, Wasp, Spitfire Hornet, Cyclone (Restored)
Two Alpha #808609 05/11/20 10:57 pm
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Lot of wasted time and effort with that case, they are cheap and plentiful.

Re: Hornet, Wasp, Spitfire Hornet, Cyclone (Restored)
Two Alpha #808621 05/12/20 2:04 am
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Not if it's a "C" case and the numbers match up to a Cyclone Competition which it does. But, if you are not purist, or you are just a bitsa builder, you wouldn't understand.


1967 BSA Wasp
1967 BSA Hornet (West Coast Model)
1967 BSA Hornet (East Coast Model)
1968 BSA Firebird Scrambler
1968 BSA Spitfire Mark IV
1965 Cyclone Competition Build
Re: Hornet, Wasp, Spitfire Hornet, Cyclone (Restored)
Two Alpha #808625 05/12/20 2:48 am
Joined: Aug 2001
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Great job Gary. A few of us are purists we do it for many reasons and it’s never easy. Knackered nuts and bolts don’t cut it. Every detail has to be correct even if you can’t see it. It’s sort of the spirit of restoration.
Plenty of room in the vintage motorcycle world for us all and it’s all highly respected.

1 member likes this: Gary E
Re: Hornet, Wasp, Spitfire Hornet, Cyclone (Restored)
Two Alpha #809385 05/18/20 11:39 pm
Joined: Dec 2006
Posts: 127
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ljm Offline
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Gary

That is one fine job on that repair.I would have to say you definitely saved that cyclone. from the scrap pile.

ljm

1 member likes this: Gary E
Re: Hornet, Wasp, Spitfire Hornet, Cyclone (Restored)
Two Alpha #809675 05/20/20 8:32 pm
Joined: Jan 2006
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Back to the side cover repair. After multiple steps, Phase 2 is complete. All repairs have been made. After stripping the cover of its "as received" condition, it had multiple issues in need of repair, most of which were hidden by all of the layers of various colored paint over the years. It was not the worst cover I've had to re-build, but not the best either.

An image of the typical issues after grinding out the bad areas.

[Linked Image from i.postimg.cc]

[Linked Image from i.postimg.cc]

The cracks and ground out areas were reinforced on the backside. The top corner was reinforced when it is constantly pushing on the frame tube when mounted. As a result, this spot typically develops a crack in the paint over time..

[Linked Image from i.postimg.cc]

The oil tank filler cutout is a typical spot for breakage. It was also reinforced on the backside.

[Linked Image from i.postimg.cc]

The chipped corner was reinforced on the backside, then filled in with flox for strength.

[Linked Image from i.postimg.cc]

The missing leading edge was fiberglassed up and then built-up with a flox mixture for strength. A top layer of glass was added to avoid any possibility that a crack could develop.

[Linked Image from i.postimg.cc]

The cover is now ready for primer and paint.


1967 BSA Wasp
1967 BSA Hornet (West Coast Model)
1967 BSA Hornet (East Coast Model)
1968 BSA Firebird Scrambler
1968 BSA Spitfire Mark IV
1965 Cyclone Competition Build
Page 26 of 26 1 2 24 25 26

Moderated by  Allan G, Jon W. Whitley 

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