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Re: 67 68 BSA primary cover.
Adam M. #795624 01/14/20 10:25 pm
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Exactly why I'd like to exchange my nice 68 for a later 70/71.
Finally they came to their senses and realized you can't have the same bolt holding a cover and be used for draining / oil level check.
70 has all the same bolts around, and 2 additional for draining and oil level check, so everything works as expected and cover stays tight.

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Re: 67 68 BSA primary cover.
Adam M. #795627 01/14/20 10:56 pm
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Hex socket screw heads are 0.365" - 0.375". An assortment of 1/4" Posi-driv screws that I have measured from 0.380" to 0.407", not much bigger. Any screw that is frequently removed and retightened (which is essentially any screw on a British bike) should have a washer underneath. NAS washers are the most accurate. A 1/4" NAS washer has a 0.255" (+0.010, -0.000) hole and 0.468" (+0.015", -0.005") O.D., made of 300 series passivated stainless steel. They come in 0.032" (416L) and 0.063" (416) thickness.

Re: 67 68 BSA primary cover.
Adam M. #795642 01/15/20 2:27 am
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Heck, so I should have a 300 series passivated washer beneath all my Allen screws. How on earth has it stayed together this last 40 years without them?

Re: 67 68 BSA primary cover.
DMadigan #795663 01/15/20 7:43 am
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Originally Posted by DMadigan
Hex socket screw heads are 0.365" - 0.375". An assortment of 1/4" Posi-driv screws that I have measured from 0.380" to 0.407", not much bigger. Any screw that is frequently removed and retightened (which is essentially any screw on a British bike) should have a washer underneath. NAS washers are the most accurate. A 1/4" NAS washer has a 0.255" (+0.010, -0.000) hole and 0.468" (+0.015", -0.005") O.D., made of 300 series passivated stainless steel. They come in 0.032" (416L) and 0.063" (416) thickness.


Were they original BSA Phillister headed screws ?
Me thinks you will find them to be bigger still
And yes fitting a thick washer capable of spreading the load ofer an even bigger surface area is always a good Idea on alloy


Bike Beesa
Trevor
Re: 67 68 BSA primary cover.
Adam M. #795763 01/16/20 3:09 pm
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I found thick, 3/8 OD alu washers but their ID is 1/8 not 1/4", and I have to buy 150 of them in box for roughly $25 CAD ( with shipping ) to make those 2 washers enlarging their ID to 1/4 ". Above deal on eBay is even more expensive with high cost of shipping in US $.
anyway still looking for solution.

Re: 67 68 BSA primary cover.
Adam M. #795765 01/16/20 3:24 pm
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Re: 67 68 BSA primary cover.
Adam M. #795772 01/16/20 4:38 pm
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Either you are reading too much into it or trying to be sarcastic. I did not say fasteners cannot be used or would not hold without a washer. Take a plate of aluminum, drill a 1/4" hole in it then put a screw through it and tighten it down to 7 ft-lb (typical torque on a 1/4" screw). Take out the screw and see the surface has been scored by the screw because it was rotated against the surface whilst pushing down.
That is the point of using a washer, to keep the surface from being damaged and spreading out the load. Look at the surface of any screw into aluminum on a Brit bike that is often removed and the surface has been scored and crushed (although most of the damage is probably from the high quality mechanics that work on them).
NAS620 (National Aerospace Standard) are made in several materials, I prefer stainless. http://truefocusengr.com/NAS620.pdf

Re: 67 68 BSA primary cover.
Adam M. #795816 01/17/20 1:20 am
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mak yer ane Al washers, use a coke can or two, use a motorhome body, ( better), use any bit of Al sheet you can find that is about the right thickness, cut out squares, trim the corners, drill a 9/32" ( just bigger than a 1/4 for clearance) hole through the middle , put an old bolt through them, tighten the stack with a nut, fit to power drill, have at it with a coarse file till it fits, sand a wee bit to take the burrs off.
Then
A day after that take a trip to the boat store and notice pop rivet Al washers, buy the size you need.


71 Devimead, John Hill, John Holmes A65 750
56 Norbsa 68 Longstroke A65
Cagiva Raptor 650
MZ TS 250
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Re: 67 68 BSA primary cover.
Adam M. #795839 01/17/20 4:30 am
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The washers I found are pop rivet Al washers used for planes, just the thicker type.
Only problem with amount they sell and their shop is 100 km from my place.
Thanks Gavin, I will check boat shops now.

Beach, my handrail doesn't look very good, one tab was broken and welded back later, I will make a photo later during a day and attach here to show you.

Last edited by Adam M.; 01/17/20 2:09 pm.
Re: 67 68 BSA primary cover.
Adam M. #795859 01/17/20 2:27 pm
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Maybe it's preferred but does the washer itself have to be aluminum?


1966 BSA Lightning
(2) 1967 Triumph "Choppa"s
1974 Indian ME125
Re: 67 68 BSA primary cover.
Adam M. #795865 01/17/20 4:29 pm
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Doesn't need to be aluminum, a fiber washer will work just as well and probably seals better.

Just my tuppence worth.


1968 A65 Firebird
1967 B44 Shooting Star
1972 Norton Commando
Re: 67 68 BSA primary cover.
Adam M. #795896 01/18/20 12:55 am
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I can't believe we went full circle back to square one with this. I'm the one who first suggested the alu washer, so let me explain one more time: The whole idea of the alu. washer is that it's soft enough to conform to the irregularities in the cover as you tighten down the screw. In fact, if done right, the washer will not turn once it's secured. It's also good to have the o.d. of the washer fit snugly in the recess, so the washer jambs in place. Now when I remove the screw, the washer stays in place in the cover. In a sense we have repaired the screw seat.

Note: In my case at least, before this fix, fiber washers DID NOT work.

Note 2: If the screw seat in the cover is not damaged, i.e., the screws have never been overtightened, etc., none of the above is probably necessary. But who out there has a pristine primary cover?


Mark Z

'65(lower)/'66(upper, wheels, front end, controls)/'67(seat, exhaust, fuel tank, headlamp)/'70(frame) A65 Bitsa.
Re: 67 68 BSA primary cover.
Adam M. #795944 01/18/20 5:57 pm
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Aluminum washers also deform to take up the space around the screw itself, helping seal any fluids making it's easy up the threads.

Re: 67 68 BSA primary cover.
Adam M. #795946 01/18/20 6:58 pm
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I have some M6 dowty washers I use on fork drain screws, must try them out on the same offending cover bolts on my B44 and see if that helps.

Re: 67 68 BSA primary cover.
Adam M. #797015 01/30/20 4:45 pm
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M6 Dowty washers work including fitting the cover.

[Linked Image from i.postimg.cc]

Re: 67 68 BSA primary cover.
Adam M. #797093 01/31/20 5:37 am
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Looks effective Kommando. I have to get used to the idea that one can find just about anything on the internet these days.

https://www.eBay.com/i/183860090947?chn=ps&norover=1&mkevt=1&mkrid=711-117182-37290-0&mkcid=2&itemid=183860090947&targetid=859853091318&device=c&mktype=pla&googleloc=9005396&poi=&campaignid=6470552772&mkgroupid=91562449080&rlsatarget=aud-412677883135:pla-859853091318&abcId=1139336&merchantid=112300624&gclid=EAIaIQobChMIlqz4346t5wIVyZ-zCh3ndAAwEAQYASABEgKaYPD_BwE


Mark Z

'65(lower)/'66(upper, wheels, front end, controls)/'67(seat, exhaust, fuel tank, headlamp)/'70(frame) A65 Bitsa.
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