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#352909 - 01/14/11 12:24 am Re: '59 Velocette Venom [Re: Bry]  
Joined: Aug 2001
Posts: 333
Bob E Offline
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Bob E  Offline
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Connecticut, USA
excellent job on the speedo.

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#354345 - 01/22/11 9:53 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
...I got the kickstart lever, push rod tube, and brake actuating arms back from the chrome plater and fitted these with new stainless steel fasteners.

Next was to fit the mudguards; the rear mudguard was missing (except for a short section cut and screwed to the seat pan) when I got the bike so I replaced this with a new stainless steel item with new brackets. There was a front mudguard that came with the bike, although this was undrilled and had never been fitted it was corroded so I treated it with rust remover gel and a wire brush and fitted it temporarily using new stays. I�ll send this for plating later.

Other new bolt on items (after a bit of adjustment!) were the seat, dynamo cover, battery strap, control levers, front number plate and footrest rubbers.

I have sent the original tank off to be chrome plated and painted by a specialist in England.

[Linked Image]

[Linked Image]


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#355423 - 01/28/11 11:31 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
�the tool box was in pretty good shape with no big dents, but the lid hinge was stuck and bent a bit and there was a hole in the back plate where it hade been rubbing against the rear mud guard and some corrosion inside.

A nice feature of the tool box is that it has the original �L Stevens� dealer plate riveted to the lid, I removed this and will refit in its original state after the tool box is refurbished.

First thing was to remove the lid by knocking out the hinge pin using a small punch and hammer and WD40. Then the paint was removed using chemical stripper then a light grit blasting.

There were some small dings and dents in the edges of the box which were straightened out using a hammer and dolly.

The damaged section of the back plate was cut out and replaced with a new piece of sheet steel and welded in place. I also filled three holes in the back plate by welding then I ground the welds flush.

After straightening out the hinge I run a small hand reamer through the pin holes then refitted the lid using a new piece of bar stock for the pin.

I will send the toolbox for powder coating with by next batch of items.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#359715 - 02/24/11 12:01 am Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
�the last few weeks have been spent mainly sourcing and ordering the remaining large parts and fitting them.

I decided to go with a new BT-H electronic magneto as I have had good reports from other Velocette owners on these.

The alternator selection was not so straight forward though, after a bit of research (where I also considered a dynamo) I narrowed it down to a Criterion or Alton unit. There has been a lot of reported problems with the early Alton 3 phase units but apparently the latest single phase units are much improved, the Criterion seems to be a very good unit but they look quite a bit different in shape to the original dynamo. In the end I went for the Alton unit. I made up a small stainless steel bracket for attaching the rectifier to the upper rear mudguard support, this location should keep it in free air flow while partially hiding it under the seat. According to the Alton installation instructions it is necessary to fit an isolation switch, I used a DPST on/on switch for this with the other side connected to the kill wire from the magneto, so that the alternator circuit will be closed and the magneto kill circuit open when the bike is running and vice versa when it is not. I fitted the switch in a hidden location out of sight.

There was not a horn fitted to the bike when I got it, I originally bought an unrestored Lucas altette horn from eBay with the plan to restore it. However while purchasing parts to use for the restoration from the leading expert on old horns, Lynn Isaacs in Wales (aka Taff the Horns) he correctly advised me that it was not the right parts for the model of horn that I had and indeed the horn was not the correct model for a 1950�s Velocette. We then arranged a trade-in of my Altette for a correct Clearhooters 180/A horn that Taff had beautifully restored and converted to 12v.

I went for a repro Lucas head light which fits and looks OK but the fixing screw on the chrome rim is not the same as the original item which I could not find. I will keep a look out for one of these as a replacement. I used the original nacelle top cover with the previously refurbished speedo and new miller ammeter and light switch fitted in it.

I was able to repair the original number plate bracket and fitted this with a repro number plate and replacement Miller rear light unit.

I fitted a new Monobloc carb and also purchased an AMAL battery box to hold a set of AGM batteries.

Control levers, throttle twist grip, horn/dip switch were all new replacement items.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#359750 - 02/24/11 1:48 am Re: '59 Velocette Venom [Re: Bry]  
Joined: Jul 2001
Posts: 12,050
Lannis Online content
Life member
Lannis  Online Content

Life member

Joined: Jul 2001
Posts: 12,050
Central Virginia
This continues to be an inspiring tale. Although I feel the pain in your checkbook as you reach the stage where sometimes just hard work and skill won't get it done, you've got to shell out the hard-earned ....

Keep us up to date! This is great stuff!

Lannis


OK, I admit it, I'm addicted to brake fluid.

But I can stop any time I want.
#364530 - 03/23/11 9:28 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
After fitting the control cable, the feel of the front brake was not good so I decided to skim the brake linings. I made up a tapered adapter to centralise and hold the brake plate in the lathe.

I then set the diameter of the brake shoes to the diameter of the brake drum by holding the cam actuating arm in position using a cable tie. I then run the lathe at a slow speed (160 rpm) and taking small cuts with a sharp, pointed tool turned the diameter of the linings.

I reassembled the brake and fitted the front wheel, centralising the brake plate in the drum by spinning the front wheel and holding the brake lever while tightening the axle.

The brake feels much better now, but we'll see how it performs on the road, hopefully before too long.

[Linked Image]

[Linked Image]


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#368408 - 04/15/11 10:58 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
...the exhaust pipe that was fitted to the bike when I got it was a swept back clubman type and the silencer was missing. I decided to get a new a pattern standard pipe and silencer. I ordered the exhaust pipe unchromed so that I could make any adjustments to get it to fit right if necessary (which it was!) then send it back to the manufacturer for chrome plating.

The pipe was a reasonably close fit but the connection to the spigot on the head was at a slight angle, which concerned me about getting a good seal when clamped up. Also there was not a lot of clearance for the kick start. So I cut the end of the pipe at the sleeve that fits over the cylinder head spigot and set it up so it was aligned with the spigot, rewelded it back on, then ground and finished the welded area with a sanding wheel. To get a bit more clearance for the kickstart I cut of the bracket that clamps the exhaust to the footrest and shortened it by 3/16� then welded it back on.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#372560 - 05/10/11 8:58 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
...the next job on the list was to install the push rods and set the valve timing and static ignition timing.

The original push rods and end caps were in good serviceable condition so only needed a clean and were refitted.

To set the valve timing I attached a timing disc to the drive side end of the crank and set the engine to TDC. With the rocker box removed I set a dial indicator into the upper cup of the inlet pushrod, then by turning the engine I set to the correct opening and closing crank angle position by removing, turning and re-engaging the intermediate timing pinion.

To set the static ignition timing on the new electronic BTH magneto I removed a screw in the body and inserted a steel rod that came with the mag to engage with the mag rotor and lock in to the fully advance position. Then with the engine set at the full advance crank angle, I fitted the mag pinion to the tapered shaft and torqued the securing nut. The steel rod was then removed from the mag body the screw plug refitted. I will recheck the ignition timing by strobe when the engine is running.

I then set the valve clearances, applied assembly lube to the cams, followers, timing pinions, push rods, rockers and valve stems and fitted the timing cover and rocker box and torqued down.

Moving onto the wiring. I decided to make up my own wiring harness, as I am changing to 12v and the alternator requires a negative ground system. Other than that the electrics are installed in a pretty much standard arrangement. One other modification that I did make was to install a concealed isolation switch between the battery and rectifier. I used a DPDT toggle switch for this and also wired the magneto kill wire to the switch so that the alternator needs to be in circuit with battery before the mag will spark.

Using combination of an original wiring diagram the the instructions that came with the alternator and rectifier I sketched up a new wiring diagram. Rather than using the bike frame for a ground, I located common wired ground points on the battery support plate, to one the engine bolts, inside the headlight and on the rear mudguard, each component ground was wired to one of these points for direct connection to the battery. I then pulled each wire to the respective components to set out the best routing then bundled the wires into a loom and inserted into a braided cover using shrink wrap tubing at the ends of the cover. I used traditional style bullet connectors where they can be seen and modern type sheathed connectors inside the headlight shell and in the concealed tail light area. I crimped then soldered the connectors to the wire.

I went for a modern sealed AGM battery (actually its two 6v batteries wired in series) concealed in a traditional looking "dummy" battery box. After connecting the battery all lights and the horn worked.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#381101 - 06/27/11 11:56 am Re: '59 Velocette Venom [Re: Bry]  
Joined: Feb 2006
Posts: 607
RGSROB Offline
BritBike Forum member
RGSROB  Offline
BritBike Forum member

Joined: Feb 2006
Posts: 607
Ontario , Canada
I have been following your rebuild with great interest as I have been doing exactly the same thing to my 59 Venom.
Mine is up and running but disappointingly has some vibration. I had the crank rebalanced to 65% and wonder what you had used?
Regards
Rob

#381221 - 06/27/11 9:56 pm Re: '59 Velocette Venom [Re: RGSROB]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
Originally Posted By: RGSROB
I have been following your rebuild with great interest as I have been doing exactly the same thing to my 59 Venom.
Mine is up and running but disappointingly has some vibration. I had the crank rebalanced to 65% and wonder what you had used?
Regards
Rob


Hi Rob, I also used a balance factor of 65% following a bit of research on this and this was also what I measured the existing b/f to be when I stripped the engine. Although, as I have not run this bike yet I can't comment on the success or otherwise of this. Bry


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#381314 - 06/28/11 11:09 am Re: '59 Velocette Venom [Re: Bry]  
Joined: Feb 2006
Posts: 607
RGSROB Offline
BritBike Forum member
RGSROB  Offline
BritBike Forum member

Joined: Feb 2006
Posts: 607
Ontario , Canada
Thanks Bry, the piston I have fitted is a low expansion, total seal ring set up, coated skirt , Hi Tech item designed by Dave Smith , I found out after mine was together that he actually recommends a factor of 70% as optimal for his slightly heavier piston.
I will let you know how things turn out. Great project of yours ,congratulations.
Rob

#381511 - 06/29/11 12:47 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: Jan 2006
Posts: 6,639
GrandPaul Online content
BritBike Forum member
GrandPaul  Online Content
BritBike Forum member

Joined: Jan 2006
Posts: 6,639
Laredo (South) Texas, USA
Fantaastic detail work, and a great project altogether; keep it up!


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, some BSA & European
"The Iron in your blood should be Vintage"
#387738 - 08/03/11 10:04 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
...I have not posted an update for some time now, mainly due to a hectic travel schedule with work. Anyway!, there has been some progress on the Venom project in the last few months. Mainly all the the numerous small jobs that seem to be never ending at this stage of a restoration.

After I completed the wiring, I made up new hoses and fittings for the oil lines. The hard piped oil lines were in good shape so I cleaned and replated these.

I decided to replace the v belt pulley arrangement for the alternator drive from the crank with a toothed belt assembly purchased from the Velocette owners club.

After checking fits and clearance - the toolbox, primary chain cases, clutch cover, alternator drive case and chain guard were removed and sent for powder coating gloss black. I got these back about a month ago and refitted them.

The nacelle and oil tank were also removed and sent to the painting specialist who is working on the fuel tank. There was a bit of a problem with the fuel tank, after getting chemically stripped and inspected is was deemed to be too far gone to repair to a standard suitable for chroming. My options were to either get the tank painted or find a replacement. As I really wanted to go with the chrome finish, I checked around for another tank, I eventually managed to get one from the london based Velo specialist Nick Payton who had an original very rusty but sound tank available. This is presently at the chrome platers who will hopefully have it back for painting and finishing within the next few weeks. The oil tank and nacelle have been painted and are being left for a few days to let the paint fully harden before returning them to me next week.

The exhaust pipe was sent for chrome plating and is now back and fitted to the bike.

Another small job was to refurbish the original Ewart petrol taps, these are pretty basic push pull type with cork seals. After cleaning the parts up and redressing some damaged threads they came out looking pretty good. The problem I had was getting good fitting cork seals, I order five sets in total from various sources, including a seagull outboard motor parts supplier (these also use Ewart petrol taps), but none of them were that good. In the end I turned up brass bosses with grooves cut in them for viton o-rings to fit in place of the corks, so we�ll see how that works. I made up a simple static pressure test rig and they held up ok on that, but it�ll be different story when fitted to a running bike.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#387797 - 08/04/11 8:16 am Re: '59 Velocette Venom [Re: Bry]  
Joined: Nov 2009
Posts: 2,046
Peter R Offline
BritBike Forum member
Peter R  Offline

BritBike Forum member

Joined: Nov 2009
Posts: 2,046
Netherlands
You are making good progress on that Velo, I am follwing you with interest. Your method of refurbishing the Ewarts fueltaps looks like a goos idea indeed.

Last edited by Peter R; 08/04/11 8:17 am.

Peter.
1974 Commando 850
1972 Trident T150T
1961 Goldie DBD34
1969 Benelli 250 sport special
#387847 - 08/04/11 3:31 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: Jan 2006
Posts: 6,639
GrandPaul Online content
BritBike Forum member
GrandPaul  Online Content
BritBike Forum member

Joined: Jan 2006
Posts: 6,639
Laredo (South) Texas, USA
+1 on the brass & o-ring swap-out for old cork bits.

"Mass marketing" written all over it.


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, some BSA & European
"The Iron in your blood should be Vintage"
#388367 - 08/07/11 7:14 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2011
Posts: 16
Brandycat Offline
BritBike Forum member
Brandycat  Offline
BritBike Forum member

Joined: May 2011
Posts: 16
United Kingdom
I've just spent the last hour reading this thread, and marveling at your expertise. It is breathtaking.
You Sir are an artist and the quality of your work is
truly magnificent.
I look forward to the completion of this masterpiece,
but it is like a good book that I don't want to end!

thank you

Dave

#388905 - 08/10/11 10:29 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
...I got the oil tank and nacelle back from Lewis Templeton Motorcycle Paintwork Specialists this week, they have made a superb job of the painting. They are also planning on getting the petrol tank back from the chrome platers next week for painting. I now only need the petrol tank and the stainless steel front mudguard (which hopefully I will also receive this month) to complete the assembly.

[Linked Image]

[Linked Image]

[Linked Image]


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#389083 - 08/11/11 7:33 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: Aug 2011
Posts: 1
zephyr Offline
One time poster
zephyr  Offline
One time poster

Joined: Aug 2011
Posts: 1
Wales
The shear pleasure of reading the progress of this rebuild cannot be calculated. I rebuilt a similar model, not anywhere near this quality of build I hasten to add! back in 1976, and I used an MSS crank, as the flywheels are heavier, and that made for a really sweet motor. That machine is way in the past now, so these days I ride a "naked" Suzuki SV 650, for day to day use,and its electric starter! a 1965 T100, when(if!) the sun shines, a 1935 MOV still as a 'boxed set', although I did rebuild its gearbox 25 years ago, and....well thats another story. Who can say British Engineering, and indeed Engineers, are dead when one sees this quality of work in progress, long may it thrive, and congrats on a fine piece of work, the Goodmans would be proud, I'm sure.....Morrag

#397163 - 10/02/11 10:29 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
...there has not been much progress on the Venom project in the last six weeks or so, as I have been traveling a lot. But I finally received the stainless steel front mudguard this week (I have been waiting for the manufacturer to run off a production batch) and got that fitted after a bit of finishing on the polishing wheel.

Another small job was to fit and route the oil tank breather hose, I decided to bend up some steel tubing and weld a lug onto it so I can bolt it to the rear brake torque arm fixing. The hose from the tank was then attached to the end of this behind the swing arm, not a standard Velocette arrangement but it doesn�t seem to look that out of place.

I really just need the petrol tank now before I start up the engine for the first time in probably more than forty years. The bloke who is restoring my tank is making good progress and has been sending me pictures at each stage, he should be finished within the next week.

[Linked Image]

[Linked Image]


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#399406 - 10/17/11 7:59 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
...I will shortly be getting the petrol tank back from Lewis Templeton Motorcycle Paintwork Specialists who have been restoring it. Here are some pictures that they have sent me that were taken during the work that they carried out.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#399415 - 10/17/11 9:09 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: Mar 2006
Posts: 3,647
raf940 Online content
BritBike Forum member
raf940  Online Content
BritBike Forum member

Joined: Mar 2006
Posts: 3,647
gastonia nc
a work o art


1972 Triumph T120
1968 BSA A65
1968 MGB Roadster
1979 Chevrolet Camaro Berlinetta
1969 Honda Mini Trail
1939 farmall f30 tractor
2004 Honda Shadow Aero
1972 BSA Thunderbolt
1975 yamaha xs650b
1972 Norton commando project
#401395 - 10/30/11 4:29 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2006
Posts: 257
Bry Offline
Bry  Offline



Joined: May 2006
Posts: 257
Scotland
...I got the petrol tank back and fitted it yesterday and made up the fuel lines.

It was then time to start the engine for the first time. I filled the oil tank and primed the oil pump, I then removed the spark plug and took the bike for �a walk� in gear, pushing it up and down the street to ensure that there was oil flow getting to the rocker box. I then removed the rocker box inspection cover and squirted about half a pint of oil into the rocker box using an oil can which then drained down through the push rod tube into the timing chest and hopefully ending up in the crankcase to give an initial splash feed of oil to the crank on first start-up. I then put everything back together and checked gearbox oil level and primary chain lubrication.

I then tried to start it using the procedure of; tickle carb, air slide open, find and ease piston over TDC on compression stroke, return kick start lever to top then slowly swing kickstart through a full stroke with the valve lifter open, return kick start lever to top then give it a big swinging kick. On the second attempt the engine burst willingly in to life. I let it run at fast idle then gave it a few blips of throttle and with a bit of adjustment of the idle screw it settled down to a good stable tick over. Oil started returning to the tank after only a few seconds at a healthy constant flow, increasing and reducing as the throttle was blipped. The exhaust was smoke free and there were no unusual noises or obvious problems. I let it run on the bench like this for a minute or so before shutting down.

The weather was OK this morning so I went out for a first run, again the bike started up without any problem (just as well as my son was watching, armed with his camcorder) and was running great. The clutch needed a bit of small adjustment at the cable which I did while riding along, although I will run through the complete Velo clutch adjustment procedure again now the plates have been run a bit. The bike felt great with good tractable power from the engine and a willingness to rev. After about three miles with some strong bursts of open throttle to start getting the piston rings to seat I stopped to give things a check over and to let the engine cool down. I repeated this a couple of times and put about 20 miles on the bike then took it home and changed the oil and gave it another check over. I will now go over everything in detail, e.g. chain tensions, belt tension, check for loose fasteners, valve clearances,... etc. But there is plenty time for this as I will not be running the bike over winter and the real commissioning will start next spring.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


YouTube link to first run
http://www.youtube.com/watch?v=DDNLJrrPud0


1946 Velocette MSS
1955 Triton (project)
1959 Velocette Venom
1966 Triumph T120
#401398 - 10/30/11 4:38 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: May 2005
Posts: 3,751
shel Online content
BritBike Forum member
shel  Online Content
BritBike Forum member

Joined: May 2005
Posts: 3,751
ohio
That's a beautiful bike, Bry. And it sounds wonderful.


When given the choice between two evils I picked the one I haven't tried before
#401410 - 10/30/11 5:58 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: Jul 2001
Posts: 12,050
Lannis Online content
Life member
Lannis  Online Content

Life member

Joined: Jul 2001
Posts: 12,050
Central Virginia
I have to be careful when I open this thread, because I let a little wee out every time I see this motorcycle and the way you've built it. Thanks for sharing all this!

Lannis


OK, I admit it, I'm addicted to brake fluid.

But I can stop any time I want.
#401412 - 10/30/11 6:02 pm Re: '59 Velocette Venom [Re: Bry]  
Joined: Aug 2001
Posts: 6,657
Jon W. Whitley Online content
Jon W. Whitley  Online Content



Joined: Aug 2001
Posts: 6,657
Vermont
What a beautiful machine. Well done!!


Jon W.


1957 6T Thunderbird 650
1971 TR6R Tiger 650
1955 Tiger 100 - Project
1970 BSA A65F 650 - Project

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