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#640945 - 02/20/16 5:56 pm B31 "clubman"  
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Andy Higham Online content
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Bolton Lancs UK
I suppose I'd better start a thread on this build.
I aquired a B31 rolling chassis, I scoured the internet for an engine and sourced a reasonable unit, so I have the start of yet another project.
1955ish BSA B31. 350 big fin (iron) engine bored out to 400cc using Triumph T140 piston.
Gold star headlight brackets, mudguards, chainguard, clocks, rearsets etc
I am modifying a Suzuki GS750 clutch to suit the BSA gearbox. carb will be a Mikuni TM32.
I hope to get it to the other side of 100mph with a little work. The std B31 was good for about 70-75mph.
When funds permit a full fat, fire breathing gold star engine will be installed...........................


1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
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#640947 - 02/20/16 6:02 pm Re: B31 "clubman" [Re: Andy Higham]  
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Bolton Lancs UK
Cylinder head went on a little holiday to Roy Shearwood (R S Motorcycles). Exhaust valve seat suitable for unleaded, Inlet ported to 32mm (from 1"), Gold star valves
I have brazed the lugs onto the frame for the rearsets, repaired the brake pedal stop which had broken off and repaired the missing tank mount.
I have bought a set of needle roller bearings for the swing arm pivot to replace the BSA rubber bushes. I will turn up some bronze spacers to take the end thrust with O rings to keep the water out
Yesterday I cleaned my crank cases, Mr muscle oven cleaner works brilliantly on Villiers cases, It turns BSA cases dull grey and blotchy. I am informed its due to the silicone content of the aluminium. Oh well into the blast cabinet and a good boil in soapy water and rinse. Then into the oven for bearing fitting


1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#640948 - 02/20/16 6:09 pm Re: B31 "clubman" [Re: Andy Higham]  
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Bolton Lancs UK
I have fitted a bit of pornography inside my crankcases


1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#640949 - 02/20/16 6:10 pm Re: B31 "clubman" [Re: Andy Higham]  
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Bolton Lancs UK
It appears that if I use anything hotter than Gold Star touring cams I risk breaking my cam followers. So I have ordered a set of Gold Star cam followers which have a thicker stem. I am converting to eccentric rocker shaft instead of the (heavy) lock nuts on the cam followers.
The main bearings are now fitted and the crank is temporarily in the cases, I have sorted the shims and spacer to get it central.

The frame etc is back from Triple S in lovely shiny black, yokes fitted with taper roller bearings and I have converted the swing arm to needle roller pivot bearings from the original rubber bushes (yes seriously).
The rear end is being kept in check by Ikon (formerly Koni) shocks


1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#640952 - 02/20/16 6:14 pm Re: B31 "clubman" [Re: Andy Higham]  
Joined: Aug 2015
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Bolton Lancs UK
I made this tap wrench so I could tap the head inline to suit the eccentric rocker shafts




1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#640953 - 02/20/16 6:21 pm Re: B31 "clubman" [Re: Andy Higham]  
Joined: Aug 2015
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Bolton Lancs UK
The clutch,
This is the standard BSA hub for the four spring clutch, the parallel portion is where the rollers run

I turned the flange back to make the parallel portion 2mm wider. This is very hard metal, using a carbide tipped tool the swarf was coming off between red and white hot-incandescant!!

I also turned the scrolled portion away, I am using one of Phil Pearson's oil seal plates

With the bearing fitted

Last edited by Andy Higham; 02/20/16 6:23 pm.

1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#640954 - 02/20/16 6:26 pm Re: B31 "clubman" [Re: Andy Higham]  
Joined: Aug 2015
Posts: 931
Andy Higham Online content
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Bolton Lancs UK
A bit more clutch work. I bought a rusty old BSA 4 spring clutch inner drum off eBay


Last edited by Andy Higham; 02/20/16 6:28 pm.

1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#640955 - 02/20/16 6:31 pm Re: B31 "clubman" [Re: Andy Higham]  
Joined: Aug 2015
Posts: 931
Andy Higham Online content
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Bolton Lancs UK
I modified the back of the Suzuki inner drum

The remains of the BSA drum fit in the back of the Suzuki drum


1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#640957 - 02/20/16 6:33 pm Re: B31 "clubman" [Re: Andy Higham]  
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Bolton Lancs UK
There is significant wear on my gearbox layshaft where it runs in the bronze bushes, I was thinking of machining the shaft and making some undersized bushes.
However, I have been informed I am due a tax refund (5 digit), so I have bitten the bullet and ordered a Nova 5 speed cluster. The layshaft runs in needle roller bearings and the gearbox itself is a more modern "dog ring" type
Nova

Last edited by Andy Higham; 02/20/16 6:34 pm.

1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#640958 - 02/20/16 6:39 pm Re: B31 "clubman" [Re: Andy Higham]  
Joined: Aug 2015
Posts: 931
Andy Higham Online content
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Bolton Lancs UK


I machined a steel sprocket blank to mate up with the Suzuki outer basket, then bored it to take the bearing. On the final cut I got some chatter, as a result instead of the bearing being a press fit I can throw it in from t'other side of the workshop, first cock up.
So I bored the sprocket out to 70mm and made a bearing holder a nice snug fit in the sprocket. The bearing holder has a flange which is fixed to the sprocket with 6 M5 cap head screws, on the other side of the sprocket is a bearing retaining plate held on by 6 M5 countersunk screws.


All that is required now is to reduce the basket and drum down from 8 friction / 7 plain plates down to 7 / 6 to clear the outer case.
I also made a bracket which bolts to the bottom gearbox bolt to support a GPZ500 starter motor, A bearing housing in the rear of the primary chaincase supports a shaft with a sprocket behind. Inside the chaincase is a sprocket with a pair of sprag clutches driving another sprocket bolted to the crank sprocket.
Then the second cock up, the GPZ500 engine runs BACKWARDS!!!
I drilled the starter body to relocate the power connection stud 90 degrees round and rotated the brush gear 90 degrees. The motor now rotates forwards.
The state of play now is :-
1955 BSA B31 overbored to 400cc
DB32 goldstar valves
Pearson crank with Carillo rod
ABSAF high volume oil pump
ABSAF vernier gold star cams
Morgo oil filter
Nova 5 speed gearbox
Powerdynamo electronic magdyno
Suzuki GS850 clutch
Electric start


1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#640959 - 02/20/16 6:43 pm Re: B31 "clubman" [Re: Andy Higham]  
Joined: Aug 2015
Posts: 931
Andy Higham Online content
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Posts: 931
Bolton Lancs UK
Brake porn




1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#640987 - 02/20/16 10:50 pm Re: B31 "clubman" [Re: Andy Higham]  
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Magnetoman Online content
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U.S.
This is a great thread. Although at less than an hour between your first post starting the project and your most recent one where the frame is partially assembled, you've probably finished it by now.

#641070 - 02/21/16 1:46 pm Re: B31 "clubman" [Re: Magnetoman]  
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Posts: 362
chaterlea25 Online content
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Cork Ireland
Hi Andy
Nice work indeed beerchug

PM sent
John

#641072 - 02/21/16 1:54 pm Re: B31 "clubman" [Re: chaterlea25]  
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Posts: 931
Andy Higham Online content
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Posts: 931
Bolton Lancs UK
This is a trial fitting of the clutch


1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#641074 - 02/21/16 2:00 pm Re: B31 "clubman" [Re: Andy Higham]  
Joined: Aug 2015
Posts: 931
Andy Higham Online content
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Bolton Lancs UK
The Morgo oil filter nestles comfortably between the gearbox plates

The oil pipes are routed under the gearbox with 90deg connectors to the engine. The pipe from the filter to the tank has been covered with heat shrink sleeving, I have yet to do the others


1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#641081 - 02/21/16 2:49 pm Re: B31 "clubman" [Re: Andy Higham]  
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GS DAVE Offline
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england
I see you have one of Phil's inner primary cases, very nice build by the way..

#641085 - 02/21/16 3:04 pm Re: B31 "clubman" [Re: Andy Higham]  
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Andy Higham Online content
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Bolton Lancs UK
Yes I figured I was better off buying one off Phil than a fukced second hand one for similar money


1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#641100 - 02/21/16 3:43 pm Re: B31 "clubman" [Re: Andy Higham]  
Joined: Sep 2001
Posts: 2,766
Gordo in Comox Offline
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Comox BC Canada
Very nice! Did that crank drop right into those cases or was machining required?

Gordo


Without frequent roadside repairs there is no fun in riding!
#641104 - 02/21/16 3:55 pm Re: B31 "clubman" [Re: Gordo in Comox]  
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Bolton Lancs UK
Yes the crank dropped straight in. I had to make the spacer between the two bearings on the drive side. The timing side shaft is 25mm dia instead of 7/8" dia. The drive side shaft is 30mm/25mm diameter instead of 25mm. Phil supplied the bearings, the timing side roller bearing is a sleeved metric bearing


1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#641109 - 02/21/16 4:53 pm Re: B31 "clubman" [Re: Andy Higham]  
Joined: Nov 2009
Posts: 2,048
Peter R Online content
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Netherlands
Very high standard of workmanship, I like it. bigt


Peter.
1974 Commando 850
1972 Trident T150T
1961 Goldie DBD34
1969 Benelli 250 sport special
#641130 - 02/21/16 6:58 pm Re: B31 "clubman" [Re: Andy Higham]  
Joined: May 2013
Posts: 4,533
Allan Gill Offline
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Posts: 4,533
Rotherham - S. Yorkshire
Nice work.

I would have looked closely at what the DB(D?)32 motors were like and used those parts they weren't much slower than the 500 bigger brother and I believe quicker off the line and out of corners.


beerchug
#641142 - 02/21/16 9:27 pm Re: B31 "clubman" [Re: Andy Higham]  
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old mule Online content
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Chihuahuan Desert
Thank you for sharing your workshop pictures, keep us updated please.

#641557 - 02/24/16 5:14 pm Re: B31 "clubman" [Re: old mule]  
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Posts: 432
GS DAVE Offline
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england
Hi Andy, could you tell me the dimensions of the brake linings, Length and width if you don't mind..

#641618 - 02/25/16 5:15 am Re: B31 "clubman" [Re: Andy Higham]  
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Andy Higham Online content
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Bolton Lancs UK
Dave,
The drum diameter is 230mm
The lining width is 30mm
The lining length measured around the circumference is 200mm


1955 BSA B31 400cc "Stargazer"
1962 Greeves 200cc "Blue Meanie"
1962/67 Greeves 350cc
1967 Greeves 360cc Challenger
1984 Suzuki GSX1100 EFE "Sorcerers Apprentice"
Modified Nu-Trak GM500cc sprint/LSR bike "Deofol"
2003 Aprilia RSV Mille "Lo Stregone"
#641682 - 02/25/16 1:25 pm Re: B31 "clubman" [Re: Andy Higham]  
Joined: May 2011
Posts: 432
GS DAVE Offline
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england
Ta m8, In Czech at the moment, May look into buying one..

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