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perfect.tommy
perfect.tommy
vancouver, canada
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Installing the inner primary case; need to first do a test-fit with gasket and bolt up the 3 bolts at the crankcase, while checking the gap to the stand-off stud. This is fully nipped up, and there is a 1/16" gap. While doing this step, keep checking this gap! If it closes fully before the 3 bolts are tight, you COULD crack the case by tightening further.

[Linked Image]

This washer is a little thicker than 1/16

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This washer is just right

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Inner case now fully tightened with zero deflection and no possibility of cracking the case when I tighten the outer cover.

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
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I don't care for the long alternator stand-offs, they leave too much of the rotor/stator interface unused.

[Linked Image]

That's over 1/4" gap on a part that is only 1-1/4" wide; that's basically 20% inefficient.

I sorted (3) 1/4" spacers and get almost full interface between the alternator components, for maximum effect.

[Linked Image]

Plenty of chain clearance to the stator.

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Primary system done after having to add 2 thin shims behind the clutch basket to properly align the primary chain with the front edge of the primary case.

[Linked Image]

Finally looking like a motorcycle instead of a pile of parts...

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Assembled the brake caliper, installed & bled it; both brakes are done.

[Linked Image]

Slides are 3-1/2 cutaway

[Linked Image]

Main jets are 220s

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Needle jets are 106s

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Carb parts swimming in 50/50 pine oil cleaner & hot water.

[Linked Image]

Quick rattle-can spray job on the left sidecover 'till the final decision is made as to what parts the painter will deal with.

[Linked Image]

I only had 40 minutes for the carbs to soak before I had to shut down for the evening. I'll heat up the mix tomorrow and give 'em another hour with each part getting hit with a toothbrush while they soak. 40 minutes made a difference, but not as much as Berrymean's Chem-Dip does (at 3x the price).

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Carbs got 4 more hours of soaking, then a soft brass wire brushing.. Nice, but not as good as Berryman's Chem-Dip. Oh well, it was worth the attempt.

[Linked Image]

Spiffy carbs ready to bolt back on.

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Valve lapping time!

First the coarse, then the fine.

[Linked Image]

Hand lapping tool works great. Using a drill on the stem end is not recommended.

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Closeup of intake valve lapped face also came out blurry so hard to clearly see the thin gray band of mating face.

[Linked Image]

Done with lapping valves. I'm going to polish up the combustion chambers tomorrow.

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Engine mocked up in preparation to have the bike serial numbers inspected by the local Police Dept.

[Linked Image]

Took some 0000 steel wool and Simple Green degreaser to the pipes; not too bad! There are 2 or 3 scratches, mostly covered by the bodywork.

[Linked Image]

Pipes, tank and temporary seat in place.

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Bodywork in place FINALLY. It's only mocked up, but it's looking pretty close to what it will look like when it's done. Now to book the P.D. inspection.

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Headlights installed but not wired. (front lower mount installed, but you can't see it)

[Linked Image]

Tail light temporarily installed with previously installed (incorrect) license plate back, (chrome bit)). Mufflers wil be aligned after final assembly.

[Linked Image]

Right side beauty shot, front fender not drilled or mounted yet.

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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I need the proper original layout of the indicator lights (red, blue & amber)

[Linked Image]

Cockpit looking almost complete. Clutch pull is a little heavy, I'm going to install a stuffer plate to bring the stack height up.

[Linked Image]

Last edited by GrandPaul; 01/21/16 7:34 pm.

GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
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What a GREAT looking machine Mr. GrandPaul!

I haven't read the entire thread yet but I am in awe of how cool it looks.
What gets me the most about it is, I remember those bikes zooming around the television, and seeing the model kits in the stores.

It's almost hard to believe that something from my childhood comes back to remind me of how frickin old I'm getting.

For the fellas in their 70's-80's, I cant imagine it. It must have been insane watching the chariot races, and being constantly on guard for T-Rex-s, and Pterodactyl-s.

Very cool bike Mr. Paul!

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Really nice to see a proper narrative and photos of "how to assemble", with the right shims and all. This is going to be a great bike, and the build info is much appreciated!

Lannis


"Why do you wear that thing, Dobby?" "This, sir? 'Tis a mark of the house-elf’s enslavement, sir."
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I have been getting one heck of an education about the medium-rare John Player Norton from people on the various forums, facebook, and vendors including Phil Radford of Fair Spares America who is a recognized authority on the subject.

This thread brings everything I've learned into one place (not to say there isn't a lot more to know "out there", I'm still searching for details).

The back story on this bike is definitely unique to me. "One of the ones that got away" came back (at a price). Even though I've acquired the taste for it, I knew I was going to be selling it before I ever bought it.


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Zener diodes, "before & after"

[Linked Image]

Spiffy clean underside; centerstand installed.

[Linked Image]

Just a mock-up. I sure love timing side shots of Commandos and Bonnevilles.

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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One of these two tanks will be for sale; still haven't decided which one.

[Linked Image]

"Stable mates", sans bodywork. Waiting for rings for the JPN and title for the 880 Special...

[Linked Image]

(2) Replica OEM solo seats ordered for the JPN today. I made a deal to send them my fairing and they'll send me a brand new one after they model it and start making new ones. So, I will have a FULL JPN bodywork set for sale soon (fairing, mounts, windscreen, tank shroud, tank & seat), plus one spare rough fairing.


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Shipped out my new JPN fairing on FedEx insured for full replacement cost, to Airtech. They'll make a mould to reproduce it, then send it back to me. I'll get the first clean copy they produce at no charge (other than the cost to send it to them, which wasn't cheap).

So, will soon have one complete JPN bodywork set for sale, ready to bolt on (with extended gas tank)

I'm going to have them copy my Tracy 2000 & 2001 quarter fairings, on the same terms. I've searched high and low for those...

[Linked Image]

[Linked Image]


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
Joined: Jan 2006
Posts: 7,720
Likes: 132
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Just got done reverse engineering the JPN fairing brackets and ordering all the materials to build a few sets for myself & Airtech. I love playing with AutoCAD.

I may be the only source for the brackets once they're done (other than onsie-twosies stashed in people's sheds and garages) I haven't found any after searching pretty extensively.

Really itching to get in my rings and get the engine done. Less than a day's work left to fire it up...


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
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you've moved really fast on this paul.


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)

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Originally Posted by GrandPaul

[Linked Image]


[Linked Image]


The back end on yours looks a little lower than the auction photo, are there different spring lengths for the JPS compared to the normal Commando?


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)

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Allan, look at the relationship between the rear tyre and the mudguard and the bottom shock nut and the silencer on both, they are very similar. What you are picking up on is the seats being different and GP's is not as high has the lower extension for the racing number and that makes his look like its riding lower but if it is its only by mm's.

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I think your right John. The number board also makes it look closer to the back tyre


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)

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A
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The seat looks "droopy"


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Correct seat is winging it's way from the west coast.

I'll have it upholstered and installed in a week or two at the most.


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, a BSA, & some Japanese
"The Iron in your blood should be Vintage"
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