Britbike forum Forums British Motorcycle specific Brands Ajs & Matchless forum Ally Barrel G80s

Hi I’m in the process of fitting an ally barrel to an old set of cases I was given.
I have welded up one set of barrel stud holes ready to be repositioned and repaired the corrosion in the crank cases horrible casting to weld but got there eventually next I need to bore the case to take the larger spigot on the barrel it is a modern repro with cast pushrod tubes bore is 87.2 mm so I’ve ordered a Harley Shovelhead std piston to go in it just need honing hopefully and maybe a spacer plate fitting be interesting to see how it goes head is going to be fun and games I think.

Harley Piston turned up from America today and seems a perfect fit just a light hone needed think I’ll need to make a new small end bush as the gudgeon pin is a bit smaller and who knows what else when I get the barrel fitted to the case I’ll be able to see

Milled the welds of the crankcase and took a thou off to remove some imperfections next I need to bore it out for the larger spigot just waiting on a larger boring head.

https://youtube.com/shorts/NWNk8PQIXcs

Managed to bore the cases for the barrel and make some studs need to drill and tap the case and make a start on the head

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Fitted the studs and turned some ally plugs to check barrel to crankcase pushrod alignment and all seem good head needs holes repositioning and enlarging for sleeve nuts and fins welding in and pushrod tubes extending but I need to find a 500 head first later ones with the pushrod tubes all the way through seem near impossible to find so will have to modify an early one then I can build it up and see what I need in the way of a compression plate progress will halt till I can find a suitable head

All ready for barrel now I might have to use the head from my other engine for now if I want continue while I look for another was hoping to find a damaged one as I need to modify it anyway but I’ll see how impatient I get

Couldn’t resist a dry run to see what its going to look like not interested in performance more aesthetics it’s going in a G80R I’m building I’ve always loved the look of them and have no hope of owning a real one so this is just a bit of fun .

Bit more progress building up the engine need to sort the head now stripped the magneto and it’s giving a good spark now and hopefully build the rigid rear at the weekend then see what fits and what doesn’t