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by Mal Marsden - 06/16/22 7:00 pm
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May 8th, 2022
Thread Like Summary
Allan G, BrizzoBrit, chainreaction, D.Bachtel, Gary E, Gordon Gray, Hugh Jörgen, leon bee, ozziebsa, SpeedyV, Vincent Esposito
Total Likes: 40
Original Post (Thread Starter)
by Two Alpha
Two Alpha
Ok folks, this is a start to restoring the thread started by Gary E. It's a little bit raw, I'll dress it up if it becomes necessary.
Hope you like it, feel free to post away.

Hornet, Wasp, Spitfire Hornet, Cyclone (pages 1 to 64)
Liked Replies
by Gary E
Gary E
The '65 Spitfire Hornet tank that I brought back from the dead. See earlier images. Now ready for base coat/clear coat primer/sealer then paint and clear.

[Linked Image from i.postimg.cc]

[Linked Image from i.postimg.cc]
5 members like this
by Gary E
Gary E
Here is the latest on the '65 Cyclone Competition build. It's going a bit slow as some parts are hard to source. I had to fabricate the rear sprocket on a milling machine since I couldn't find an original. It is different than '66 and newer. The bolt pattern spacing is 2-5/8" instead of the newer 2-1/2".

[Linked Image from i.postimg.cc]

[Linked Image from i.postimg.cc]

[Linked Image from i.postimg.cc]
2 members like this
by Richard Phillips
Richard Phillips
I let my powder coater handle the whole job. She also uses a primer coat prior to top coat.
Attached Images
2 members like this
by Soupdragon
Soupdragon
I don't have a 65 Cyclone but I do have a 64! Just fresh out of restoration. Very happy with it, don't know anyone over here that's actually seen one.
[Linked Image from i184.photobucket.com]
1 member likes this
by ljm
ljm
[Linked Image from i.postimg.cc]

Handlebars for my West Coast Hornet. It has the part # stamped on them.
ljm
1 member likes this
by ljm
ljm
[Linked Image from i.postimg.cc]

This shows the wall thickness.
1 member likes this
by Richard Phillips
Richard Phillips
Thanks Gary
1 member likes this
by Gary E
Gary E
Since it is larger, and the fill neck is taller, it is more difficult to to install than the standard oil tank. Installation can be done from the right side, and it needs to go in before the rear fender is installed.
1 member likes this
by Allan G
Allan G
Great job on the repair!
1 member likes this
by Richard Phillips
Richard Phillips
Great job Gary. A few of us are purists we do it for many reasons and it’s never easy. Knackered nuts and bolts don’t cut it. Every detail has to be correct even if you can’t see it. It’s sort of the spirit of restoration.
Plenty of room in the vintage motorcycle world for us all and it’s all highly respected.
1 member likes this
by ljm
ljm
Gary

That is one fine job on that repair.I would have to say you definitely saved that cyclone. from the scrap pile.

ljm
1 member likes this
by Gary E
Gary E
Back to the side cover repair. After multiple steps, Phase 2 is complete. All repairs have been made. After stripping the cover of its "as received" condition, it had multiple issues in need of repair, most of which were hidden by all of the layers of various colored paint over the years. It was not the worst cover I've had to re-build, but not the best either.

An image of the typical issues after grinding out the bad areas.

[Linked Image from i.postimg.cc]

[Linked Image from i.postimg.cc]

The cracks and ground out areas were reinforced on the backside. The top corner was reinforced when it is constantly pushing on the frame tube when mounted. As a result, this spot typically develops a crack in the paint over time..

[Linked Image from i.postimg.cc]

The oil tank filler cutout is a typical spot for breakage. It was also reinforced on the backside.

[Linked Image from i.postimg.cc]

The chipped corner was reinforced on the backside, then filled in with flox for strength.

[Linked Image from i.postimg.cc]

The missing leading edge was fiberglassed up and then built-up with a flox mixture for strength. A top layer of glass was added to avoid any possibility that a crack could develop.

[Linked Image from i.postimg.cc]

The cover is now ready for primer and paint.
1 member likes this
by ljm
ljm
[Linked Image from i.postimg.cc]
1 member likes this
by ljm
ljm
[Linked Image from i.postimg.cc]

Gary

The sidestand that was on my west coast hornet is the one on the left. It has attach points that are thicker than the 66 sidestand and a different bolt. Of course it could be the wrong one that was on it. The parts number say the 66 and 67 years are the same. Which one goes on it?
1 member likes this
by ljm
ljm
Gary

Ok thanks. That was about the only thing that I have found on this bike that wasnt correct. The only other thing was the side covers. Someone had trimmed about a half inch off the top of the covers. Probably had nicks on them. I looked at them for a long time scratching my head.

ljm
1 member likes this
by leon bee
leon bee
That still pisses me off that got dumped. Like throwing away an encyclopedia.
1 member likes this
by BrizzoBrit
BrizzoBrit
I have a folder with 63 pages recovered from archives or somewhere. I've not looked at this in some time, but I just quickly looked at a couple of pages. None of the photos on those 2 pages have been photo*ucketed. All pages are saved as MHTML files. Someone smarter than me must know how to recover this. Or at least make a repository of these files so they are accessible. There was some effort underway at the time which seemed to work, but not sure what happened with that.

I would be exceedingly happy to see this material get back into circulation and will pass on copies to anyone who could do that. Gary as OP you might PM me and I might be able to share on dropbox or something.

This might be the most useful thing I've ever done in my life. smile

Ray
1 member likes this
by Gary E
Gary E
With the help of Richard P. and BrizzoBrit I got the last couple of parts sourced for the NOS ET coils. Assembled them to the triangular brackets and temporarily mounted on the bike. I had to fabricate the "U" shaped wire tabs on the condensors as I didn't find a Lucas part number for them.

[Linked Image from i.postimg.cc]
1 member likes this
by Spitfire Ken
Spitfire Ken
https://mikesclassiccyclespares.com/product/66-5541/
https://bsaunitsingles.com/itemlist.wws?cpubcode=bsa&category=Wheels
1 member likes this
by VicCyclone
VicCyclone
Originally Posted by Gary Ori
Thanks, Out of Stock everywhere including Queensland. I probably will have to make one. It could be worse.
Burton Bike Bits still have 66-5541 listed as in stock. I bought one a couple of years ago. It is the original M20 part with a small diameter hole for the spindle. I drilled out the hole and had it replated. The actual A65 part with the larger hole is 68-6102
1 member likes this
by Gary E
Gary E
Glad you revived the thread.

No dogleg, nor right angle bends. Bent in the middle, then more at each end. But each ends bend is different. I've always found I have to tweek the bends a little to make both left and right sides fit correctly. Typical BSA. They both have the same part number.

[Linked Image]
1 member likes this
by ljm
ljm
Lookin good Gary!!!

ljm
1 member likes this
by Gary E
Gary E
It's coming along nicely.

[Linked Image from i.postimg.cc]

[Linked Image from i.postimg.cc]
1 member likes this
by C.B.S
C.B.S
fantastic work
1 member likes this
by quinten
quinten
nice set of ET coils you have there .
1 member likes this
by Gary E
Gary E
Picked up the Cyclone tank and side covers from my painter today.

[Linked Image from i.postimg.cc]

[Linked Image from i.postimg.cc]
1 member likes this
by Gary E
Gary E
Bringing a '65 Spitfire Hornet tank back from the dead.

AS RESCUED
[Linked Image from i.postimg.cc]

Multiple layers of paint stripped down to the original gelcoat. Gelcoat heavily deteriorated.
[Linked Image from i.postimg.cc]

Prior attempts to seal the tank.
[Linked Image from i.postimg.cc]

Lots of tank rot.
[Linked Image from i.postimg.cc]

All deterioration and damage repaired and filled.
[Linked Image from i.postimg.cc]

All previous attempts at sealing removed, seams and tank rot repaired and filled.
[Linked Image from i.postimg.cc]
1 member likes this
by Gary E
Gary E
Before and after first batch of parts back from the powder coat shop for '65 Spitfire Hornet restoration. I prep them before I deliver them to the powder coater. Time to start assembly.

[Linked Image from i.postimg.cc]

[Linked Image from i.postimg.cc]
1 member likes this
by Gordon Gray
Gordon Gray
We've had disagreements.........but you really are an artist at this and I'm sure this will turn out just as stunning as your other work.

Gordon
1 member likes this
by Gary E
Gary E
Originally Posted by Gordon Gray
Gary.......I probably just missed it but how in the world do you get that BEFORE look? Vapor or some type of media blasting? I have a soda/media set up but mine wouldn't get those bits looking THAT good.

Gordon
I utilize 80 grit glass bead blasting medium in the blast cabinet. It works well, but some parts like the brake drums where the original black paint has been baked on can be very stubborn and slow to remove. I use it to clean aluminum parts before the polishing process, and also to clean and remove paint from fiberglass parts. If the blast gun is not held in one place it works fine on gel coated parts. Epoxy paints are stubborn to remove, as are powder coated parts.
1 member likes this
by Gary E
Gary E
Originally Posted by Allan G
I find methylenechloride based paint stripper removed powder coat even quicker than it does "normal" (wet) paint. its otherwise a pain to remove.

I had some new harris (powder coated) foot pegs, I started off using the powder as a base for the dove grey and primer but it didn't like the etch prime much, so removed it with the m.c. stripper and it came off almost in one piece.
I usually burn the powder coat with the ac torch, then it comes off in the blast cabinet.
1 member likes this
by Ian Ashdown
Ian Ashdown
Sharp looking!

Ian
SoCal
1 member likes this
by Gary E
Gary E
'65 Spitfire Hornet is coming along nicely.

[Linked Image from i.postimg.cc]
1 member likes this
by konon
konon
Tank looks new already.
1 member likes this
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