Albion BJ

Adjusted and simplified the scanned pages I found to only contain the BJ two-speed gearbox.

Notes.

- A5 Ball Bearing(s): 47x20x14 is equal to bearing number 6204 (originally SKF England)

- A35 & A36 Felt Washer & Retainer could be replaced by Honda oil seal xxxxx-xxx-xxx

- Use chain 415H

- Gearbox Ratios: 1st = 0,6 and 2nd =1

Zinc soldering

Since I have gathered a lot of Albion BJ gearboxes in various stage of decay. I decide to try to repair and fix a couple of them.

There seems to be two main trouble areas:

1. The Gear Box Case on the final drive sprocket side, damaged by chan wear.
    Need welding and machining.

2. Broken Gear Box Cover where the clutch cable adjuster is mounted.
    Can be fixed at home without any special tools.


The gear box cover can be repaired by making a mold from stainless metal sheet and soldering / casting with shavings from an zinc sacrificial anode.

First make a mold. Cut some zinc shavings an make a scraper from stainless welding wire.

Solder with a propane gas torch and zinc. 

Break the oxide layer on the gearbox cover with the scraper.

File to desired form.

 Drill and thread for Clutch Cable Adjuster.

As good as new and probably stronger.

Albion BJ & Clutch reference

Gearbox

Visited a swap meet today. My intention was to buy a Sturmey Archer 3-speed gearbox. For some reason I bought one Albion 3-speed and three Albion 2-speed gearboxes.

I maybe could use the 3-speed for the Baby Nut but why did I buy the 2-speed gearboxes. And I do not think I can get one working 2-speed out of the three of them.