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.

Scrap

One Man's Junk is Another Man's Treasure.

Last weekend I managed to come by a box of parts that I hope can be used for the engine rebuild.

The camshaft and lifters are not in mint condition bout should be usable. At least in a much better condition than the ones I've got.

Framed

The other day I found a frame that, with some modifications, maybe could be used for the 350cc.

A rusty old Douglas EW 350cc frame and a HVA wheel with clincher rim.

Since it was made for a boxer engine there is no belly, the lover frame tube will have to be replaced with a new one. The clearence is 33cm but the JAP engine need at least 44cm to fit

Made a rust solvent from Acetone and ATF oil. Hopefully the steering stem is still usable. 

The handle bar is no longer seized but the steering stem is...

More books

Time to revive this project. Bought one more book for inspiration.

New One

The Project is not completely dead. There are just many other ongoing projects...

I am always looking for parts, and the other day I bougt yet another oil pump. Not that I need one, just because is new and shiny.

Albion BJ & Clutch reference

Carb & Wheel

The other day I bought another restauration project. An Amal 276 / 011F carb, almost complete. According to the buyer from a BSA. According to interner and other experts also used by Norton 16h

Today I bought yet another wheel

Now I really need a frame.