Take two

The hunt for parts for the Matchless girder fork has NOT been successful. Now I have found another lost cause instead.

Monark circa 1929 about 250 - 350cc. As rusty as the Douglas frame, if not worse.

There are some parts missing from the front forks (fastener for the handle bar) but nothing crucial that can not be replaced or made.

I did not get the correct petrol tank, that might be a problem. Now I am waiting for the Husqvarna oil tank I bought. Almost the same model as the ones used for the old Monarks. Hope it fits.

Excavation

Got these parts from an excavation. They had been burried in the ground for many years. Maybe too bad condition for use with the JAP 600sv.

Think it's from an early 1930s Harley-Davidsson.

After some light grinding with a wire wheel.

Parts needed or could be used for parts?

Girder Parts

For some time I have been planning for making the missing parts for the Girder Fork. First information I got from a "specialist" was that my fork is home made by some local black smith.

This I have believed for years but now I found an identical on some 1920:s Matchless motorcycles.

Searching the internet I also found a Parts List front fork.

I think I will have to make my own version of the upper yoke and linkage. With or without dampening.

Databook

Would have preferred an older original version of The Book of the JAP but opted for a newer cheaper version.

And if one want, there is (not so good) scanned version that can be downloaded from the internet at https://motos-of-war.ru/wp-content/uploads/2016/05/The-Book-of-the-JAP-Engine.pdf

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.

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.