Pieces

According to an expert, the frame is from a Monark 1929 350sv. 

As it happens I have a sutable engine (should have been a Blackburn), a JAP 350sv from 1929, featured in another post in this blog. I also have got a 1929-ish Albion 3 speed gearbox (should have been a Burman) that also fits the frame.

Featured in the picture is a Husqvarna 250 1929 oil tank. Got it cheap, did not know why, not before I started looking for an oil cap.  Had to buy a new replica oil cap and thar was not that cheap.

Rear wheel has now got a NOS Trelleborg Trial tire.

The seat is a rear seat from an unknown bike. But in wery good condition and from the same manufacturer that made seats for Monark, Husqvarna, Rex an other Swedish motorcycles at the time.

Slow but steady progress, not.

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.

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.

Wheels

Bought me a couple of wheels today.

I believ the rusty one to the right to be an old motorcycle wheel and the new one to the left might be a small wagon or cart wheel or similar.

Maybe I'll change the hub on the new eheel to brake hub for a rear wheel.

Cam Timing

According to the interweb

Model(s)	IN open	IN close	EX open	EX close	Ign.Adv.
	BTDC	ABDC	BBDC	ATDC	BTDC
175, 250, 350 sv	15°	50°	50°	20°	40°
500, 600 sv	16°	65°	65°	25°	40°
1100 sv	16°	65°	65°	25°	38°

Reference

 

Guess what

About a month ago I bought me another SEM magneto that is not working,
It is missing the pick-up coil and spring, along with the ignition lead.
Hopefully there is a spark when I get the missing parts. No big hopes though.

SEM stands for AB Svenska ElektroMagneter Åmål, an existing company. Theay are not the least interested in answering any questons about the old magnets. Either that or their contact email address is not working.

Getting closer

Bought some 1/2" stainless axles, thread taps and dies from the interweb. Most everything went sour. Managed to buy 304 instead of 303 material for the axles. Tried to save some money and bought cheep BSCY thread dies that probably are made in India and worthless. (my lathe is missing the low gear that would allow me to make threads)

Anyway, have made axles that are almost ready. Missing only lubrication grooves and hexagon in one end, for adjustment (3/8" spanner). 

Also:
Bought an expensive extra long 4mm bore for the axle center hole for lubrication. Managed to get "unlucky when thinking" and burned the bore at once. After re-thinking and re-sharpening of the bore I managed to drill the 105mm deep holes in the center of the axles. (only 85mm deep in the longer axles).

Girder

Started looking closer att the girder fork i bought. There are some parts missing, the top yoke and the steering stem column/axle,

I have not found any pictures of the same forg model, for reference, on the internet or in any books I've got. Have asked a couple of "experts" but the only ansver I have got is: -"looks like it´s made by som Swedish blacksmith". That does not help me mch.

The data I really would want is the lenght ocf the top linkage arms and if possible the steeering axis angle. As it is, I probably will make the upper linkage lenght somewhat shorter than the lover ones, to make the fork parallel to the steering stem. Or maybe I will simulate the action in some computer progarm.

Anyway. The axles are not good, besides I'm missing one axle, the other tree all have some issues.

To the left. The original 3/8 BSC thread has been re-threaded to UNC
The one middle is the least bad one. The 3/8 thread cleaned out pretty well.
The one to the right, see below.

The axle is very worn and the 3/8 BSC thread in a bad state.

Thougt I should give the thread a try just for the fun of it and it turrned out pretty good. That does not matter since the axle is bad anyway. And since it is the same model as the missing axle, I think it's not much more work to make two of them at the same time. Now I have to find me some 1/2 inch axle to start from.

The lubrication slit will be a challange since I have no milling machine. Migt replace it with a bushing instead.

 

Magneto

In my quest for sparks I have started piling up useful things. Junk might be a better word.

Todays visit to a swapmeet got me a SEM magneto and a brand new 18mm Lodge spark plug that might be useful for the 350cc engine.

Yesterdays swapmeet got me a brand new ignition coil, that might fit the Wico magneto that came with the 600cc engine.

The used coil at the bottom..

At last weeks swapmeet I got me a pile of used and new spark plugs for both engines.