BSA Thunderbolt build, its going to be a while

[Thunderdome74]

Fantastic, thank you so much. I feel better about it now.

[Thunderdome74]

Only a little done, testfitting

[Gup holland]

Nice job, I've have also replacement speedometer. No smiths. The are slightly higher than the originals. I managed to make these in rubbers , so it looks like original.
There is a trick to it, you have to cut the bottom out of the rubbers. Fake speedo's in original rubbers

Succes with your bike, looks good.

Gr alex

[Thunderdome74]

Nice! I toyed around with getting another rubber surround but the bike only came with one in ratty condition..so would need two... plus springing for replica clocks... And mounting plate ..,just put it outta reach, but it's a neverending story and I might one-day get a clock base...then back to original

[Thunderdome74]

Ok , got some time, but now stuck, I put the front for together (see numbers , assembly order from ground up) but for the life of me the bushes (brass) are now getting firmly stuck in the lower for legs.... when taking apart i did have to hit the bushes quite hard to get em off the chrome stanchion, so i am busy filing down any high spots...


But even getting bush one (bottom of fork No 4 ) further into the lower fork leg it's being quite difficult... (No 7 would be the fork screw on chrome oring and forkseal holder , and fork seal, not pictured)

Am i missing any tips or tricks

Also when i dissasembled i have a spare felt washer about 4mm.. thick and a ally washer areound 1mm thick, do these go at the top of the spring (in the fork ears)... as i cannot place them on the schematic

Any help is greatly appreciated

Got some rubber on


And badges

[Gup holland]

Few years back when I renewed the forks with new bushes I had same problem. In my case where the bracket for the mudguards are welded on the lower fork, they were a bit disformed.
With a fine file and a bit of sandpaper I cured the problem.

Never put a lower leg in a vice, only on the bottom end with one side flat.

Gr alex

[Thunderdome74]

Thanks Gup!

Yeah, only read about the vice and lower leg After i had already dissasembled them...but spent the day (got time due to writers strike) sanding dnw any high spots then fitting and refitting until i beleieve they will be ok

A confusing thing is the fork seal , which sits in the chrome stanchion surround(screws into lower leg). Is there nothing actually keeping it in place other than various assorted washers?

[Gup holland]

Your right, normally it's pressed in the cover. I think the covers are a bite to wide. ( new ones).
Over it comes the washer and then the outer spring.
I pressed with a pliers a small flat surface on diverent sides so that it can't come out easily. Bit expanding.

Don't forget the o-ring in the cover above the thread to keep the oil in the leg.

Succes, gup.

Ps the thin end has to go up of the nylon bush.

[Thunderdome74]

Thanks mate! I think i got it right(lets hope). Forks are on! Rear wheel is on! Pics to follow tommorrow

[Thunderdome74]

Ok, then, rear wheel went fine, front not so much in  that my painter took apart the bearings and left em in a bag, I have bought new bearing, but i dont actually know what the bearing cup/Seal looks like, i have these two amongst my bits, but they are the same diameter as the bearings, do they get packed with grease?
Ny help as i'm kinda stuck in findign out what the washers are supposed to look like?(the ones to the right and left of the red arrows, (couldnt find a great schematic



This is what i have


Second row (i have a new reverse thread bush already made up)  Spacer 1 and spacer 02(flat washer)
Third row: cupped spacer 01 and cupped spacer 02 (different inner diameters...)

any help with this will be really appreciated

[Thunderdome74]

Ok, got it sorted. Cross referenced the pics with dragonfly..very useful

[Allan G]

Your exploded diagram is of a pre 68 bike. (Though 68 single carb models had this type of drum).

I wouldn't put all your faith in DraganFly if they have the online schematic wrong, get yourself a factory WSM and Parts book. It will help a lot.

[Thunderdome74]

Will do, i hvae been crossreferencing with the haynes and parts book

  managed to get the wheels on

[Gup holland]

That's gone be a Beauty , I think.

Good luck , gr alex

[Thunderdome74]

OK, been going slowly, had a few problems with the headers being too short and the angle of the balancer being wrong, so getting em modified... also been dividing the time between the A65 and a A10 that followed me home ,
and  more polishing , which is ending up tougher that usual, as i normally spray some Duplicolor mag wheel clear over the polished ally , but i seems to still be corroding, which tells me its not polished properly




The A10 I've been re-doing (will post a thread on its build )



Where i'm headed on the A65