A65 Lightning project......

[Bess]

Hi Editor,
             I managed to fit the cover by using slotted bolts, admittedly not easy. I have some spare if needed

Best wishes...

[geraldhattrick75]

Sprocket cover is in place.

I'll fit the gear change and kickstart levers in place and make sure I leave the rear mounting brackets loosely in place (as you say).

Thanks for putting me straight on the installation- much appreciated.....

Photos are about due......


I know I keep saying it but honestly folks... a huge THANKS.

[Bess]

Hi Dave,
             An update on manufacturing stays.

  I just made some stainless, thinner diameter front stays up for a A65 build. I made the ends first, a diameter bigger and sliver soldered them in place. This gave more character than an all in one plus it gave me the plenty of scope to get the length and alignment right.

Best wishes...

[geraldhattrick75]

Wow Bess, they look superb.....

What sizes and wall thickness tube did you use?

And how did you make the jig?

I've got a proper vice now:  https://www.ebay.co.uk/itm/Record-No-6-vice-Heavy-Duty-Engineer-Vice-Jaws-are-6-wide-and-open-a-full-8/303611637996?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649
- which I reckon ought to have the 'squishing power'... (Oh and it cost £60.00- not £35.00  (oh, and I got the money back off the one that broke)

The mates are coming round tomorrow- so it's 'engine in the frame day'........ and a week for our aged backs to recover.......

Thanks again for the info.

Regards,
Dave.

[Bess]

Hi Dave,
             The tubes are 1mm wall thickness of 8 and 10mm OD.

The jig is two lumps of mild steel put together in the vice. Drilled a 13mm blind hole and then using a power file shaped the bottom to a acceptable profile as shown. All sorted in a hour or so.

Best wishes...

[geraldhattrick75]

Wow bess, you work a lot faster than me, it'd have taken me a day or two...... (Mind, the first day would be spent finding all the bits of material...)

Well, the three man biker gang set into fitting 'the lump' into the frame on Friday... What a game though.  Tilting the engine forward with the rear plates in place proved a nightmare, and we had to remove one of the plates in order to get the, 2nd bolt from bottom of the plate. (and even then we had to substitute it for a stud- 'cos the gap for getting it in was so minimal)


Any road up- the engine is now firmly bolted in..... Which pleases me immensely.


Next question, if I may - do I need a clutch abutment when fitting the clutch cable to the clutch lever (timing cover) https://www.ebay.co.uk/itm/Clutch-Cable-Abutment-BSA-A50-A65-1962-69/323671707851?hash=item4b5c5650cb:g:ZY0AAOSwWrxcUH1M

Thanks again.....

[Nanonevol]

It's a 1965, correct?  Clutch parts at the cover look like this:

[geraldhattrick75]

Dunno about the spring thingie on the right of the picture Nano...
My cable just slots into the end of the clutch lever (timing side case)

Technically my bike is a 65 but the factory fiddled about with it for 4 years or so, so it's hard to know what modifications they may have done......

Thanks for the picture though..... (You may have just shown me another list of things I need to throw my money at...)

Best regards,
Dave.

[geraldhattrick75]

OK, i've made a clutch cable and fitted it as shown in the picture. It doesn't look particularly prone to slipping out of the clutch lever- but what do I know. (my way of saying "if I've got it wrong don't hesitate to let me know...please")

I'm also trying to fit the kick start spring and retaining washer, and not doing too well.... (no problem if I had a third hand to stop the spring riding up onto the flatted shaft - thus preventing the flatted washer fitting into position...)

Is there a technique to this please?

Finally, am I correct in assuming that there is no gasket for the outer case cover (timing side)?

Many thanks,
Dave.

[geraldhattrick75]

Wahoo, I've sorted the kick start spring..... (took the bike outside and put it on the side stand.... Access. I just needed better access to see what I was doing)

[Nanonevol]

Good job!  That can be a tough one.
I see you're not using that odd looking piece with the spring on your clutch cable.  I think it is partly to make it easier to change the cable when the engine is all assembled.
If what you got works for you, fine, but my photo shows the stock parts.

[geraldhattrick75]

Thanks N... I'll definitely keep my eyes on it.....

[Bess]

Hi,
    I too have had issues fitting the kickstart return spring so made a tool as the images and drilled 2 holes in the kickstart plate. That solved the issue for me.

Best wishes...

[geraldhattrick75]

That's ingenious Bess....

[geraldhattrick75]

Well I made the mudguard stays and they look, er..... adequate. (nothing like as good as yours Bess..... But they ought to do the job ok ( 12mm stainless with 1mm walls))

I've screwed the timing side outer cover on.... after grinding the 3 alan screws to the appropriate length. (Primary side tomorrow.)


My next problem is the rear brake spring- which binds up when I tighten the nut.

Wheel out over the weekend to investigate.