A wee Matchless project

[Rannsachair]

They all looked like latter (post WW2) BSA variants.

I do like the Balloon tyred S7 like @Shox Dr has too.

 

[Shox Dr]

On a total tangent, a load of Sunbeams came through Belper yesterday sounding lovely, unfortunately no photos. Did make me thin of buying an old British bike to play with.

It was the main rally of the year I believe. I was invited, but Ive been full of snot for the last week
Picture of mine to swoon over


currently in bits

@Rannsachair. I wish I had too (sic) I might have a running one

 

[Rannsachair]

A little more slow progress:

Clutch/chaincase rebuilt, footrests fitted, rear brake arm and started fitting wiring harness:

Realised exhaust mounting sleeve bolt was the wrong size as would not clear the footrest. also jammed on the stud. So turned the nut down until it peeled off the stud and fitted a longer one, also polished up the exhaust and fitted a few more parts:

Repainted the timing cover red M, will clean it up when paint dries.

 

[Rannsachair]

Speedo packed up on my 54 Matchless, so sent off for a recon.

and back:

Was working in the shed and decided I would tidy the wiring and a few other jobs.

I have another headlamp and fork shrouds to fit, so wheeled into the workshop today:

will tidy wiring and solder on bullet connectors while at it.


Forks have suffered from last few winters, so getting a rebuild too:

Came apart fairly easily:

Stainless fork seal holders and painted headlamp etc on the bench:

Fork stanchions proving a challenge to free off, so left them after a good spray with release oil:

Been mainly working on Landy, vans and cars recently, therapeutic getting out to the old bikes.

 

[Robotstar5]

I'd get rid of the scotchlock connectors in the headlamp shell, they are usually a source of future problems.

 

[Rannsachair]

I'd get rid of the scotchlock connectors in the headlamp shell, they are usually a source of future problems.

Absolutely, they were in the bin last night.

 

[Rannsachair]

Forks now dismantled, needed to drop the lower yoke to access the rusty stanchion, so out with the big Whitworth spanners.

can see the problem:

Wire brush then penetrating oil:

There was plenty oil in them and it was clean.

Why folk don't grease the fork stanchions prior to assembly!

Bike looking a bit sorry for itself for now:

 

[dobbslc]

Wow!
I'm surprised they didn't go down and stay down when riding.

 

[Rannsachair]

Wow!
I'm surprised they didn't go down and stay down when riding.

The springs are external to the stanchion and removed so sitting at the end of the stroke, its the part from above the seal travel up that is rusty. So hopefully they can be reused.

 

[RWD3M]

Bike looking a bit sorry for itself for now:

Yes, but it's in good hands!

 

[Seadog]

Forks now dismantled, needed to drop the lower yoke to access the rusty stanchion, so out with the big Whitworth spanners.
View attachment 483359


can see the problem:
View attachment 483360
Wire brush then penetrating oil:
View attachment 483361
There was plenty oil in them and it was clean.

Why folk don't grease the fork stanchions prior to assembly!

Bike looking a bit sorry for itself for now:
View attachment 483362

Greasing the hidden sections was something that i always did.

 

[Rannsachair]

Greasing the hidden sections was something that i always did.

Me too

 

[Rannsachair]

After a few jobs on the Landrover, a long running chest infection and a new kitten, finally back to the Matchless.

Yokes refitted, ball races cleaned and well greased:

There is a knack to stripping the stanchions from the sliders as the nylon bushes swell, so judicial application of heat and it comes apart with some momentum of the slider, using it like a slide hammer

Workshop is a Bùrach!

Fork oil was the viscosity of grease in one leg, both had water traces in them. No surprise at condition of stachions

So cleaning parts, buffing the alloy fork legs of salt corrosion and deciding on new stanchions or hard chroming.

 

[redlig]

As someone who is forever dropping bits on the floor ,never to be seen again, I love the idea of working at floor level at least nothing can bounce and get lost.

 

[Rannsachair]

Between weeks with a chest infection (3rd week of different antibiotics just completed) and servicing 2 outboards for my brother, one outboard had rusted transom screws that needed a few goes with the induction heater to free, The other (Suzuki DF4) had been put away a few years ago and the fuel left in to evaporate . The mess it made: strip out fuel tank and clean, find fuel pump jammed with aluminium corrosion (new one ordered) and even the steel inside the fuel cap had rotted, so new one ordered plus strip and clean carb, fuel tap and replace fuel lines, then finally back to the forks:

Buffed up the sliders of road salt corrosion:

rebuilt the dampers with new rods as threads were damaged:

new stanchions, bushes, seals and rubbers all ready:

the new seals are longer and the bushes shorter to match, also nylon replaced with bronze:

cross drillings in new English made stanchions need deburred:

Hopefully will get rebuilt fully by the weekend.

 

[RWD3M]

They've come up really nice, good work sir!

 

[redlig]

Seeing those fork bottoms reminded me of when I replaced the Fontana front brake fer a Norvil set up in my classic bike it was supplied with an oversized top bush in the new fork leg causing an abnormal amount of freeplay . As I was due to ride at Mallory the next day I decided to put up with it and see. i discovered that it locked the suspension as soon as I braked hard for the hairpin but but it was OK for the rest of the lap. Basically acting as a crude antidive. Has 3 wins that weekend so never bothered to replace the bush. Was still like it 3 years later when I gave up racing . Just told everyone it was a secret development from the early Norvil days.

 

[Rannsachair]

The other end of the stanchion was worse with swarf:

so a little filing and deburring.
Next found the new damper rod bolts were 60 thou too large:

So onto the lathe:

and perfect fit:

So finally got the forks assembled with new stainless oil seal retainers.:

then on with all the rubbers, leather washers and springs then assemble to the bike:

Also dragged the R75 out from the back of the shed, its due a service, though is running well.

I am out tomorrow night, so will get back to it on Saturday.

 

[redlig]

The other end of the stanchion was worse with swarf:
View attachment 493630
View attachment 493631
so a little filing and deburring.
Next found the new damper rod bolts were 60 thou too large:
View attachment 493633

So onto the lathe:
View attachment 493634
and perfect fit:
View attachment 493635
So finally got the forks assembled with new stainless oil seal retainers.:
View attachment 493636
then on with all the rubbers, leather washers and springs then assemble to the bike:
View attachment 493637
Also dragged the R75 out from the back of the shed, its due a service, though is running well.
View attachment 493638

I am out tomorrow night, so will get back to it on Saturday.

So who was this P.P.P. "Purveyor of Perfect Parts " or could they be called "**** Poor Presales Preparation. " ?

 

[Rannsachair]

So who was this P.P.P. "Purveyor of Perfect Parts " or could they be called "**** Poor Presales Preparation. " ?

RGM Norton Ltd., I emailed them pictures to check their stock.