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Royal Enfield Bullet 612cc project

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pepperami
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Joined: 17 Jan 2010
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PostPosted: 09:36 - 06 Aug 2018    Post subject: Reply with quote

Very impressed.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 18:09 - 07 Aug 2018    Post subject: Reply with quote

Pegs/stand update. SImple really, just needed some spacers. I copied the right one off my 350 bullet then had to make the LHS one to fit with the stand.

https://lh3.googleusercontent.com/TRf_-M-iuexB_PX37jIEoFBz8XVoNc50ijSXByzr_GQNO31Nr2CpyHDZL2j6DApA128gdQGwqqFAQeFaO4F0kDPRDSK4HfbHSeQA9-biOTYsYfdwg_CpVy8zpAJ3p06Tr8rZkF3fug=w657-h876-no

https://lh3.googleusercontent.com/0sJLmEnE1niumKAAYcAfV6xmcZZM-4LiEufU7urwOx2FdiyiXKY08SU-XAXEcUESR4zVXSB46X_NByQjG0I51nrUw0cPktuF9Ifa7dA7CDidw4d96TeMFKKjrSbJoxThpIKw-L8o_A=w1168-h876-no

The choke cable was annoying the crap out of me. Cable adjuster right where I don't want it (topmost cable) blocking the hole in the nacelle. It's also entirely unecessary, there is an adjuster on the top of the carb.

https://lh3.googleusercontent.com/EZsFf9MuxZ7Qzx9IVqE4nKBNogwxGijhfTKpH4FRX7iBo579BM215LYbKicY7JQpLFztR8DtkRe8nliVt2nawBoHlyMl-pWdevldxoMb4QkptezcqL2tFKCJlVtGX4xLPVkK3-UG_w=w1168-h876-no

So I made a new one with no adjuster and of a thinner grade cable, the stuff supplied would work a brake, never mind lift a choke slide.

https://lh3.googleusercontent.com/KOkLs86EOSI3GujpaDKm1ly9VSNzeHS9hREWl7jdkBkdImA2PUNnVynkn9rGeVG2wmeut0K9v73co23uZCjN-KBNiiE7hWW7TIZyOWHkSFKXwAuiXC_X2_to-FAY-oc1WtYXcyIgWg=w1168-h876-no

My nipple soldering is improving.

https://lh3.googleusercontent.com/JRfJHUOwl6ScK2TBs7YDcesmSQgqgdmAKDq0UT9boVF8pgsQWBZc7JPLoK-rp6PAfPZb1zq-dscE1LrmfiHyzwvXBZ17RkY98L2enoULlTlB1dZEWS2bWbRGYMIQ4KJDoaU9pLhvRA=w1168-h876-no

So. Electrics. I started by sawing off the forward facing metal "spout" on one side of the tea caddy and replacing it with a 40mm stuffing gland. Th eother spout faces down and inwards so shouldn't get any serious water in.

https://lh3.googleusercontent.com/YRqr37wfIOqyTe8Kl4NGiBIXxtc9_WXcOLIO3Tv4jxQTQf6h2DxL0Uyu2mQrHM3BriYWdeCfdDwH7kmJzMQ8YtLZDQScIMgaBatj-mNa7A9xJm3rLbzPA97CyLu-ZplxD_FR8E1Bmw=w1168-h876-no

Automatic wire strippers really speed this job up. I'm using non insulated crimps so the correct crimping die is essential.

https://lh3.googleusercontent.com/LPadKNiRRP0gUz_n4IF9tcuBRGYB3eXcUubKxXKcFX8IG9yZm58uheTuP_DvbV0Z9jHvfHP88GQqQv2hbBCD3-v3xc03UF0DngfUNUtnihgfubplh7iAaf_JSg-3hJ8bcGBi4_LGTA=w1168-h876-no

To prevent corrosion, I'll be applying this dielectric silicone grease to pretty much everything.

https://lh3.googleusercontent.com/BZN_ahfABi6m4s_vLPCp6YvttW0PnsKdpxpuLG1icySuQFJXS8uTzAzFlkmjcqBh74opHmTsZAvSvb1QnGh3W-VeCThgje1G6HSr1-1OoOCigCBGYoYKjXboNTPjPRkHMBIlcNJQCw=w1168-h876-no

Here's what most of my connections will look like when complete. (ignore the ones inthe background, they were from my lash-up loom)

https://lh3.googleusercontent.com/6l45Uufwd1QU1kjSMr9Znaw-f1VHoz_8O_PVhYrRJsKwM5iaX9HFZADnL82N2KHCaZJdN8R4LqyotjnetuiuloffKsFs0lWo3oU2iCV_6-MMXKFHHKxz0YQsDLv5VOCNn-gJkZoJOA=w1168-h876-no

Main earth point. I'm doing earths seperately to the rest of the loom. They will all loop to at least one earth point AND to one another, effectively making redundant connections.

https://lh3.googleusercontent.com/8y-sGSaTbE6mIj0G-n9swGhriwu9hroJcCWcptpZh-sRrAeFrk-9bmRFdBKYdisejRJxDgavnKKRZMevonYdfu3Vyp4WfXv9UV5gePrzxEqDPm6EzTYymlVSNV_7yM4oGZ_EaY3m5A=w1168-h876-no

The big earth rings only have one crimp point so I've soldered them and aplied silicone insulation tube.

https://lh3.googleusercontent.com/9crUts03Rc4yFRtfddEuzIkJWbaKooPUoCxVbFf7bfxU2F5g3C38uhkvgBP7BdXRZ7ZkUB29UTYWY-O68inOfywbVzA9CXX8XjshyIfs52_wUlM2UPklKKASG0ivRTrsFcwUQlz_sw=w1168-h876-no

https://lh3.googleusercontent.com/QHAP3onqHybOjhbUPwD8hNjU0Wjj_FqWays3pABmwhAs3gojcpNHyLBbkHQRONrkzgFUpdOSIElajcXnmCUnq65y0Mdh6cIPN_-Yk9O-ntvZExnKzmQYPHiBLX8CksJEEM6TW3dfaw=w1168-h876-no

The smaller ones are brass and have two crimps as normal.

https://lh3.googleusercontent.com/6rajAJX3qJmUCnAZvu8zdt4-7sSRsfXCKG4XotDNOkDoa7P-UvSB-n1AKwzMfdgIcfo3KVoxHVBBMjE0kdWBn_DaLgkmqd9GeyMeYoi5czW5XwA0VihNA0SJzDQPA5MnEQPBluG5cw=w1168-h876-no

reg/rec needs to be out in the breeze.

https://lh3.googleusercontent.com/GwcNrp-sLuEtBUDT09sFlS--kSk8iRr2EeMSoOJH11aiwMt2fnqApouPOllwLxgkAKg5p0XPu-JMyc1gx56IxmaGuWAZX8bQvxq1Wv2HiBx58GJ9t1aU1OJBHLGv1_-1VdEDLqyN5g=w1168-h876-no

I'm using multicore for the main loom. 8 core for the front loom, 5 core for the rear loom. As such, the wire colours are determined by what I get supplied. I did myself a list and have tried to carry the same colour through both looms (the white is unswitched live for the front one because it's the thickest wire and earth for the rear one for the same reason, they will carry most load).

https://lh3.googleusercontent.com/U1uBBhOmwQXwYTBwruE7Ihiv5Dnw1E-u5I2gTv09g7bvxwJymAixncJrq6jR-RJBUKgtp8kDJCwJrZwRnzVZwIhQO_u2o8uLQjClUz9j9xLTtCfyntFXqN4UZaws-Qge_WCvoiw5Hw=w1168-h876-no

https://lh3.googleusercontent.com/lv1HOfrA2pIDbHw-huhvRYwsid_AK2a7HqEEL7DSnTn57VU-E_3DsjJlpC1HGxYbmvDo-Wo_DNGEd4QwyMNifBPG2HoceFMhe9KXdiqS-9mKREha4cECqW-dPZ9l2daIMxrr3-j--w=w657-h876-no

Earths inside headlamp casquette, double bullet terminals connected to rings, the bottom ring loops back to the main frame earth effectively earthing the front end properly too.

https://lh3.googleusercontent.com/TLCFE3DE64984rXhSTaYUiZq5zQez0CK4Zwa7NpTIjPjDx59zad9leihJv2TiGM112vgewWOl1BUzetWJb4BSdaNWNaOzrTdoYs44CNT9_uT-B9iPMmoHDyzsZdcdNXyfxlilM9U-w=w1168-h876-no

Oh, another type of cable joint. A butt splice crimp. Crimp then shrinkwrap. Here it's bringing three earths together. You can also see the electronic flasher relay which will be hidden inside the tea-caddy. There is a bit of wire with PVC tape on there. It's just holding the two wires together, there is nothing under it, it's the wires that will connect to the battery.

https://lh3.googleusercontent.com/muhq7eWi8ek2iQoaoCSjgy5Q2tjhEyvxjCWgtUy7teiM4x4J5y9UUzf0GjWmbj309Q4Lpa7n-jdBycoONYO4GCnYAzvwA8MYAjTHJBwi_eNWg4TTm7cfTcifLR8wKe13z995cSLlzw=w1168-h876-no

https://lh3.googleusercontent.com/Kxf1TNFo7rJHZ6Uv99TX0M7gZdUuoropBl1EQcVQw2Digch1qOsXfqoQvZQBB1UkncZXOboI3qXesTJj-NqgVMr6ULFw0t-IXhX4YPAiLr5jqhaCZyZAt8-Zl6gUWoPiZQOl5TS7eQ=w1168-h876-no

This is the lot. All the wiring for the dash lights, headlights, ignition, flashers and indicators in place.

https://lh3.googleusercontent.com/dA5OtzVOtlKBFg0kiEhU3a2jDCFtN-VXQY7X6vZYGPH5F2IfldfTZ-SFEM_Wch6kMe670VVC3ZOHKdS2tIer3cSm-8jmPJ101MDglw7TfW6Iy1Kz8Gxv-Aeo-eXH3-NbNSl7wnng8Q=w1168-h876-no

The LED headlamp has a seperate electronics pack (to keep the bulb itself compact and cool).

https://lh3.googleusercontent.com/Z3iAHWKJwxJFwCmqWnI4-ryTVS8AVmbZqL4IWhJluURxdEAOgSL8pPPT19_xx3qijviVkExfJPZ6TApOdsutVEonAO6_49i0bSOJK_u0RY0GVTi3hVu5ZMoGB6P5VFW9j-iE0yDxeA=w1168-h876-no

Plug 'n play.

https://lh3.googleusercontent.com/SXPxYJEgHVuYfyg1uKubkHWNP9M9a31xVp-bkUv0VwlXeRGR8JUnwAYpMCvwjRr9opQK84sAn_iEZ9tXjIj2x6RgiRoavGxpVB4tu957d-DyV1SWp65eeV9g6Jq-8J9uGA7XMPwh1g=w1168-h876-no

Donk. headlight on.

https://lh3.googleusercontent.com/jUYaDrNQyETjDNlSolpqFpDiYwnJNLGI_XQYOE8p-CkNd1rMDv7EJ4WmgTbGq3PF7f8op24fnc-sLAKPn2zGyMxQzQIruiWKEnxpzMVoQVulSgvKvGb9S454LL2cV1tHjpzrtgnrQw=w1168-h876-no

Some details. I didn't have enough thickness of wire to be clamped by the stuffing gland so i wound some loom tape round it for now. There's the alternator cable coming in, main loom going out and the orange wire is the live supply to the ignition coil (keeps the ignition seperate from the lighting).

https://lh3.googleusercontent.com/dzjXt0rCDQ_EBvHA5sXUFO9W4ki20S2X9-b0zQWFUsA6com5Ga56C8x3XJi3-z_L24bXkKQdrSgj_gfrWHIAuDc2doM7oEA9zmJNQaersuUrNnDGaDEWP3prIAauYslI7eiTg2G-xQ=w1168-h876-no

Hydraulic brake light switch.

https://lh3.googleusercontent.com/W8wHZJkvxa0tHzlLMDJvxvM8lmCmjg_5zSn3D1p0RP-EcyrV74mXaBYXew3dXUxhpvllOVqUs8lQ11wLmGyVkEYb8If4NFsyoEfQkMqsHYewffiGUqdkcfDGqnjJC99yS8XPFX6Iwg=w1168-h876-no

This all worked first go with the exception of the position lamp which had unplugged itself.

A few cock-ups due to user error. I ordered blue sidelight bulbs by mistake (I read it a blue-white but they are blue), mis-ordered the speedo backlight size and the flashers turned out to be more oddball than I thought. As well as an offset bayonet, they also have a low profile globe so the LEDs I bought don't fit.

If anyone wants to buy 4, high-end BAU15S LED bulbs, let me know.

Still need to fit the rear sub-loom and lights but a quick measure shows the lighting drawing around 20W with the headlamp on full beam. Total output is 65W so I'm comfortably off for charging and my diddy battery should run the headlight for about 2 hours on a full charge anyway.

I'll save the "Blackpool Illuminations" pics for when I have the whole lot wired up.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
Karma :

PostPosted: 00:07 - 12 Aug 2018    Post subject: Reply with quote

I'm using a screw-together multi-pin connector and multicore cable to attach the rear sub-loom. It solders on. A bit of a fiddle using this size connector. SHould have gone for the next size up.

https://lh3.googleusercontent.com/7h3GHoe5O5RU6qW9ErWUlxmPCS9usE7lMfDGpmGZ7t5VVewBSfnj76XnCWLID3JqN7G0oCgUwXlEtbDhUm0b90Gp7QcSCKzg2NCjTMTAd4qdD243evvW3SSeuqOKG_ogOiLZJENRbA=w1168-h876-no

https://lh3.googleusercontent.com/j8f57-ia5ZqnGHsrtZtVqT847SSPSiv0lCxggB29qDwfQ0Y4TBJozojLM66GaQ1iWqH6VGMwBWmHSuywj0H-HUJVSG7FXqZ3eUTvwz75_7PzwaHnANuclNpIVcC5oboFR-6pLn2IXA=w1168-h876-no

With this, I'll be able to quickly remove the rear subframe by undoing this connector and loosening 4 nuts. At some point in the future I may want to be able to drop a different one on with a pillion seat or luggage racks.

https://lh3.googleusercontent.com/ifj7ZrRAluRhjPq0A6Pdd856qIsqf2EODsHI3zhQy4AvjQQQ11zVkg8s6vVitIqYi5O7ksZ2E9FnVVWirq0fV-5fdlQjybcjTEzCKTfaGJgvdmXNFEPXajRb1USEh2Ir2n--U6amAw=w1168-h876-no

All the wires and the battery in place in the tea caddy. The brown and black will be for the rear brake switch.

https://lh3.googleusercontent.com/9CO9cermtxXSjtbygWmfJnEh7SjckA5ARs0oE5sTqLXEKoQSlI-lW9vvhVy9vskctDREOeLi14u20mNtA4GiFFLNG4hn1KzyTpXQUlLZ_bjIHC2p0wChVtQOFVowQReRTYxHIScvHQ=w1168-h876-no

https://lh3.googleusercontent.com/FHjH62xwin8TX4FJHx-qWe9ymztbBGsLHj6ZClN8_ZolEvDPBqfBOe9TAE75tbPXNQIJgaBGugIN_MlMrDNCFKQq-TA-iJQK5IbPiVkK7n7ZoJe9zvvX3YGu2SvSZ5Pb4vgoRfsdng=w1168-h876-no

I wanted this style of lucas tail light. It's turned out to be more of a fiddle than I expected but I'm pleased with the result.

https://lh3.googleusercontent.com/hqPG5dSeviNqTzPPwm6ZxogZFlWl91ukujzecWbrUD5WDKmswd7K55S1dia3pFOlClA_jD5CCL9ziWc82TMKcmv33e5CCR39P77U-POV0rNmSuS0WZQKY_LHS5tPPh9DpClFgXguMw=w1168-h876-no

I had to order in 2BA threaded screws just for the tail light.

https://lh3.googleusercontent.com/FhzHT7r3GI6bdcdRj2DiQbClpfYrIymJ_a526mOCLulpT1Rb759YEPQ_nmZmplxTEBmw1VrATB5FllzfNiJqpeks3t3ajzqeOfG0P-iTscd0jLJW4r1iBi2l3kLGGZMvtovE0HxXNA=w1168-h876-no

Multicore cable should be very resistant to being damaged where it runs under the mudguard.

https://lh3.googleusercontent.com/u4WOX1ge4_SGmHSA4jRMc7GMKzl-fw3ZZea7qrT97I8-ZBdFDO36UctDUTXALye02I64C5qFb1QDzMcautnCYr34pcrtd2KHcCRmm7W3q66uNB3CACKKgtJoY5HASxO4e1niXswW5g=w1168-h876-no

As I said, purely aesthetic. Not really a proper enfield feature, you're more likely to find one of these on a BSA.

https://lh3.googleusercontent.com/gXBpjLm08FfhWVmFy27nPdumZmMdMSkDHxleAxpg-WdzyWo6QMPbdmejM3iJd6NTKO-S7_oP58umu8MzW8leQruILFJ066E73Aig6ZUI_81ahol88iM6y5q7zqQ7SyFs29MWHfZUyA=w1168-h876-no

Daylight running light (no, really, it appears you get what you pay for with LEDs). Doesn't even make the ammeter needle move when you turn this on.

https://lh3.googleusercontent.com/NkAjtQb5X0GnsO79kbJi-TbMYxrwUXq-cElgWaNqtKWD-dqcJX2yk7zkXIfsSrDCxtDYIz5T6gRcRBmFYn68ujhDRtAfA7szz6lASlFiTWbRdDvBOCAJzFnMyf3Nr9UT6ZlncJzR7g=w1168-h876-no

Sidelights.
https://lh3.googleusercontent.com/fs0MaIl3YH3F50ylYYjSFB7DoufRBXJEk9SE-iAnwgSusHCWjiacq_tNr4livGDMt0P7InZeX2DEKtj7hjq-ieEeu9WE54FTThKTEjsLa2McnJSp70iX-AFhaWEoOF2sbGxUB1pkDg=w1168-h876-no

Headlight.

https://lh3.googleusercontent.com/CyCeiYkJ7uX7GvKbA6_C8opbYiMEX_qEaoFA6yPbwENglcLJvmY7249mxapjkZvS6meM8B5HjeOG0kJdgERZqL8f-RIOwAnS69jW_-Kvkxi8U_ZmDc0W3INcKbuJinbtpwfCO2lM4g=w1168-h876-no

Turns out this speedo has a blue filter built into the light reflector ring. A little chavvy for my taste but ah well.

https://lh3.googleusercontent.com/UKmcIs0GWueWIoPhpJebDTyLoFeLmdh1eG65m3efbnwVyEnyPKP5IJnXBEEZE96j9qpD2gofcYaAP7bMZo6f_TtssLifebq34BeqRakL5kanezDpMtHBPol7lhA0JnGN1JVzHXoaDA=w1168-h876-no

The ammeter however,is supposed to be blue. This is my high-beam tell-tale (I may need to point this out the the MOT tester).

https://lh3.googleusercontent.com/wKgk9u0_7kqCh7kfy8mTDbb6s_STo1-uvIDzUJV30owDE4K0ZAtCQqG-mtvfp93NcLV39r7gYjEXEM3F-G2S21DRkKoMBxyzLfIg3jvsnXH21FO5Lp6G9gwlYZa6RyPsThMs8HbvmA=w1168-h876-no

I made a bent alloy bracket to take the flashers, it should double as a numberplate mount.

https://lh3.googleusercontent.com/IcH-2rrYlMLjFV1KlyDeH-gSyLUf9jUOUBCHg9ZhIutu46smWF0hRIauxs1oX1tcFCF9FG0pHApbb_EqA68VPC05gWxI2eeVV8AdttvcWYGOFJXSorjGS-YuFHkq5GvjP-O1ZUpuLQ=w1168-h876-no

Unlike many LED sytstems I've seen, this makes a good differentiation between the tail and the brake light.

https://lh3.googleusercontent.com/MekzQoDV1gehE4kCMyHpSqu47Cf2AdbJXjev_vYiX-mBEV3pEyUft2YAVx4oCSQbKH1T3GrIL-4YyeGlrRwC4KE0l8ro2w1Dvxt467LUg24adUrK0Eso2KZmPRmP9hwT7QXESu1gBw=w1168-h876-no

And that's it wired up with the exception of the rear brake switch. Still trying to find some low profile LEDs with offset pins for the flashers but it's not the end of the world if I use incandescents.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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