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Minsk 125. CCCP era 2-stroke commuter of the people.

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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 14:19 - 14 Nov 2023    Post subject: Minsk 125. CCCP era 2-stroke commuter of the people. Reply with quote

I had one of these as my first bike. Cost me £500 brand new from Lossiemouth motorcycles in 1994. I rode it for 3 years and passed my test on it then two of my mates had it and passed their tests too. It finally died when a lorry driver missed his junction and reversed over it.

Mine was a dark blue on badged as a Motobeno but they also sold them as Regents cossack and I think Nevals. Looked something like this:
https://lh3.googleusercontent.com/pw/ADCreHeAfQvxOtVf1oqf1AbUEbsv269Zbf81PFxAMY-6WBBK8mUdKI8W_xg3Ek59NSHUI_jUqlPa7EcxEYYlUkpWyDgO6LPidJo-rNBf4bN5RO9DQoPdJ8_XgxMWgXS6MPfek0PZURgSC2VHNILNb4rLJ7Ad=w1158-h870-s-no

I always wanted another one and one came up on ebay, it was more modern but the guy said he had loads of them and in one of his pictures i saw a dark blue motobeno at the back of the shed. A deal was done and I picked up a vanload of parts for £450.

https://lh3.googleusercontent.com/pw/ADCreHfenZu6_Be3wngJUDRvrcQkXpvysf9PS4GP5RCdKqZz8j8rXDX4Apz-g57AjN5Rt7-3nhs0xBSRy8_-4VI0E68dM-eMKZTqXD4vu0dsm_sztyjB-Vkvu6Vus1JP8jdevks4mREnFcx4BweSYr89jV9a=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHdavTypzstQa25kBalXD7JB6UCeXPSEjvNR0dEdd_BEC0Sk3sdDIkV7t1n1hjXfXZZJEPbCe9hSLPSyTt5nv4w21o_T715phbgSI-wddlbJlME1xzBzCT_vacKUwLcdqqwpBF8CjUyQ2kS5-hmIXLmT=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHfGdz8T3LzO0rmQBNnE18t5aPRPOUULxOsruDU-XPuoMhJ15hkD3qE_D7JroD6XkCzokUSyRGRyTJSbhObKaq_s6woBwfpsa17nT5KRZSydYUj-HWn_TdYjfSYcjHoOp5S1ZSWp72AOngbA1OL7tcsR=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHdv-Xro7YVf1z3_UcsCkokg6Vx7hDw4LWjGnqRSJM71hnqjbLdJOBqmL-82PdxRW5N7ZgLG5XHXp9vLheYwv_iZ6hq7OGrxpwmQfz3m7jXtoXXDkN8702DLfp1RSitFLDd70a0s4HWpA94tMUep3bH1=w1547-h870-s-no

Quite a project but they are very simple bikes. I actually have 2 frames but it turns out one of them has never been registered but I managed to the the registration for the other one (typically the worse of the two) transferred to my name so it's game on.

I've spent the last 4 days clearing stuff out of my garage and shed and transferring it to my new lockup (3 bikes and three vanloads of assorted crap) so I now have the space and personal permission to get cracked into it.

It's going to be a ground up build and I want to keep as much as possible original. I'll need to do the paintwork myself too, they were originally done in enamel paint so I think tractol is going to be my friend there. One thing I will do is fit a Vape ignition/charging system because the original dynamos eat brushes which are hard to get now and I don't trust a 1980's soviet era CDI.
____________________
“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
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PostPosted: 14:26 - 14 Nov 2023    Post subject: Reply with quote

First job is engine. No point doing a load of cosmetics if you don't have a good runner. I'm going to start with a full teardown, clean up and replace all the bearings and seals because Soviet bearings aren't round. I'll also be replacing the majority of the fasteners which are a weak point on them, I was forever replacing snapped bolts on my original one.

One filthy donk. But oily muck is good, stops stuff rusting.

https://lh3.googleusercontent.com/pw/ADCreHfZ5OYOcSjtb8dk2tMakpfp15_vgBp92kkUhzwUCciTpRQshI-AXFHW84UG0g7wahcXS9lHeSukm5_x6SvCkd_rOxOHBn7PiCajQrKxM3BK82Tst9CLpsMrpdfo-EcCkqzlmvdVoihYUvWWLfM3e8is=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHe7JOwcbzlYWA5AsId1CMKv04hTNUPdVY4z2Pq6EBZFGgAlqtdS08WVqTPQoZ1tSgnWKaDhi0nVSCdTQMzHEdoz5x8KTvFUaMa0KY92I5i-ynDcvX0rPwRqrGjQ50pER766FK0GPPaHa6MTJTXZig_w=w1547-h870-s-no

10 minutes with a brush, paraffin and a hosepipe and it's a bit more of a state to start work on it.

https://lh3.googleusercontent.com/pw/ADCreHc8WUNtTtEYkHJm6_xS75LNHJSOsBQ6nr2yL1Nq6BuChvtRLz53ziQlhaKsRrRTO1hBI1Kx-jXmvfEc3Disufp3SygNn2m-T2gy1NFBfupjHZGfk5teSO7WS05spXTVETx6Y3lcNYS90H9UmdhI5B0K=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHde2rnzMue176Nh_ZQJgVKiXi0xdnDU_z7xkIA_hBuCxsduIX1LR-LrCsRrFfh7yBDR8JFzefwuxcjPPE9RavC_ijthM9k3Gm1uZYHQI9Wxj9sQJim5nsUWpvHqahMGfTq1c_7ifbRpWHKLbTmpwAic=w1547-h870-s-no

I'll need to take loads of photos because the only manual I have is in Russian and it's not all that comprehensive. It does have some proper engineering drawings though. It should have dripped dry enough by now to get downstairs and have at it!
____________________
“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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A100man
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Joined: 19 Aug 2013
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PostPosted: 14:29 - 14 Nov 2023    Post subject: Re: Minsk 125. CCCP era 2-stroke commuter of the people. Reply with quote

stinkwheel wrote:


Oh my.. Shocked

..how fast does it go mister?
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WD Forte
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Joined: 17 Jun 2010
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PostPosted: 15:48 - 14 Nov 2023    Post subject: Reply with quote

Good luck with that

This guys done a few Minsk resto vids which may be of interest

https://www.youtube.com/watch?v=DCsjwj3x3NE

Edit:
I found it strangely satisfying to watch
but at around 20 mins I see he uses cement/oil on the piston to bed it in
Thats a new one for me!
At one point he appears to tap a new main bearing in by hitting
the inner race which is no no for me but hey, its his bike.

Using an old footpeg rubber as primary chain tensioner is interesting.

It looks nice and runs at the end, but without any paint or clearcoat it
will oxidise like buggery which would be a shame.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 17:19 - 14 Nov 2023    Post subject: Reply with quote

Should do 55mph. Maybe hit 60 with a fair wind.

Cheers for the link to the resto guy. I may try and be a little less Russian about it when it comes to the build.

No horrible surprises so far.

Head off nice and simple. 4 nuts. No head gasket. As I remember they come with one and you are instructed to throw it away at the first de-coke. It has a spigot so it can be lapped in. No evidence of roller bearing impact damage so that's a plus.
https://lh3.googleusercontent.com/pw/ADCreHdq6QpuCVK8iNPLP6NTKy_BHe71RB8AwMXX0EUUFTXsE6MYIkO5ZCxEcpI4VX_MnI_mA9C1_UzRB0RfQf5iGVJswMJU7NQoBcFAoiKaK4oeDjTjdAOT4Z2pbcY2t5o1CWdJgvObXylq9jgLyefY6CkZ=w489-h870-s-no

Piston says it's been run after it was built. I've learned to fear a shiny clean piston because it indicates someone rebuilding then having it fail to start.
https://lh3.googleusercontent.com/pw/ADCreHd609CGUvKsnGMrbxmDa9ltSB4_6nYzLYgxakGXg7ZcjValeNaSHn67nlWI7P2GF8DEWGRuBDnadrcKCL0JW_nywWEbU4XMyepjxEgSCtDE4TtKCZKakQM7jPUWbxeNLhTI13azofBynvCemxDrAn0x=w1547-h870-s-no

Bore is clean, no smears or scratches, no appreciable step.
https://lh3.googleusercontent.com/pw/ADCreHfY88H9uMEIxJeADeJ_N-k0ERgHw24PgYwVs5PLk_ZAx5UdIXZOUEpwKUsT9cBMtyAV14B9CkjnczCNeWNK9XSGh0dzDsZnjQi9np2pxCQjpuhJ7-k9o2beg4joTE4xc2p3qPftN1biR8PdqEConIyh=w1547-h870-s-no

Here's a good sign. Previous owner filled the crankcases with engine oil prior to putting it away. Clapping
https://lh3.googleusercontent.com/pw/ADCreHfZE7FI3H449OOtGfFJiEbKLNWngYAkZMUkdTnkt_pgCgUAd6dmmgJ_tfi0XhUH1Z_NueuufbNUf7c1gi96FuE-PYy6YoqoliMPDJSF9YeNDi_AsfNX1M-k0dWka-YrI0S0HEslnUGHsHadWTlkseYW=w1547-h870-s-no

#2 piston. I'll need to dive into the Russian handbook to see what that indicates.
https://lh3.googleusercontent.com/pw/ADCreHcxBJtCFyzhyhS87u-NnoFavDuIQ1xcPcxxMMLRdVcof7_dmtm9Kz4elaaAIKITeGu-VLsWtw1A6hwUptNI5qhFAitu_rsEMz2UD-otaPwe6ZhCvRxOqKzrSpJWS2EpKB9lsGUrzzz4HdPgyflgZvDv=w1547-h870-s-no

Hmmm. Not ideal. Something bad happened to this. I think possibly involving a ring location pin. It almost certainly didn't happen to it in this barrel because there are no scores or chips on the edges of the transfer ports.
https://lh3.googleusercontent.com/pw/ADCreHd-tPqb06oAbj3cVpWbxnL4Fb5lQXD_M2u_erIuqXNFBU-q-NTnHHm9koWNmRzhZni6TFdMCr8haaq-bBBOv7DnisEjdlBB0Ge-KE9y0zEuFz_RzJ6OCYrXoaheXq7EAuTwZF5srLSM9lkTfvCBtRrk=w489-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHfTjAPCnUDksjebWurjkLCL__dAhi3-68fbybK2pxS7t6aAAK1FpIV9xxKojrfICAiY-Llxlb-vMYpib6fjB9CbV8_vivyQX_LuHBwsh5IalreBnRdYMTuvSGt8ZrpdbBpwIOXo-PjrPFs4koKUTdas=w489-h870-s-no

First surprise reverse thread on the gearbox sprocket. Also an oil seal to replace for the clutch pushrod.
https://lh3.googleusercontent.com/pw/ADCreHdCfxt3lNqeiGL8Rr59p8EGGd9QRbO0kP7STa4TFas29oWOO9TiCgOGf7Qvp0B9pl0g8lae4q5lP2q9z80c-QO0DFtist7eIuUh4EscdGHeBjgOnmIYvtV61Vy4iX8_fHRNUqdTG7IRPpCJw2zkwVK8=w1547-h870-s-no

Pulled the rotor with a leg puller. You're not supposed to but I'm going to bin this. It's barely magnetic. Also note the two little bits of metal at the bottom right which were stuck to the magnet. I'm pretty sure they're drive chain roller. They actually list a service limit for broken drive chain rollers. I remember you used to find them in the bottom of the chain enclosure quite regularly on my old one.
https://lh3.googleusercontent.com/pw/ADCreHf1A9O9DIGL6PlaYpEbOc2HMOKvSEJkDaWLZ3VkrYe5jpeifyMA4o9Kn_dNQiytVHOWE21r9gkk____JQOC8rq1kPwSiG_O1uyjFA-SqqXgmTD6sfwVI3T6fGM-3canZ5MtjePBDVTFSJVGqTOhZ8YF=w489-h870-s-no

No sign of damage or modification to the crank taper, which is a good thing and not always a given on these bikes because they sometimes spin up the rotor so the vape rotor should fit right on.
https://lh3.googleusercontent.com/pw/ADCreHfIraTb7vuIle10eUfWQO4KaSK8Pp9aiwDZW0kr60xOEASNPyIAj6mf3paB2v6l1kgdBsQnjUnb3JKOncYMbQnHVA9X0TBctq_W5pCCm6uA8Dtia7sp7fawIizgDCsOPC00D07ab2LW9jV2oJdnJ4R9=w1547-h870-s-no

Kickstart oil seal is fucked.
https://lh3.googleusercontent.com/pw/ADCreHfekiyGGXs5wo8KeFuc8UhRaS4ISXfP1MZnTGXME1ivpReCSJoK_kFK6EjnztlMMTrwpY87nHkYgnSqFqUtwlsjvmRm1NiH91p7Fb1p343Wy2ekrRV7PIanFTA5zglwocLglBriPWANZPDvqsBw5656=w1547-h870-s-no

Helpfully marked with the size.
https://lh3.googleusercontent.com/pw/ADCreHe_fGa24bx7ZGwtMEVSgHp1OfTpNJXh_Jd0zu3dD75rC4IBGb4iXYY9ByCz22eLdMaRUu81vR0oufkKZjLWde80LB_AzAMYdHy2S5KJdk1URw24o-EE15kA0mUlFfZvNVGeIMKHueEZTao1ZrZ_SEmV=w1547-h870-s-no

Dinky little primary drive. No tensioner on this. Not sure if I need to replace the chain, it seems ok.
https://lh3.googleusercontent.com/pw/ADCreHcKKGJYO_SSjAGj5SI3h9LPAmZAOzJpJGwfGR3ZA1OmNENGh9sLUdUShY61EEwKCq1rJc3HM9BBpeWjd8HDEyCRxcT3_uwhPSKJgEaGt6iEYUR6Pns1xIHGPWKRB2NfvOs_Txw6QtNZdVwYbtWrke5f=w1547-h870-s-no

Note to self, kickstart spring goes under the dowel.
https://lh3.googleusercontent.com/pw/ADCreHdA06qjxAnQP-xwuy1rwS8erGXb7I6EAY0P-zYyeK6qHNoceZPLky_1QBS3qVMHsS0Bm1TKPJ1EaPLx0rFlONGlHCW-v_sippZdCoGMhVsT00PWa4PXx74uI_V_YXfxso7cGUXHt_bZryp6xtjl0RO7=w1547-h870-s-no

Clutch springs are just hooked over. They are just as much of a bastard as I remember them being.
https://lh3.googleusercontent.com/pw/ADCreHeIsk8RGzGmOh5sQ7Kouh1muHC6pKZ1LeS9Sz0Bti2pW7pi9f8v0CKJxvNCfsUHv9FJ0MxMPhrU19mjv6FT5YqFjMWq_CdJkrrrQ8GlxAQcMER7Qi0azJ6mM_Cjwjcpxqizt6ctxdJenw53GpoZXEmC=w1547-h870-s-no

Second surprise reverse thread.
https://lh3.googleusercontent.com/pw/ADCreHcekbjgmKp8R6ehP--7qijguTSLf3iKi8BYzBSAWOcx12vhtrvl5W-t_vEbJZedFdTuBoNgdo2pjlHsZjBVCskPp6fPmPKqiWSMe1N59kg3bPLyO_0UhnYi1p5s_ZBiSsD2Q7sBCyD331eAElrur4cy=w1547-h870-s-no

The clutch plates are solid bakelite. Unfortunately one has gone brittle and a tang has snapped off.
https://lh3.googleusercontent.com/pw/ADCreHeTZyOH1-9zkWFmsqegfH0oiexlWdh9rHfH7W9ZlYbBz3Z6HF2v_uixWJPVl9ZncKcnk8LSM9ZkbTjMBBsvQY_rUveZrCZqXuhKLiiVTSTJnJtCBgG8PQQ8-pS8lp_aju3OexICoJc8RmjtMA3Q_7bC=w1547-h870-s-no

Engine sprocket was very tight on the taper. I don't have the correct puller so i heated it up then pried it off using tyre levers and alloy plates to protect the gasket surface.
https://lh3.googleusercontent.com/pw/ADCreHfRrjiXdUImna316D-5axavznK-NXAlLeKSxk8z6ADjwHXQLuYtqKYFwa_E3TIuIbdSfjUAOWiB3K5QGvTogxEwkp8FpqHhIiFvNQZmBLmR8nqD0zcz2_xOxHICSm-PWKKz4KtJgkTncKV96zSuwLtD=w1547-h870-s-no

Off to look for spares. Looks like I need a #2 piston and some clutch plates so far. There are quite a few suppliers on ebay but they come from Eastern Europe so I'll get them ordered now.
____________________
“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
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PostPosted: 18:01 - 14 Nov 2023    Post subject: Reply with quote

It's a standard piston, group 2. I don't have a bore guage but as far as I can see, my bore is pretty tight. Maybe too tight if anything which may be why it nipped because group 2 is the larger end of standard.

I've ordered a standard piston and rings and I'll take it up to my local engineering guy to see if it needs a hone/bore running up it. Every chance it's not round anyway.

Got a set of clutch plates on the way from a Uk supplier. Aftermarket ones which I think have metal tangs.
____________________
“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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virus
World Chat Champion



Joined: 17 Aug 2006
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PostPosted: 19:14 - 14 Nov 2023    Post subject: Reply with quote

ah I was wondering how long it would be before an eastern bloc smoker got to you again Very Happy

Looks like a fun little project and a good few spares too?

Bet ya a pint you cant ride it to the dragon next feb Wink Thumbs Up
____________________
own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 20:15 - 14 Nov 2023    Post subject: Reply with quote

virus wrote:


Bet ya a pint you cant ride it to the dragon next feb Wink Thumbs Up


Quoted for future reference.
____________________
“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
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PostPosted: 21:05 - 14 Nov 2023    Post subject: Reply with quote

Kickstart springs always get me confused.
https://lh3.googleusercontent.com/pw/ADCreHfOS4Oo7niC0dqMSEgtKZmzU7EW0F2f5eFoo77OJzDuq2PZv7mMTb2ubp9aGhBjT7lEmKI9ptfShEO1F7Lf0AcycukwotClV66Z87L6lq7a541g58mVpycrxI93Ne_fGpqLZnMLr2jtxC9Vic8F34Os=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHc2gY7mwLx98zLJk6N-RvjmQiSbiy-PXSoU8eS_48BZb0THKzh5n5wPotQNiW9SLZu1yBMlprWc3P6VYhKkibxbVC7AIjQxq6yrfxO7bzC5s1cLdXtYXerULabSyouW1KShljZiAoJ7lYDWFP7FDbmy=w1547-h870-s-no

Drive shaft oil seal retaining plate.
https://lh3.googleusercontent.com/pw/ADCreHenC8Vt6ShcLnlXBrjhYzUcVti2Mb7IzggAl5E1ONKfUxLZ5X4MIA6fi8Dchz0Bg5267M5mRHSMP0Z0afl3mjwnSV5xaS9GySdPLbhQnj2EEjmG-Ob7kkc5xlv2bzZQdNMuloXXvi3hcC6q5b-1SlX2=w1547-h870-s-no

With another knackered seal.
https://lh3.googleusercontent.com/pw/ADCreHd3BTNlPR3_-nEjQ9uCbb9GWjNbjm6-zd47FYPDkwq2KoB7W2WAbH0D8UzZzl0dEN7KLJlQ4RrXyZsMmAskymIOLSoF9U-oRELfjnjOcFEa8UGYu-5oIxlrfOGDOxhTJfdNlaH8QweA4IWnSLQe21ko=w1547-h870-s-no

And here's why. Also probably the reason for the bike being taken off the road. Someone's been over-tightening their chain. I bet that made a lovely noise.
https://lh3.googleusercontent.com/pw/ADCreHd4rhFYdzBBJGd8GiFRDoBn60oV6-x0vKq69YPiB_zY_FvHSs-h1sOY64hwq96QkDRxVr6kzI8w94W6UZHStfy29pcQquzkrbyjED1FfHVPCVVXAwc1lNyD1P70V9oKtsBLf7vsUzMSVTUvFsjwO3-k=w1547-h870-s-no

Remarkably, all but one of the cheese-head screws came loose. This one did not. Tried heat, penetrating oil, percussion and punching it round. No joy. I punched it so much, I landed upeffectively cold-chiselling most of the head off it so out with the drill.
https://lh3.googleusercontent.com/pw/ADCreHdUYuJgIGh0__M2vP2CW99k_2m-sxanaNJWtP5hE03FFoPkFFeKs7ZkvfTxH1-v2TmBWp_-Oi5ytozh-shI93On2D4fU_AM3VI9k98D7nYV8wKdAt3e3uKbJvboLFakBCqRgesAjDj0OVVhrQ4Tu30t=w489-h870-s-no

I'm going to replace these anyway. Not decided what head yet, several of them are in a recess so I can't use shouldered hex heads. Maybe even just better quality cheese heads.
https://lh3.googleusercontent.com/pw/ADCreHd6qZIfyk4lVd4jYrYxH_bxQ_g2nRKJIYsmH_700sKepUSGjElmciTcLjEq1RTFg0YNlFqiMEOPuDi4Ro3MT4pQD4E58xU77Vr4YXVZHuVN-4OKNZF-TYW_DMlRLDl8n7_Un1tEj06gQxYV9DtrgKnn=w1547-h870-s-no

Gearbox cover off.
https://lh3.googleusercontent.com/pw/ADCreHeCco5u6tvzPViXk50pn8KRtGCRKtVco0-d2ZYKoONl8isAzMbOfXX_v-5DbDO78lEUw8JxJ5wuZPA-Doj8K15OrpLQQndSKxCiEQaT_Gw5u-vxBS5MS70fqClG9WymCC4JMN8KpEm7C4qq1aQCH-cl=w1547-h870-s-no

Basic but way better engineered than the one in my enfield.
https://lh3.googleusercontent.com/pw/ADCreHe4LsH46kwVSpdtPP-jQU6e0AejygVSPN0RRKfUpsGN68IJAWfvdz5vMaeuZSeWcWcp7qLCS6osHo7P-RhmVz4Iw25Ao6XuG1vl4qfRJYWszD1nvz4r4DHwMuHuRROgk0Ajp5tQPS3eTbPc89_mmZqg=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHcOpPdDHbKDKfIx-UjTvz5ZfTjU-flzall05iJUMW82pkpogjKQhzg6yRropbuEfd_09EtBFG964ccgNmGF9P-nAZSBCwjC4wLYoWOHTc3almtjnN5WN4D1cAg0ZaGolb3AA2nAP7thrE4CRpphTKHL=w1547-h870-s-no

And that's a wrap for the day. I need a puller to split the motor so I'm going to pop into machine mart and see if one of their harmonic balancer pullers will bodge on. If it doesn't, I'll need to make a plate to bolt it to.

Plan for tomorrow is make up a list of bearings and seals, extract the bearings and take the crank to the engineers to see if it's worth splitting and swapping out the big end roller bearing.
____________________
“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
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PostPosted: 18:57 - 15 Nov 2023    Post subject: Reply with quote

Harmonic balancer puller duly bodged on. It took a hell of a lot of pressure to pull the two drive side bearings off the crank.
https://lh3.googleusercontent.com/pw/ADCreHeJC75nCLOFJOC6JFSfpXjJfFgNFHriR6zcjIMyk0HIV2Gsx2ItSNXuscQpwohgYR3voG3-HouOuTS00JQSWV2LRoO20pBgTZc9ZrtdpKmPWbf2xtGxcsaw-OK9XyY8UhCth53tQTHpRSk-I8Ne_MmO=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHeQt-Zu8ISfcA0QLFgrvuGVagIolEVx5-Fc3XUxjghXYXlUhRNQO-0iNit3aUwb3Ksf0fcMfiQW1weDVbHjah1NVwhpFmabEwEZ7ihvepdAxGum1br9bkym98_g8-feGrRq22H3vUBY3eM0TYnDIS2y=w1547-h870-s-no

Crank out.
https://lh3.googleusercontent.com/pw/ADCreHeTzMMCBfXC5vSDnuvYJwNRwdFon271fHOVMZT9PsfLAnbGOKM1aoBHgXfkZBsTdJvZittUZG-ghB5lPDcnYtx9gWuMXJhERs2e-gXYoW3fDmrzeozQHT9tuN0Pc1VJIplx3chcfYYWU1VjtAYaIf5z=w1547-h870-s-no

I took the crank down to my local engineering guy, he reckons it's probably just best to go with it because if I change the big end bearings for good quality ones, it might turn out the crankpin/big end doesn't fit properly. There's no play or signs of damage so we'll leave it as-is.

It also turns out I had several spare pistons in my boxes and an inordinate number of piston rings. Three brand new pistons, two of different grades of standard bore and one oversize.

https://lh3.googleusercontent.com/pw/ADCreHeG-P4ZH20FUkCBE-MQzjseco59P4oTk1eH3zTVOZMTgIHVhdScxzwf3jyuGQhxCNu5Htks1i3PS42VIoBpJQzUTTyfJESY6mnxYYwuNC7xBLv6cYl1o4S4zCuJlOIYCFARFIHl0kRhM_pGr8bO2j_6=w1547-h870-s-no

I was very suspicious about the damaged piston that was in it, the lack of corresponding cylinder damage suggested someone had slapped a damaged piston into a new barrel with new rings. My measurements with a vernier seemed to suggest it was actually a bit too tight which explains the smearing on the skirt. The bore gauge confirmed this. It also showed the cylinder was slightly oval and slightly tapered. One of the new pistons was 0.003" too big which is perfect, it's still within standard bore and leaves room to hone the cylinder paralell so I left that with him.

Dragged the garage oven out. This vastly increases the level of marital harmony. i got it free off a neighbour who was throwing it in a skip and I just plug it into the cooker socket in the kitchen. Ideal for bearing fitting/removal and curing paint.

https://lh3.googleusercontent.com/pw/ADCreHf2rdjoENim_qxTZ8CS3cilpArT4yh9zI_EmkPcbtYJFruNTDR2Gbm_ZF2Nu074npSGsO3ef8fzm4GpbVVP6WKN6ZnD95UHbjP4yqEQP2Mx3c234PIV9wPdjN_Dh2E4cpClIGT_D9ElgbWW5X6PCA43=w1547-h870-s-no

This made short work of extracting the bearings.

https://lh3.googleusercontent.com/pw/ADCreHcMb0Pa8e0MzKwVuycQ7muSkJ5wab5BwumEiaUR3cVcM3aFW71gEAkgl8h8z9nqqq9jR5exQP2tu2_eGxvEFOj13G1YFFUL-xMWnuZpeVsk-tiDQOR8JR3a0H80mzYXIe3O9Sz8aU_Qb0Srpp0on7ZH=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHfZBSKnTqab2atlcUtAx4ERkmj3bWoLwrK1ZyO-JEEisF8rRNXv-KM3aWS5jVvNKdPwYbe7gl4-89fWFKUnK4RnlKSTZM7bQiyKtVIHvc8AKHVTyScbxtUnIfPs_sS7GgVrYE_n3XTjQnoaj_jvXIjF=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHcd9MZHCEFqZ54gq4o71x7Bz3MsO2lQxkJSDq-zDDTaNLWwIhAvsWK28ax4LpC2mBJ6FcqRJMJYZtwrGfqJXo95tyc9LkiFyS_ipWRt5NY03NfONdkleqC9T96OpAvyP2YIKxN0VooY_RW5p3nAiMt0=w1547-h870-s-no

Now they've cooled down, I'll make a list of bearings, seals and fasteners to order.

Tomorrows job is to clean up the casings and get them ready for paint.
https://lh3.googleusercontent.com/pw/ADCreHeRFL5Bwpp9v3Wxc3lHnS9Y102baVkBX7keJiNy93pScvS09i74OUx7Zf5dpNhKK1E9UtLhuR0VeGRhtHnC3TaEVewQle4OlgAehp9NUU8gj4QKNrIUduBSI59YlAoO_NC8Fri3nTnoOSUDQ3OU-4Ci=w1547-h870-s-no
____________________
“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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Lone-Wolf
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PostPosted: 19:13 - 15 Nov 2023    Post subject: Reply with quote

Wotcha.

Very, very similar to a Bantam engine . . . there again, considering the Bantam's history, it should be.
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WD Forte
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PostPosted: 19:53 - 15 Nov 2023    Post subject: Reply with quote

Lone-Wolf wrote:
Wotcha.

Very, very similar to a Bantam engine . . . there again, considering the Bantam's history, it should be.


Both cloned from post war DKW reparation grabs I assume?
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stinkwheel
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PostPosted: 21:07 - 15 Nov 2023    Post subject: Reply with quote

WD Forte wrote:
Lone-Wolf wrote:
Wotcha.

Very, very similar to a Bantam engine . . . there again, considering the Bantam's history, it should be.


Both cloned from post war DKW reparation grabs I assume?


Exactly that. Same bore and stroke as a Bantam but metric bearings. Also a mirror image, final drive on the right, clutch on the left.
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I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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A100man
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PostPosted: 11:03 - 16 Nov 2023    Post subject: Reply with quote

Great work - enjoying the ride so far..
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stinkwheel
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PostPosted: 14:44 - 16 Nov 2023    Post subject: Reply with quote

It's all going to slow down a bit now. Mainly because I'm back at work next week.

There are some tedious and manky jobs to do now before things can progress.

I've cleaned off all the engine casings with paraffin and hosed off the rough. They're now soaking in dishawasher tablets (If I had one, I'd run them through the dishawasher). Then they need a wash off in soapy water, rinsing, plusgas on the steel parts to stop it rusting.

Then there's the super boring bit of scraping off all the old gasket material and removing the paint.

The plan is to do it with aluminim simoniz engine paint on the casings and aluminium VHT on the barrel/head (garage oven for the win!). Not sure how best to go about painting the casings, there are a lot of fiddly bits to mask. I think bolting them all together than painting it as one unit is probably going to be the way, then I can run a scalpel down the joints while it's stilll soft, seperate the componant parts and bake them off seperately.

I also need to pull out the frame, swingarm, steering yoke and amy assorted bracketry and get them media blasted then blow over a coat of primer (or keep them inside somewhere until I have time to paint). I'm going to be faithful to the original which was all enamel and use tractol paint. I've used it before and it's very forgiving even with a old fashioned blow gun. I now have a HPLV gun so hopefully more of it will go onto the frame and less on everything else.
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“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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Rob Fzs
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PostPosted: 18:20 - 16 Nov 2023    Post subject: Reply with quote

Great thread, love stuff like this because i just dont have the time nor can be arsed when i do, to restore bikes anymore
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stinkwheel
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PostPosted: 18:33 - 16 Nov 2023    Post subject: Reply with quote

Cases all clean and de-greased.
https://lh3.googleusercontent.com/pw/ADCreHeUjlhfBpPdTKR0Qy6Hf-lr6V9P6UH7RrcfYwdhHgVYAwxpdRbM9tOONjlX9k55JyyBeTKweDnT1QjFmno5Maua9A2w-dL88x1o9ssMmr2XrF3PuunKVsG8H6Gpe5B23t1r9CMltPG4pXpVGrVVbIfP=w1547-h870-s-no

This is the first time I've had any success with the new DCM free paint stripper. Still took a significant amount of elbow grease to scrape/wire brush the stuff off but it did soften and loosen the bulk of it. Mind you, it sat 40 minutes. I bet with the old stuff I'd have been able to leave it 5 minutes then simply hose the paint off.
https://lh3.googleusercontent.com/pw/ADCreHfeM5tpKHVjBgUVv5WTo_QUBnNTMtKqB9bMUSN4wOud93ZrFm0D_togk4k7F57iJ50lLjUf5kUbcpNPVN-WL7d5ysXli5RYGTrsXSvCRZbSD5WZA_gk3jzzPtOTn_ChNB49xIKIzwURRqAn2nrK1QYx=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHfAxte-IBxPbb2iMX0Oo5NbZK2lWAptYLFldCeOE9vTjd1atl2n1IlkqNI6D5JXkDG5EXouq1URbfbVXZHys2kbtIETO_wDa8nBr0mwezJ3fE8SMm22HWT1Sh8y5hKFcyNa9crRJ4_OHVjfQvdEeGic=w1547-h870-s-no

Not a bad job. Once they've dried, I'm going to bolt them together, rub down any corroded areas then wipe it over with acetone and mask off the holes ready for the paint arriving.

https://lh3.googleusercontent.com/pw/ADCreHdRgHUsofLfcVty9sxedgigmcGOd6U1wviDeTuyG6OkSaPB-IKdUNHEd1sF8LhnOsuQh2PytYsYquCk4Hib9MQptn7SYcPagPCChF74Hm7C1b4MdpCpJSJijqN-mVCDkkrUPgI6Nh6aivQxESlYpYAP=w1547-h870-s-no
____________________
“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
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PostPosted: 11:59 - 17 Nov 2023    Post subject: Reply with quote

Engine masked and de-greased ready for paint.

https://lh3.googleusercontent.com/pw/ADCreHcIGT4CdkXpkw6-bX8yY4H_scqPciR2WW4XlHYNXFpGs5inyne5jd7Qcn9rCCNjPfZGL8b0VpJKp55BkZOgQniN3CWJTy58KHqas889dKeZzVS2WPwdlNTDgzLqMLaZDF_gD1tQpX2pGzfHKuOFlSok=w1547-h870-s-no

Frame is a bit on the tatty side. It's got a footpeg bracket missing which will need welding on although I might go down the line of fitting a set of Sammy Miller footpegs. There's heaps of the original footpegs in my box of bits but they are dead flimsy things, a bent steel tube with rubber over them and I haven't dismissed the idea of doing some light trials work on this bike. Then the question is do I wled the brackets on directly or do I weld a drilled and tapped slug into the tube and bolt them on.

It'll need stripping for media blasting and painting anyway. Haven't found all the headstock bearing cups yet but there's a UK stockist if I can't.

https://lh3.googleusercontent.com/pw/ADCreHcN6-SgyDbLkVEfwGJ619C4SL-y2-pg-fNv7ZQk094DqDFB7bw-TbW0PXrclMjJ1PlBDiEOMJgisbc9kW9uapHx3vDSdD0TgILO4MrM1pPTChhWGBEM5MkLH9iawHG0xAiDUb0kq2kLo8KrUGv5o7-5=w1547-h870-s-no

Yokes and swingarm are in remarkably good order. Corrosion free. Still need painting though. Might get away with a sand and blow over.

https://lh3.googleusercontent.com/pw/ADCreHcB6_LQePWAPKfB2ugJCkG2n2rD1KdYDR4obzpsJrMUbKWVgcH69B3Be3mtTXNCrCv3mXJUWiQ6Gd_3pwBBNh51MNRPFNtKuoCIM2O3MnOAM2ertws3ewzsfB3UJau1OSQ9gzObPvdJWLqTAZqPNEfm=w1547-h870-s-no

I've contacted Vape about a charging/ignition system.
____________________
“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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Easy-X
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PostPosted: 13:12 - 17 Nov 2023    Post subject: Reply with quote

With regards to footpegs, if you're aiming to do trials then something that "breaks well" when you end up at the bottom of a ditch Smile
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stinkwheel
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PostPosted: 13:21 - 17 Nov 2023    Post subject: Reply with quote

Easy-X wrote:
With regards to footpegs, if you're aiming to do trials then something that "breaks well" when you end up at the bottom of a ditch Smile


I'm thinking I'd like a slug in there anyway rather than just welding the brackets to the end of the tube. I think I'll drill and plug weld the brackets to a slug, press them in then weld to the bar.

The Sammy Miller pegs are pretty much standard fitment to most trials bikes. Fold up readily and your feet don't come off them, even when saturated in mud.
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“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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Easy-X
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PostPosted: 17:59 - 20 Nov 2023    Post subject: Reply with quote

They look like bear traps compared to standard pegs Smile
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Robby
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PostPosted: 18:40 - 20 Nov 2023    Post subject: Reply with quote

I recommend inspecting the frame between blasting and coating, if someone else is coating it. Any pinholes and thin areas will become very apparent. Seeing as you're getting stuff blasted, it would be silly to only sand the swingarm.
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stinkwheel
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PostPosted: 21:22 - 20 Nov 2023    Post subject: Reply with quote

Robby wrote:
I recommend inspecting the frame between blasting and coating, if someone else is coating it. Any pinholes and thin areas will become very apparent. Seeing as you're getting stuff blasted, it would be silly to only sand the swingarm.


The frame is very solid, just cosmetically poor, there's no flaky rust, only surface damage. One advantage of a poorly sealed, very rich running 2-stroke. The whole bike is covered in a film of partially burned/spilled 2-stroke oil, leaked out gear oil and cosmoline.

I'll be painting it myself in alkyd resin machine enamel. I've kind of gone off powder coating as a finish, If you need to do any repairs or modifications afterwards or if there's any damage, it's very tricky to repair/re-finish powder coating.

Although I suppose I really ought to just strip the swingarm and have it media blasted too.
____________________
“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
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PostPosted: 17:58 - 21 Nov 2023    Post subject: Reply with quote

Got the frame all stripped down and the threads blanked off with spare old bolts ready for media blasting. The only skightly tricky bits were getting the VIn plate and steering lock off. The rivets seem to have been hand-peened iron and drilled/filed off quite easily though. I could try putting the VIN plate back on after using a hot lost-head nail and chiseling the inside off after, I have no key for the steering lock and never use them so it can stay off.

https://lh3.googleusercontent.com/pw/ADCreHdefdYM0htroPl-3_2PT3QVOgDO6AxJ_2s-I6SdenYfqNbyIzZgBCB3Kx2b1jLeVaOLx1p48vqNtXR6PJV9ijdVE6NSOG-jyT0jHv-KCzY4oKgq614t4uHrQXjEMft1w3PnvNTZPKG7IHjusAGqeuD6=w1547-h870-s-no

I was going to take the bearings out of the swingarm ready for blasting but it turns out it's on a metelastic bushing so I'll just bung the ends. They work remarkably well, I have them on both of my enfields. I also know that there's at best a 50:50 chance of getting an old one out non-destructively, or indeed at all. An air chisel is the best tool for this but since there's no play or slop, they can stay where they are.

https://lh3.googleusercontent.com/pw/ADCreHc0lV9HQwvaL-rKwZtKOhXaMuXBZoPeI3qaTXuMHnXFtqrkggjU79udpeM4J3aHRZljvMyLnvJZ0Jz91sPhvYCHNVn44zkW65Ut47HacN3H7t3EA0MJ7lWwTYvSpaLYFDJ0oebIBqqTwHkbdfjReZE1=w1547-h870-s-no

Engine painted. Paint needs 24h to dry then I can seperate the cases and bake them off to cure the paint.
https://lh3.googleusercontent.com/pw/ADCreHdm_gg_9wNX1EmpIUbRJHJNWkUmPJINxkNb6qV4vTkY7PTE_6kvFeJDsKUijUBrBb2X9xe5WGWprztHdpRVmifiKbQEqWgucNnTJNFw3USDOmj3b4eCvcB6jAOYIwLq5YagFqxDleGBk70s_gwIcS1Y=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHd1ZwtNniWbethVc3aAHpkrC3VLRwOJLf6Lz8w3DQEMlG2aU6wh2OmAPImqAsTvnXGwT89T4dsJ2IdXkcZiHHWmboXJHliBOgroSz7KXbMbZB-OPjncBpkqaLhrGG6Qb7oDOOX5z0qFljOqXqkhm7pQ=w1547-h870-s-no

I'll leave the head for now. It'll need lapping into the barrel spigot which will make a mess.

Paint stripper actually worked again.
https://lh3.googleusercontent.com/pw/ADCreHd2jrUIVeIz0CY_WMVATM2M01dopk3yLe8xzK7ouRqi-XfLDERjfDPUJqFrRKpJ5g-8v0BUlZ5feK719Fnt0i8P1fKi9GMnvC1PXrHO7RsYEPU9ozdAPfTmOuBRjpCidGRCFIOA2vMCQqDPvtCC6yLr=w1547-h870-s-no

I have a choice of two carbs. Both are correct. I'll try to get them both apart and see what looks best. Flatslide as standard. Head says to use the concentric one. Heart likes the look of the seperate float bowl.

https://lh3.googleusercontent.com/pw/ADCreHdKaK7coWsTKuchhuVqLFeXuym9BiQ2bRh_qSlCzJ7XFL-UuEMF1lPgV0PBhTT7V_bciIlpRXsXOIGujO01QiV2awwCudaJokWz7BB3eN4lGQaluzZLJHx2fRPJMBSufIfW5Ad2ztlfbruiNNJb5Hlc=w1547-h870-s-no

https://lh3.googleusercontent.com/pw/ADCreHfj3uVMMlxUYrcTAN02gRfk18DG5w2spHcYqx4TR75WaYwvSVONwY0G3PAc2inmlcrU1i9SdPGejuTdQftQfz-oEDor3mUgR6jU8GVzf1RgQYK-ON3NDrSPOazF6Kkjo3S6EOBZHKTSddMprg7Xlskn=w1547-h870-s-no

I've thrown them both into the ultrasonic fully assembled while the paint fumes clear from the garage them have a go at them. They have cast alloy hexes on some of the fittings which are notoriously brittle so no garauntee they'll come apart nicely.
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“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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virus
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PostPosted: 20:13 - 21 Nov 2023    Post subject: Reply with quote

Id go for the separate bloat bowl one as well if I could but as you say its probably more about which one is in best condition.
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stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.
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