Tap and Die Storage

Last year I made a few purchases of Taps and Dies for cleaning/chasing threads on the Matchless and other projects. This is partly helped by my job as I am now a lot more aware of the array of threads used on things.

I ordered the bits from Tracy Tools down in Devon and ordered them loose so not in a case, I have seen sets in cases at shows but always disappointed about the standard of the taps and the cases.

So I made my own cases,

I have some gaps, that is because the tap normally come in sets of 3, Start, Second and Bottom but the sets I bought only had the Start and Bottom taps. The inserts for the boxes are basic and loose. Once I am happy with it all I might give it a varnish but this is just version 1.

Clare V142 Calibration Unit

So randomly looking at eBay one evening and I spotted a bit of test gear for Clare Flash Testers. I have the task of calibrating these at work and the chance to get a bit of kit for actually testing them was beyond tempting.

Next thing I know I had bought it, followed shortly by some other bits such as a Resistance and Capacitance box. Not sure why other than its nice to have some stable things to check my new multimeter against (more of that later).

I can’t seem to find much info on this unit as Clare has been bought out and is now owned by Seaward. Though I did find a page referring to a Seaward V242

V242 Calibration Check Unit

The V242 is intended for on-site verification of the Clare range of electrical safety testers. It is recommended that this instrument is returned to Clare Instruments for annual re-calibration.

The V242 is capable of checking the following parameters.

90, 115, 450, and 575 mΩ (Calibration limits ± 5% of value)
0 – 5000 Volts A.C. (Calibration limits ± 1.5% f.s.d.)
0 – 2500 Volts D.C. (Calibration limits ± 1.5% f.s.d.)
100 KW – 200 KW – 400 KW – 1 MW – 2 MW 5 MW – 10 MΩ – 20 MW. (Calibration limits ± 1%)
50 MW (Calibration limit ± 3%) – 100 MW (Calibration limit ± 4%)

The flash trip value of 5 mA can be checked using the Insulation Resistance value of 200 KΩ, which will give a reading of 5 mA at 1000 Volts A.C. or D.C.

No facilities provided for checking live load modules, such as ammeters and wattmeters, fitted to many Clare test stations. Such modules should be checked using a good quality AC test set.

This is from the above website.

I did some quick checks and most of the resistances are good but the Low ohm earth ones aren’t so good but that is mostly due to my meter not being designed to measure that low and the unit being designed to have 25A running though those resistances. So unless I find a 25A power supply that I can use then measure the ohms in the same way you do with a shunt.

Annoyingly someone has stuck stickers on the instruction sheet, I am looking at how I might be able to remove them. The brass/copper connectors on the front are also in rather poor condition so I thought I would open it up so I could give it a clean.

Now that I could see inside I noted it is rather basic. More importantly I can get to the nuts to remove the posts. So I removed one and had a go at cleaning it in a solution of salt and white vinegar.

I will admit I did make a mistake with cleaning some of the bits as I put them all in the same cup. The washers are zinc and that attracted the copper so ended up with the bits going black, but thankfully it only took a little light cleaning with a copper brush. The next connector I did them separately.

What will I use it for….I don’t quite know. Might take it on-site the next time I have a few of the old Clare flash testers to look at and see how it compares.

Oh look another project

Now this isn’t one of my bikes. This belongs to my Dad and was bought many years ago.

I had to fit the bike rack as originally the idea was to pickup my TY175 but the BSA was in the way so that came home first. I did make a start on painting the rack, might get the rest powder coated.

Now the BSA,

This is a BSA B25S Starfire (250cc) from 1969 and was sent to Canada. Then brought back to the UK. We still have the fun of getting this road registered. But for now we just wanted to get it going, my Brother-in-law had this for a while and had got it going. But after a few prods of the kick starter there was no life. So we made up new HT leads and Dad got on with looking at the points. Not long later it was running, of not a little high revving and a bit smokey but it started first kick.

Later that day I was painting some BMW bits and I happened to trip on some of the Buzzweld PIO (Plastics in One). Therefore I painted the seat. I suspect it will need recovering or repairing as there is a small hole in it.

While I wait for parts

So the parts are taking their time to get to me so I took the opportunity to do some work on some of the bits that I can’t normally get to. Now this isn’t going to be a concourse bike this for now is just to slow the deterioration and to tidy a few bits up.

Just a coat of primer, black paint and a self-etching lacquer to finish it off. This is mostly hidden, I just wanted it to sparkle a little. I also painted the airbox and the airbox cover while I was at it.

Another job was to clean the gearbox and the clutch housing. It took quite a bit of time to get it this tidy. Next stage would to get it vapour blasted but I just don’t want to spend that kind of money yet.

While I have the rear shaft assembly out I gave that a damned good clean and then sealed with some more self-etching lacquer from the people at Buzzweld.

Now to await the parts so I can get this thing back together.

And it was a nice day

As lockdown is easing a little I had to drop some stuff off at my sisters in Wiltshire so I took the bike. That went well, the bike was going well so I thought I might as well take the shortcut home and wave at a friend that keeps offering me money for the bike.

Just outside of Cirencester while in the outside lane doing 70mph on a dual cabbageway I lost drive, but I could rev. The first thought was oh dear the chain has snapped but being a BMW shaft-driven bike I wasn’t so lucky. I pulled over and there was little or no drive. I noticed a sign ahead for parking so with some luck I was able to ease the bike to a safe place under the trees. I rang home to say what had happened and Dad though happy to come to get me wasn’t going to be able to make it for a quite a few hours. This is when I made a mistake, I thought I would just get the RAC out. They have been good to me in the past.

I rang, told them what was wrong and I needed recovery. They said they would send a van. The van driver rang, he agreed that he doubts he could repair it at the road side so called the office to get them to recover it.

So 45mins later, he turned up. Looked at the bike and listed to the clanking etc. Said “yup, its broken alright”. So told the office and a recovery lorry would come out soon. I rang at 5pm, it was now 6pm. I waited, I crossed the road to keep in the sun as I had a feeling I might get cold.

Had a call at 8 from a chap in Frome saying he would be 1.5hrs, oh someone else local has the job now, they will call you shortly. Just after 9pm a chap turns up.

The bike is strapped down, I never like the way bikes get strapped down to flatbeds. On the centre stand, straps to pull it forwards and down. Straps on the rear to pull it down. Just the centre stand keeping it on the ground. At one point both front and rear wheels touched the deck…I whelped and we changed the straps about. Eventually home for midnight. It was a long day.

The next day filled with ideas of what had failed we started to strip the bike down. Its amazing how quickly these things go from big bike to half a bike.

As you can see we were tempted to make it into a some sort of BikeExif custom thing, but as I don’t own any exhaust wrap we didn’t bother. After the removal of the gearbox it was easy to see what the problem was.

That would be a rather broken clutch. So a new one has been ordered. I decided to go for a nice Sachs one as that is what BMW fitted. I was tempted to go for a Heavy Duty one that is happy to get oily etc but I wanted to go with tested an proven.

Sorting – Jubilee Clips

So some of you may already know but I do like collecting a sorting parts. Mostly nuts a bolts. The reason, I dislike taking time to search and hunt for bolts. Many times have I gone looking for a bolt only to find 3 of the right size but not a 4th. Then there is the “we have some, but not sure where” thing. So I like to sort and label the boxes, yes even the label maker have a label on it saying label printer.

Yes, spelling isn’t my strong suit.

During my last sort out a lot of the boxes got new labels. Lots of labels. I spent a good afternoon messing with the software for Brother Label printers as you can do stuff with spreadsheets etc and I use that at work often enough but this printer isn’t as smart and OMG the software is a nightmare to work with. So I resorted to hand typing lots of it out.

The boxes look rather smart as well. I ended up buying more tape and then reprinted a lot of the labels at a larger size as I may well end up like my Dad and needing glasses.

Then I faced this,

It is just a mess and drives me up the wall whenever I look for one the right size, not helped by the container also ending up with a good amount of oil in it. I was thinking of a neat way to sort these, then I remembered someone I know had got fed up of not having the jubilee clips he needed so he bought some but he went the extra mile and just bought a shop display unit of them.

I thought about this, as it is just so shiny and neat and oh shiny. But then I looked at the cost and though hmm I have plenty I just need a rack. Time to fire up the laser we have sharks to fry….erm OK. A quick bit of skilled drawing and I had an idea.

It made sense to me and I went and started drawing in Illastrator and Inkscape to get the design just the way I liked it. Then it came to cutting with the laser.

A bit of jiggering about and I had it assembled, I didn’t have any PVA glue to had therefore I used some hot glue.

Its not perfect, but it does what I wanted to do.

If you want to make your own based on my design then head over to thingverse where I have uploaded a slightly modified version as I made a few slight design changes.

Matchless loom mk2 part 2

Now it is time to fit the loom, not too hard on these old bikes but you still need to start off with the right mindset so make a brew and drink it as you work out what to do.

Basically, that is my crimp tools for un-insulated wire and I tend to use both of them as work on this bike. Some are better for the bullets others are better for others. Though I ought to look at what AMP/DMC/Tyco make for this as I am sure it is expensive but they would do the job right.

It didn’t take long to feed the main part of the loom into place. Now the fun task of crimping the ends and making the various connections.

Lots of tea was needed for this task as its a right pain to follow the diagram and get it to work. The switches I have don’t seem to have the same bridged connections as suggested in the wiring diagram. Thankfully it isn’t to hard, but you can still make mistakes (more of that later).

While I was in there I had thought it would be a good time to fit a new horn & dip/main switch but annoyingly the new switches aren’t the same and the wire colours were wrong. Oh well, not wasted, this will go on the AJS once I get to it.

After a lot of faffing its starting to come along,

As with the modern loom, I had tried a few months back I also fitted and extra earth to the headlight for extra care. I must say the old way of using these connector blocks is quite nice. You can usually and up combining a few connections with little mess or bulk.

Then it was time for the midsection to get a look at. I fitted a modern rectifier (KPBC3510) as I was suspicious the old one was not in the best of shape. The modern bridge rectifyer I bought at the bike show but a search shows its avaible at RS for not a lot.

Then I had to wire in the rear brake switch and rear lights. The rear lights have caused me issues in the past, at one point using the rear brake was enough to act as a kill switch for the bike which was never fun as I approached junctions. I had again ordered a new rear switch only to find that the mounting holes didn’t align so more stuff for other bikes.

I’m glad I did this as the wire wasn’t in good condition. Then it was just a case of wiring the battery up and the ignition coil which again wasn’t too mad.

After all this, I revisited the Points and condenser. I replaced both units as I had a suspicion that the condenser was on its way out. While also in there the springs for the auto-advance/retard unit were replaced. Many of these bits aren’t that expensive but at least give you a bit of confidence when it comes to starting.

Now it is all done, so I do a few tests and erm it’s not working. Not getting a good spark and but the lights work but if I hit the horn I don’t get any sound but the horn gets warm to the touch rather quickly. More tea, and maybe dinner I rechecked my wiring in the headlight, I had make a error and had turned the horn into a dead short for the battery and the points wasn’t getting any more than the power from your kick. Thankfully I had used good thick wire so no burnouts. I was kicking myself for not fitting fuses but then again I didn’t see any fuse boxes I liked the look of, may fit one in the future to be safe.

After that was sorted out I took it for a ride and its working fine, then dad went for a ride. Later a neighbour who last saw this bike on the road the day he moved in 6 years ago managed to start it and off he went for a ride. I have yet to take it on a long ride but I will soon.

Matchless Wiring Loom mk2

I bought a Lucas loom, it didn’t work. I suspect I could make it work but considering I have moved the coil and added a modern rectifier I thought I might as well make my own. So an order went into Vehicle Wiring Products for some wire with the right colours stipes on and a selection of uninsulated Bullet (4.7mm/0.1850″ for the old bikes), and spade connectors.

I ordered wire in 1.0mm² (16.5A) and 2mm² (25A). I did some tests and the bike uses 11A but the larger wire diameter means a little less voltage drop. I got the 1mm² in case the 2mm² was way too big for my needs. Turns out the 2mm² was about the same as the old stuff. I took the original Matchless wiring diagram for my bike and added some colour to help with the wiring.

Now before I could start I had to sort, so the boxes of electrical bits came out and I procrastinated for a while sorting out the bits. This won’t be the last time. By the way, I have a large selection of Red and Blue insulated crimps with heat shrink, I have gone off them as a few times now I have done the crimp and it’s just pulled out, this could be a wire gauge issue or a crimp tool issue but I am converting to uninsulated crimps as I can get a good grip when crimping.

With that done and a cup of tea I started to look at the old loom. Its rather basic but I would like to have a neat loom.

I started off with tying the wire together with bailer twine so I could work out where the wires go an where they branch off etc.

Now I ordered 5m of each colour I needed to be safe, which means I have plenty left over for other projects.

With the basics done I started to think about how I was going to get the sleeving on. I had gone for the Braided Sleeving which is a pain to work with but does look nice once done. But with several cups of tea, I managed to get it on and the wires branching off where I needed them.

Then I added heat shrink to prevent the braid from falling to bits.

Now I have done the basic bit of the loom. I will fit it to the bike then make the wires shorter where I need them and then start crimping. I added a length of protective sleeving to prevent any undue wear from the tank and steering.

There is an extra wire in this loom, a red one. Its to run an earth (remember positive earth) to some where in the headlight as a backup. During this process I thought that I needed more eyelets to crimp on, I have a few but I ordered some to add to the collection, plus a new horn/dip switch and a new rear brake switch. This re-wire won’t be cheap but I enjoy having a go at stuff and learning new/developing skills.

In other news, I also challenged my friend with a Welder, “This Old Hoddy” to make me a tool for taking the inspection covers off the bike. It is rough but does the job. I just don’t like using a screw driver to undo them.

New Rear Mudguard for the BMW

I had a birthday recently, I spent that weekend painting the BMW. At the end of the day, my Dad’s only disappointment was the hacked up rear mudguard and how rubbish it looked. So as a present he offered to buy me a good second hand one. So moments later I ordered the BMW brake light from Motorworks and a more paint from Craig at Buzzweld because the mudguard we found was, of course, the wrong colour.

The guard eventually turned up and as I had to take some Holiday during this COVID-19 stuff I thought oh well might as well do something with the time.

A quick scrub down and I masked off the stickers and the BMW logo. Then out with the paint. I chose to go red again as it covers well compared to the white. and I thought I like to be different.

Then came time to fit, oh how much of a pain that was. It decided to interfere with the Metal Mule Pannier kit, and so, therefore, got a few scuffs in the new paint. I will touch that up another day. I took the opportunity while the mudguard was off to paint some Coo-Var Rust Converter as I do plan to repaint the frame one day but not just now, but I would like to prevent it getting any worse anytime soon.

Looks a lot nicer with the proper guard in place and I have got rid of the horrible bracket for the numberplate. Decided to fit the new brake light so the LED one I made had to be removed.

The indicator bracket I made up one afternoon looks like it needs to be removed and something else made. The Resistors for the Indicators also needs to move now. I am thinking under the seat on a new mount.

One of the other things I have been meaning to do is sort the Screen mounting points but I can’t seem to get the BMW bolts which are M6 with a 10mm spigot on top with an M5 tapped into that. I asked a friend if he could have a go so “This Old Hoddy” made up a few, they are interesting as he is still learning his lathe and Mill. I needed 4 but he had only made 2 that could be used.

But he told be he had ordered some hexagonal bar stock and would be having another go. A week later and he had done them, I collected on the way home from work kept distancing rules etc I even left them on a bag for a few more days before taking them out for a clean etc.

Technically they should look like this,

With a 17mm spanner head on them etc etc. But they fit and look right and they are mostly hidden. As the ones Hoddy made for me were plain steel I had to treat them. The idea of Cold Bluing them sounded like a good idea. Its a technique used on Guns to give them a layer of dark blue rust that can be oiled and precents the red rust we are all used to. Ordered a bottle and gave it a go, as I did this I asked some of the Ixies on Ixion and they were strongly against it but it was too late I had done it.

Doesn’t look too bad, if it doesn’t work I will take them off and either spray them or get them treated. I am trying to avoid buy a DIY Zinc plating kit but I am getting weaker by the day.

Fitting the screen etc was rather easier than before as I now had the right sized bolts and wasn’t faffing about.

You might also noticed I fitted the head light surround, using some more of the 3M double sided tape. With the evening starting to draw in I decided to give the headlight grill I found at the bike show a bit of a spruce up.

I went for white to go against the red. Now she has pretty white teeth to smile at others as she goes by. Maybe then people wont stare at her saggy pistons (she isn’t a MV).

Squeal Like a Land Rover

For ages, I have had a squeal on the Land Rover. I made the mistake of asking on the forums etc. Which is never a good idea as you always have people quoting the most expensive item to fix. I decided to let it develop so that I could finally be able to hear it easily and know that it was.

I had thought it was the Viscus Fan Pulley Bearing but as I stripped it down to get to that bearing I removed the serpentine belt and behold the two idler wheels were rather wobbly and one was crunchy. Look at the price of the parts, £45 without the postage, eek. https://www.lrworkshop.com/diagrams/land-rover-defender-engine/td5/drive-belt_53211

Hmm, they look like standard bearings, a quick call to Frome Bearings and Belts LTD and they have them in stock. Less than £20 and I had the bearings, admittedly it should be 6303LHA and I fitted 6303LLU but it will do. The only info I can find is HA is case hardened outers but not sure how that is going to make a difference.

I started to tap the bearings out but soon the shed dwelling parent turned up and using some random old sockets and a number 2 hammer managed to convince the old bearings to leave and move in the new ones. I refitted and now the Land Rover it quieter, for now. I may need to give the Land Rover a wash now.