Guzzi 1100 custom build
Printed From: guzziriders.org - moto guzzi forum
Category: Technical
Forum Name: Big Block Tonti
Forum Description: Spada, Le Mans and Cali
URL: http://www.guzziriders.org/forum_posts.asp?TID=14245
Printed Date: 07 Jun 2023 at 00:42
Software Version: Web Wiz Forums 12.03 - http://www.webwizforums.com
Topic: Guzzi 1100 custom build
Posted By: Buzzer
Subject: Guzzi 1100 custom build
Date Posted: 16 Jan 2022 at 11:34
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thought I would start a thread on the build of my Guzzi 1100... not sure on the final look yet... but it will be a comfortable bike, so no clip ons! this is my first Guzzi build, but i have 9 Ducatis under my belt! Here it is as it came, and what's left after I took all the parts off I know I wont use...    ------------- My blog! Www.jtccc.Wordpress.com |
Replies:
Posted By: Buzzer
Date Posted: 17 Jan 2022 at 10:18
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As you can see not much progress at the moment, that's because I am finishing off my last build... However I did have some time to spare to make some Bell Mouths for the Keihin carbs I will be using on this build. I made them using the old method of metal spinning in the lathe. At first I just made them open, but when I thought about it I wanted some gauze on there. It took a bit of thinking about to come up with a method of attaching it that looed neat. here is the result, and a link to a video of how I did it! https://www.youtube.com/watch?v=brYe3Hnpd1g" rel="nofollow - Link to my video!  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: paulbricey
Date Posted: 17 Jan 2022 at 11:01
They look beautiful & great work (love the bellmouth turning !)..... wish I had the skills & a bigger lathe....wish the engineer monkey on my back wouldn't scream 5 micron air-borne particles  ------------- Griso 1200 8V, V50 |
Posted By: Buzzer
Date Posted: 17 Jan 2022 at 14:11
Do you think we have the same Monkey   mine keeps saying "fit filters, fit the filters..."  ------------- My blog! Www.jtccc.Wordpress.com |
paulbricey wrote:Posted By: Brian UK
Date Posted: 17 Jan 2022 at 16:08
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There is no doubt filters are fitted for a very good reason. ------------- Brian. Better 5 minutes late in this world than years early in the next. |
Posted By: Buzzer
Date Posted: 31 Jan 2022 at 09:50
Time to make some silencers(lose word!) I bought these cheap stainless ones off eBay as the hard part in making silencers is rolling the cone… and they are expensive to bye. I cut the end off, removed the inner resonator tune and made some cones for the end. this makes them re-packable for the future. I can also fit the baffle for MOT time.
 ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 12 Feb 2022 at 13:57
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Up on the hoist for the first time… I have temporarily used
a build stand that I have used for Ducati’s, but I will have to make a specific
one as this one will impede making the exhaust fit on the bike. First job has
been to make some inlet manifolds to fit the carbs… I wanted them angled
upwards and inwards, and that took some working out to get the compound angle
right! it ended up as 68.5 degrees. As the carb diameter is larger than the
head inlet, I needed to use a tapered tube… To do this I turned up a tapered
mandrel, and after annealing the alloy tube, I pressed it in with the vice,
which expanded the tube by the required few mm. I then turned a grove to accept
the lip inside the carb mounting blocks. the next bit was actually quite difficult… I needed to make
the hole on the flange a nice fit on the tube, but at an angle. I deliberately
cut the 10mm plate quite large so I could get it mounted on the milling machine
at the exact angle. I then bored the hole with an indexable boring head. If
that milling machine looks old, it is! I did some work on it a few months ago
and found a date… 1929! Next job was to TIG weld the flanges on, drill the holes,
and finally cut to shape. here is a short video of the manifolds being made... https://www.youtube.com/watch?v=-2EfrVdAiKo" rel="nofollow - https://www.youtube.com/watch?v=-2EfrVdAiKo
------------- My blog! Www.jtccc.Wordpress.com |
Posted By: R100CS
Date Posted: 12 Feb 2022 at 17:31
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1929 those were the days things were made to last, not use once, throw away and buy a new next time. ------------- 1st R100CS flattened by a truck 2nd R1150R modified 3rd V7iii GREEN |
Posted By: Buzzer
Date Posted: 14 Feb 2022 at 11:32
yep, I replaced the miller a few years ago with a new one... but went back to the old one within a month as the new one was so poor... a little side track as I had a new facing cutter for my milling machine and wanted to try it! I took the top yoke off and removed the section where the ignition switch fits… and milled it flat. I then contoured the edge to blend it in. Those power files are a great piece of kit, something i bought thinking I may not use it much, but I use it all the time! Then into the blaster to clean it up, it can wait a while for polishing….  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 15 Feb 2022 at 18:35
One thing I hated about the bike was the side stand… Just how agricultural is that bracket! I know its a great functional design, but its SO ugly! so out come the angle grinder and it is no more! In the loft (or as my wife calls it the spares department!!) i had a side stand off a 1994 Honda CBR 600… it bolted straight on! Just need to adjust the angle a little when the ride height has been set. a job for much later on...
 ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Ken-Guzzibear
Date Posted: 15 Feb 2022 at 18:38
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The Ev /Cali long side stand was designed for Police use ( Some Harleys use exactly the same stand) It means you can operate it with a boot from the saddle and once deployed the bike will not be knocked over by the wind blast of a passing truck.
The bracket is designed so it allows the bike to lean furthermore there can be an additional gismo that operates a secondary rear calliper to effectively add a park brake, used mainly on the Convert auto box. ------------- The Older i Get, The Better I Was |
Posted By: Brian UK
Date Posted: 15 Feb 2022 at 21:18
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Beauty is in the eye of the beholder, as they say. ------------- Brian. Better 5 minutes late in this world than years early in the next. |
Posted By: Buzzer
Date Posted: 17 Feb 2022 at 10:00
That is so True Brian yesterdays job was to mock up the exhaust... I had ordered some 2" mandrel bends and straight pipe as I wanted that chunky look, and for the pipe to fit straight into the silencer with no reducer. From a performance aspect, the large headers are probably not I deal... but I wont miss a few BHP! I also wanted that angled swept back look (old School!!) The bends are 135, 45 and 30 degrees. It should all polish nicely as its stainless steel. This bike will have more forward mounted foot rests, hence I could kick up the silencers earlier... I find making exhaust systems quite therapeutic, although sometimes I could do with a third hand. My wife used to help, but since I burned the back of her hand with the hot end of the filler rod, all help has been withdrawn!   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: johnno
Date Posted: 17 Feb 2022 at 12:52
Pipe work  ------------- 1100 sport corsa , Yam R1, guzzi 650tt rider |
Posted By: Ken-Guzzibear
Date Posted: 18 Feb 2022 at 12:06
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Nicely done on the zorst do you tig it? ------------- The Older i Get, The Better I Was |
Posted By: Buzzer
Date Posted: 19 Feb 2022 at 12:02
yes, its all TIGed together   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Ken-Guzzibear
Date Posted: 19 Feb 2022 at 12:57
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Nice work the only item I don't have a welder .... but then rarely need to braize or weld things on the odd occasion I pop to a local fabrication shop and for a few beers can use their gear ------------- The Older i Get, The Better I Was |
Posted By: Buzzer
Date Posted: 20 Feb 2022 at 12:18
I only had a MIG for years, I do some consultancy work for a fabrication company so any TIG i just popped in there... What I found though was making things like inlet manifolds I needed to have the TIG there on hand, hence I bought one in the end... its AC/DC so it does alloy and ferrous. I have to say its brilliant! The nice thing about TIG is you can also TIG braze with the right rods... I have recently made some rear footrest hangers, which was my first ever go at brazing with it.. My mate has just bought a cheap DC TIG inverter so he can only do ferrous, but that's all he needs. He paid less than £100 for it new, and I have to say its superb! he uses the small gas bottles with it that are around £16 each.  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Simond
Date Posted: 20 Feb 2022 at 13:54
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I can run to the hundred quid for the welder, it’s whether I can afford the mountain of scrap that would be required for me to learn to use it…
Which is a roundabout way of saying, “the exhaust looks good”. :)
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Posted By: Buzzer
Date Posted: 22 Feb 2022 at 10:44
I know what you mean... there are some great tutorials on YouTube though! Next on the list is the new foot controls… I sat on the bike and decided where I wanted the foot pegs to be. This bike wont have rear-sets, I want to to be comfortable to ride! I then measured how long from the peg the brake and gear lever needed to be and set about designing some controls. It would have been easier to have had them water jet cut, but that’s a 3 hour round trip for me, and usually quite a wait, so I decided to mill them out instead. What has made a BIG difference to me is the acquisition of a band saw… Its great for cutting stuff like this out! I was so lucky to acquire it… my mate was throwing it out! I made a couple of spigots to mount them on the frame which I will weld on. I have used a couple of Oilite bushes on the holes rather than run the alloy directly on the steel. the first spigot I made I realised I had counter bored it a bit too far and it would have been too weak… a case of measure twice cut once! I then bent them in the vice to get the correct crank angle to clear the exhaust.   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Ken-Guzzibear
Date Posted: 22 Feb 2022 at 13:22
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Some time ago I was taught to gas weld Copper then tig weld copper cylinders ...went on to work for a place that sold specialist repair rods and Mig/Tig machines so learned to braize/weld stainless, Cast Iron, steel, Alloy and of course copper sheet. BUT like any skill when you don't use it you loose quite alot of skill. Therefore to "get into" it again takes time and patience. As an apprentice I also learned to solder to very high Telephonic standards but soldering now takes me time to complete. ------------- The Older i Get, The Better I Was |
Posted By: Buzzer
Date Posted: 25 Feb 2022 at 13:50
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The finished results, apart from a good polish... As I am going to use a Ducati rear calliper, I have also used a Ducati Master cylinder, and also used the same leverage ratio for the pedal... here is a short video   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 02 Mar 2022 at 13:32
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As I am taking off the linked brakes I needed to use a different rear caliper. I toyed around with making the rear caliper floating and using a torque arm… but in the end decided to use a neater, smaller bracket instead. It also meant that I could mount the speed sensor for the speedo as I am using a combined speedo / tacho.  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Brian UK
Date Posted: 02 Mar 2022 at 15:36
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Why did you need to use a different caliper? De-linking means the master cyclinder is too big. ------------- Brian. Better 5 minutes late in this world than years early in the next. |
Posted By: Buzzer
Date Posted: 02 Mar 2022 at 16:52
I used a different caliper for a few reasons... firstly its physically smaller than the original... second, I didn't want the complication / pipe runs / compensation valve associated with with the split system and finally I wanted to use a smaller physical size master cylinder due to where its now mounted. if you look on the pictures above you will see I have used a Ducati master cylinder and caliper, and made sure the leverage rations suit the new parts.... ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Ken-Guzzibear
Date Posted: 02 Mar 2022 at 21:42
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look on Digital speedos they have a unit screws into the guzzi speedo drive on gearbox takes analogue to digital most tachos work from the Lt coils ------------- The Older i Get, The Better I Was |
Posted By: Buzzer
Date Posted: 04 Mar 2022 at 16:08
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The tank I am using is off a V7… It was cheap to buy because it had a couple of big dents, which I have managed to get out. To do this I had to cut a couple of holes in the bottom to give access with a 20mm bar with a dome on the end, which I then used to knock most of the dent out, just needing a skim of filler. I then welded some plates on the holes and leak tested them with dye penetrant. I use this a lot, its great for checking for holes and cracks, they show up immediately. fortunately all was good in this case. I prefer doing it this way to filling it with petrol as if you do have a leak its a pain to clean it out again. I have taken to using the dye penetrant on frames before I have them blasted… its surprising how many have cracks! especially Ducati! A while ago my mate welded an RGV 250 engine mounting on the alloy frame. When he had welded it, he used some dye penetrant around the joints on the frame to check for cracks… There were quite a few! he welded them up and re-checked. Here is a gearbox I recently welded that still had a leak after someone had already welded it, you could not see it with the naked eye, but its easily visible with the dye…   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: professorjung
Date Posted: 06 Mar 2022 at 00:07
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loving this thread great work! advance apologies for the brief thread hijack.....
Ken, do you know which one of these would fit a california vintage? https://www.digital-speedos.co.uk/search/guzzi" rel="nofollow - https://www.digital-speedos.co.uk/search/guzzi
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Posted By: Ken-Guzzibear
Date Posted: 06 Mar 2022 at 08:49
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https://www.digital-speedos.co.uk/speed-sensors-c9/m12-type-m-cable-drive-adapter-for-smiths-and-daytona-gauges-see-post-for-applications-p432%20" rel="nofollow - https://www.digital-speedos.co.uk/speed-sensors-c9/m12-type-m-cable-drive-adapter-for-smiths-and-daytona-gauges-see-post-for-applications-p432
The Daytona M12 £27.99 click on specifications NB the Acewell one only works on Acewell Speedos but the people there are really helpful ------------- The Older i Get, The Better I Was |
Posted By: Buzzer
Date Posted: 12 Mar 2022 at 15:38
With the new master cylinder mounted I looked at a way of mounting a reservoir. I could have used one of the small plastic ones, but instead decided to make one. I am pleased with the way it came out! here is a short video of how I made it!   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 26 Mar 2022 at 16:13
Back from holiday where I unfortunaly got a dose of the virus! Not too bad though, I have had worse colds… But for a few day I have kept out the garage, and did some computer time instead and constructed the wiring diagram… I like to keep it simple, and wire from scratch, so many builds are spoiled by patching up the old loom. I am using an ignitech for the ECU, and its interesting that the the unit uses the cam sensor for one cylinder, and the crank sensor for the other. I like that idea!
 ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 27 Mar 2022 at 12:38
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I have agonised over the rear light / number plate arrangement… No matter how I plan it, it just does not look right with the number plate on the back, So I am going for a side mounted plate. that leaves the rear light to consider… the rear of the seat is angled (more later) so I needed an angled plinth to mount the light I am using on… here it is, bar a good polish. A new addition to the workshop is a bandsaw... How did I manage without one all these years! I modified the top and bottom guides so they have bearing supports and it works an absolute treat!   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 29 Mar 2022 at 16:21
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One thing I always like on a build is a light throttle… in these days of EFI its easy to forget just how heavy some carb throttles were, always a balance of lightness Vs a throttle spring strong enough to prevent sticking, As I am using flat slides on this build I really wanted to use a pull / pull throttle set up, which would either mean a pair of splitters, or a dual throttle. that way I can retain the light springs. Try as I might I couldn’t find a dual pull / pull one so I have ended up making one! If anyone knows of a company that makes them… DONT TELL ME! here is the story in pictures…    ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: johnno
Date Posted: 29 Mar 2022 at 18:25
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Excellent craftsmanship ------------- 1100 sport corsa , Yam R1, guzzi 650tt rider |
Posted By: Buzzer
Date Posted: 01 Apr 2022 at 11:14
the wheels are back from the vapour blasters… they have come out FAR better than I expected, and I quite like the finish, so I will be leaving them as they are. just a coat of ACF – 50 should keep them looking good. the spokes are stainless and have also come up well. First time in MANY years I have put my own tyres on! they are tubeless so went on very easily. just got to get them balanced. ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 02 Apr 2022 at 15:02
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seat next… I needed to bend the front to clear the tank bolt… So I made a former to press it into shape. I also made a tool so I could press some dimples where the rivinuts go, to raise the seat a little so the seat doesn’t sit directly on the frame rails… Things don’t always go to plan… I decided to mount the rear light on the frame, and cover with a piece of alloy… which I did, but then realised that on full bump the tyre would hit the plate! I had designed the rear to cater for full bump, but promptly forgot! I realised I needed to mount the light on the seat base, but I hate wires showing… so I decided to make a conduit out of copper tube so the wires can be hidden under the seat cushion. The seat is off to the trimmers today. I have not used this guy before… The girl I used for years to trim my seats left the company she worked for… the last guy I used was OK, but no where near her standard. So lets see what this new guy is like… Oh, and here she is in the daylight for the first time in a while…     ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: paulbricey
Date Posted: 02 Apr 2022 at 17:24
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That looks great ------------- Griso 1200 8V, V50 |
Posted By: Buzzer
Date Posted: 07 Apr 2022 at 18:30
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no matter how I tried I couldn’t get the number plate to look right on the rear of the bike… so on this build its going on the side, which kind of fits with the look I want to achieve…  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 10 Aug 2022 at 17:53
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Its been a while... I tend to have the summer off from garage projects, holidays, days out, bike rides take over! However I had a few spare days and thought I would make use of the warm days and paint the tank. It was badly damaged when I bought it, so I cut some holes in the underside and knocked the dents out. it takes an age to get it to shape, in fact as the metal had stretched, so I cut a 1mm slot in it, planished it, which closed the gap, and then welded the slot up! its nicely to shape, just the decals to put on now Another little job was to redo the speedo… I want to keep this build as clean as I can and wanted a smaller speedo. I decided to use one of the cheap GPS modules which is just 55mm diameter. I made a new housing for it, and will finish the bracket off when I start the assembly. it been in the car for a week on test!     ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: johnno
Date Posted: 10 Aug 2022 at 20:09
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Just 10 percent of your talent would do me fine lol ------------- 1100 sport corsa , Yam R1, guzzi 650tt rider |
Posted By: jmee54
Date Posted: 11 Aug 2022 at 12:32
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This is a fantastic post for demoralising me, but keep it up! It is great seeing machining skills that I once had and can no longer achieve. Mind you Millyard seems to achieve miraculous results with a hacksaw and a file! |
Posted By: Buzzer
Date Posted: 11 Aug 2022 at 15:48
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thanks guys, i guess its years of experience doing this sort of thing! All finished... I always have my heart in my mouth on that last coat of lacquer over the decals! I know a lot of people struggle with paintwork, its not that hard if you follow a process, so I have written a guide on my blog if anyone is interested... https://jtccc.wordpress.com/projects-2/paint-spraying-at-home/  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: jmee54
Date Posted: 12 Aug 2022 at 09:14
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A great blog too! |
Posted By: c13pep
Date Posted: 12 Aug 2022 at 16:20
What`s a blog  Now you know why I ride a Monza NO TECH involved CHRIS ------------- you can`t have any fun in a straight line Monza |
Posted By: Christy
Date Posted: 15 Aug 2022 at 08:15
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Not used the orange paint up yet then!
Great job though. ------------- Back on a Breva ... Again!! Breva 1100, Ducati Monster 900, Multistrada 950, 900SS Project |
Posted By: Buzzer
Date Posted: 15 Aug 2022 at 13:20
Thanks! I ahve plenty of orange paint left Out in the sunshine for the first time in a while… I am now happy with the look, and it now all needs to come apart for the frame to be tided up and painted silver (matches my other bikes!) I will be doing a mechanical rebuild at the same time.   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 21 Aug 2022 at 14:12
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Here is the speedo and warning lights finished, I am pleased with how this has come out, i wanted this to be as clean as I could… as with all electronic components I like to rubber mount them… so I have used some small grommets and spacers. The GPS speedo has a nice little feature which tells you which direction you are traveling in!  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 30 Sep 2022 at 12:08
Autumn arrives… Bike rides become less frequent, and the holiday and days out season slows down, so its back in the garage! the bike is now in the stage where all the fabrication is done and it all needs taking apart and cleaning and painting. Engine removal was quite easy with the removable frame rails and it was all soon apart and the engine and gearbox on the bench. I finished off all the welding on the frame and removed all the unused lugs to get that clean look, and sent it off to the powder coaters.
 I will be doing a full engine gearbox and drive unit rebuild, mainly to vapour blast the cases. This of course means making a few special tools! First off was an extra long 32mm socket. I cut down a standard one and extended it with some thick wall tube.  next was a tool to undo the 27mm nut on the gearbox output shaft. you need to hold the shaft as well as turn the but so it needs to accommodate this. I used one of the spare Ducati wheel nut spanners I had laser cut years ago and bored it to shape on my new milling machine. Picture of that to follow!  next up took some thought… I needed to hold the shaft while I undid the nut. It would have been Ideal to use an old UJ but I didn’t have one… But what I did have was an old drive shaft. Out of this I made a stepped broach in the the lathe and then hardened it. With this I was able to broach a set of splines in a block of 10mm alloy, cut to fit a large spanner. It worked a treat!  finally, I made a tool to remove the castellated nut on the input shaft from an old socket, and a tool to hold the clutch hub from an old clutch plate. I think that may be it as far as special tools go!  I have been debating replacing my milling machine for a long time… but I have had it for almost 45 years and its like an old friend! over the years it done a lot of work, but its a 1929 machine and has its limitations! When my wife asked me what I wanted for my Birthday it was an easy answer! The old machine has gone to a good home where I know it will be looked after and used…  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: paulbricey
Date Posted: 30 Sep 2022 at 13:07
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Loving the over-engineered special tools - all looks top notch quality to me (& makes my benchtop lathe & milling machines look tiny/puny). ------------- Griso 1200 8V, V50 |
Posted By: Ken-Guzzibear
Date Posted: 30 Sep 2022 at 18:20
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oh dear ------------- The Older i Get, The Better I Was |
Posted By: Buzzer
Date Posted: 30 Sep 2022 at 18:43
Oh dear ? ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: borderer
Date Posted: 30 Sep 2022 at 19:24
| Where do you source the Mini LEDs for the warning lights? |
Posted By: AdrianW
Date Posted: 01 Oct 2022 at 08:25
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Buzzer, You are fortunate that you (probably) don't live near me - I would be constantly around saying "could you just make me one of these?".. I can only admire your skills and wonder from afar... It's going to be a great bike... Cheers, Adrian Bristol UK
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Posted By: Buzzer
Date Posted: 01 Oct 2022 at 12:41
there are lots on Ebay, just search for pre wired 12V led... they come in 3, 5, 10mm and are ultra bright! ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: borderer
Date Posted: 01 Oct 2022 at 16:53
| Thanks I was looking on Amazon and they only had down to 6mm, I am guessing you are using 3mm? |
Posted By: Buzzer
Date Posted: 01 Oct 2022 at 18:05
yes, I used 3mm ones for this job, but I will probably fit a 5mm one in the middle as a shift light. these are the ones I use, they come pre wired with a resistor in them, they are VERY bright! https://www.ebay.co.uk/itm/122154513040?var=422357785935" rel="nofollow - https://www.ebay.co.uk/itm/122154513040?var=422357785935 ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 02 Oct 2022 at 09:16
I much prefer the look of the older round barrel engines... so out came the angle grinder! ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: borderer
Date Posted: 02 Oct 2022 at 17:27
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All you need is a set of round block rocker covers and make up an adapter plate for them |
Posted By: Buzzer
Date Posted: 06 Oct 2022 at 09:34
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Time to overhall the hydraulics… just waiting for some new bolts to assemble the callipers. everything was in surprisingly good condition, just a strip and rebuild needed. Then onto the job I hate most… Polishing! I have a 2 HP 3000 RPM motor I use for this. Its a long, filthy and somewhat dangerous job. I try to do it all in one day as you get filthy, and its the sort of dirt that won’t wash off with hand soap, so I have to use washing up liquid! I have also rebuilt the forks and put in new seals and dust covers, and some fresh oil. they are very simple forks, no where near the sophistication of the Ducati ones I normally do!   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Dave P.
Date Posted: 06 Oct 2022 at 14:29
The rounded barrel looks much better in my opinion but,what about the loss of cooling surface area?  ------------- TO LIVE OUTSIDE THE LAW YOU MUST BE HONEST. 1971 V7 Special. 1972 850GT. 1970 T120 Bonnie. 2009 500 Bullet. |
Posted By: Buzzer
Date Posted: 06 Oct 2022 at 19:26
the loss is minimal, and engines are built to cope with extremes of temperature...here in the UK its never going to get that hot i guess ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 07 Oct 2022 at 11:51
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I have read on a few forums that over the miles the preload on the pinion bearings gets loose, and sure enough it spun Just a little too free. So I removed a thin shim and re-torqued it up after inspecting the bearings which were like new. I couldn’t use a torque wrench so I used a balance on a long spanner and calculated the pull needed for the correct torque.  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 09 Oct 2022 at 17:27
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I am amazed at how little wear there is on the engine and gearbox components. there is no disenable wear on the crank or bores, pretty good for 30k miles! I cleaned out the sludge trap in the crank but it was clean, glad I did it though as the bung was far too lose for comfort! it has a dab of retaining compound on it now. the only wear I have found so far is a roller bearing in the rear drive, and as you can see there is pitting on the inner race. this will be replaced.    ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: paulbricey
Date Posted: 09 Oct 2022 at 17:38
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Looking great - that's defo a nut & bolt restoration job ------------- Griso 1200 8V, V50 |
Posted By: Buzzer
Date Posted: 15 Oct 2022 at 11:16
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well the frame is back from the powder coaters, along with the plating of all the smaller parts. Its always a dilemma what colour to go on the plated parts… I can have them silver, but the corrosion protection long term is much less than the yellow passivate, so yellow it is! The frame has come out superb as usual, but the swinging arm is terrible. I knew it was pitted, but he said when he blasted it, big flakes of rust came off, and although he coated it, he knew it would not be acceptable to me. The extent of the pitting was so much I decided it was a no go to tig braze the pits. He did say he could improve it, but I decided to try and find one that’s less corroded. We will see.  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: paulbricey
Date Posted: 15 Oct 2022 at 11:30
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Frame looks great (& forks/calipers)....surprised you haven't fabricated a swing arm yourself (maybe that should read YET) ------------- Griso 1200 8V, V50 |
Posted By: Buzzer
Date Posted: 17 Oct 2022 at 14:08
I have sourced a second hand one!While everything is on hold while I wait for the cases to come back ( blaster has Covid and is really poorly...) I agreed to help a friend of a friend who was struggling with two broken studs in a cylinder head, so I though I would share my knowledge on removing them... removing broken studs is always a problem, especially where someone has had a go first! in this case they had drilled off centre and then broken an easy out in the bottom! in 50 years of doing this stuff I have NEVER seen an easy out remove a broken stud in alloy… My technique for broken stud removal is to first clean the head of the stud with a burr in a Dremel to get it nice and clean. Then use a half nut the same size of the stud, but drill the threads out so again its nice and clean. Place the nut central on the stud and start off with the TIG on low amps and just puddle the weld on top of the stud.. This permeates the heat down the stud… Build up the weld inside the nut until its flush. I have the electrode sticking out a bit more than normal to get close to the stud top. Once its cooled a little, give it a tap with a small hammer for a bit of shock. then try working it back and forth… its its too tight, or squeals as you try to turn… it stop. Then if its possible drill a hole into the alloy from the side and JUST into the stud. over a couple of hours feed some Plus Gas (wonderful stuff!) in the hole and work the nut back and forth… I have had great success removing studs this way in alloy.  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 19 Oct 2022 at 18:41
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Looks like the guy that does my blasting is still poorly, so I have turned to working on the next project until I get all the Guzzi cases back... something I don't normally do as I like to do one project a time... There are a few things I can get on without getting seriously into it, one of which was to make some tapered inlet manifolds. This is another 1000DS Ducati build and I am exploring the Idea of using a small supercharger off a VW 1.4 TSFI... we will see once I get properly into it, but for now here is how I made the manifolds. ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: theone&onlymin
Date Posted: 19 Oct 2022 at 20:27
pop around to Clinton at Threadworx and he'll do it ezpz so he will. David was around with him the other day to remove the Allen Head bolt which was rounded up the bottom of his T3 fork leg. |
Posted By: Buzzer
Date Posted: 29 Oct 2022 at 11:04
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All the parts are back from the blasters, so its cleaning time… nothing scraps an engine like leaving glass media in there so its important to get it all out. I have a process I use for this. First I wash it all off in petrol… paying attention to all nooks and crannies, holes and oilways with a long thin bottle brush. then I jet wash it off, and blow it all off, including all holes. (you need goggles for this!) then its into a stainless steel tray and another wash off with petrol, and then I use carb cleaner with a long spout into all the holes and oil ways… if there is ANY single bit of media in the tray, its back to jet washing and blowing off again. Its easy to see any media in the stainless tray. Here is the gearbox in the stages of being built up.
------------- My blog! Www.jtccc.Wordpress.com |
Posted By: paulbricey
Date Posted: 29 Oct 2022 at 15:28
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Did you put all new bearings ? (Guessing you would given how cheap they are & since they were all out) ------------- Griso 1200 8V, V50 |
Posted By: #1moto-uno
Date Posted: 30 Oct 2022 at 01:25
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Maybe a bit after the fact , but some years ago I went through a similar cleaning process after bead-blasting and all appeared fine ( on a cylinder head) . I decided to heat the head ,far too hot to touch , and placed some paper towels on the wood work bench . I then slammed the head onto the towels and was quite surprised to see how much media came from the heated head ! Just something else to consider in the future :) . Peter
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Posted By: Buzzer
Date Posted: 30 Oct 2022 at 10:52
That's a good tip! It really is a pain to get all out... another tip I was told by the blaster was to thoroughly de grease oilways BEFORE blasting. he said flushing them through with petrol/carb cleaner first, prevents the beads sticking to the oil/gum in there... I have only been defeated once, and that was some Ducati Monster cylinders... in the end I had to remove and replace the core plugs to get all the bead out. Carb cleaner with one of those tubes on really is a friend here... you can even join two tubes with an inch of pen refill tube to get an extra long reach... I do quite a bit of dry bead blasting at home, which is great for small parts, but my machine is not big enough for crankcases... it works brilliantly now I have it set up right... at first I was getting a dull finish... I mentioned this to the bead supplier and he told me my presure was too high and I was shattering the beads and turning them to sharp glass dust! he said turn the presure down, and then up until you just get it cleaning, and that's the right presure. he also told me that if you mark the surface with a grubby finger and it stays after you wipe it, the surface is still "open" and its a poor finish. he also said if you wipe it with a microfiber cloth and it drags... poor. it should glide across the surface. below is a picture of my setup, with a home made centrifugal extractor underneath which works brilliantly! Also an example of good and poor blasting.    ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 31 Oct 2022 at 11:57
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Onto building the engine… of note is the tool to compress the clutch, which is actually the centre splines off the gearbox, and a threaded bar into the crankshaft. this makes the plates perfectly aligned and makes fitting the gearbox easy. next the cylinder heads… it took three attempts on these to get the bead out of one oilway! note the new tin of grinding paste, the old one has run out of the fine end, but it was 50 years old, I can remember my Dad buying it me as a teenager! Good to see the company is still going and using the same tin! Just to be sure I checked the bores for wear… there is none at all! Got to love Nikasil bores! here is the engine and gearbox all back together… I decided to add some accurate timing marks on the flywheel for each cylinder so I can use a strobe and see what’s happening in reality. used my new digital DTI gauge… not sure I like it… watching that needle go round is far more satisfying! and finally its all back together and ready to go into the frame      ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: borderer
Date Posted: 01 Nov 2022 at 10:09
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Very good but I think you need round barrel rocker covers
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Posted By: johnno
Date Posted: 01 Nov 2022 at 11:18
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That is a WOW from me ------------- 1100 sport corsa , Yam R1, guzzi 650tt rider |
Posted By: Buzzer
Date Posted: 02 Nov 2022 at 15:21
Here is the finished final drive with a new bearing and seals.  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 05 Nov 2022 at 12:29
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The engine is now back in the frame, a nice and easy job with the removeable bottom frame rails…  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 05 Nov 2022 at 18:23
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I didn't want to use the frame as a breather as it can rot them out, and rust partials can drop down so I am told... so I decided to make a new breather the vent the crank case and also the heads. Here is is... will it work? Who knows, we will see!!  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Buzzer
Date Posted: 09 Nov 2022 at 13:51
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Two jobs today... first was to make a paddock stand. I hate the universal ones as they are very difficult to get a bike on one on your own..., and often not that secure. this one positively locks onto the wheel spindle, and when its on the lift I can clamp it to the top so its nice and secure. The second was to make some bushes out of bronze to take the play put of the clutch lever as the hole had worn oval. I drilled it out and made some over size top hat bushes. Finally, here it is on its wheels!   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Stevex
Date Posted: 09 Nov 2022 at 14:06
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I think using rockers cover breathers is of little use on these bikes. Mine always used to produce mayo and the bike rarely did any low mileage journeys. I removed the rocker breathers and blanked them off. That was years ago and I've not had any problems since. The main crankcase breather is more than man enough. ------------- Steve https://imgbb.com/" rel="nofollow"> 
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Posted By: Dave P.
Date Posted: 09 Nov 2022 at 14:32
Interesting. The old Loops did not have rocker cover breathers and I've never found a trace of mayo on either of my Loops. ------------- TO LIVE OUTSIDE THE LAW YOU MUST BE HONEST. 1971 V7 Special. 1972 850GT. 1970 T120 Bonnie. 2009 500 Bullet. |
Posted By: Brian UK
Date Posted: 09 Nov 2022 at 21:08
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On the later Tonti engines, the rocker "breather" connection is actually the oil return from the breather box, or frame top tube in some cases. ------------- Brian. Better 5 minutes late in this world than years early in the next. |
Posted By: Stevex
Date Posted: 10 Nov 2022 at 16:18
It used to form in the breather pipes and drip back into the rocker covers, nasty stuff. ------------- Steve https://imgbb.com/" rel="nofollow">
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Posted By: Buzzer
Date Posted: 11 Nov 2022 at 10:40
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interesting comments on the breathers... I will suck it an see before I go too mad! I pondered for a long time on the throttle arrangement for this bike… I wanted to keep the pull to open, pull to close for a couple of reasons… First, its safer… manufactures didn’t go to this arrangement for no reason as bikes evolved. Second, it means you can have much lighter return springs, which in turn males the throttle much lighter, particularly if you are going for a quick action. . A light fast action action throttle feels like you have 20 BHP more! I do find a heavy throttle spoils a bike for me... I couldn’t find a 4 cable throttle anywhere, so I ended up making one from scratch…   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: iansoady
Date Posted: 11 Nov 2022 at 12:00
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Nice bit of engineering there. I suspect I would have gone the easy route and used splitter boxes. ------------- Ian 1952 Norton ES2 1986 Honda XBR500 1958-ish Greeves/Triumph in progress |
Posted By: Buzzer
Date Posted: 11 Nov 2022 at 13:36
I did once on a Ducati build... but I was never happy with the result... hence the 4 cable throttle...  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: krglorioso
Date Posted: 11 Nov 2022 at 15:13
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I cannot overstate my awe and admiration of this build. Ralph ------------- Ralph G. |
Posted By: johnno
Date Posted: 11 Nov 2022 at 18:56
------------- 1100 sport corsa , Yam R1, guzzi 650tt rider |
Posted By: iansoady
Date Posted: 12 Nov 2022 at 10:07
The centre stand on my ES2 is one of the worst I've ever encountered. I normally use the prop stand (adapted from a Kawasaki ZZ) but knocked this together to attend to chain oiling etc. Not engineering but bodging (in the original sense) and recycling of stuff lying about in the shed.  ------------- Ian 1952 Norton ES2 1986 Honda XBR500 1958-ish Greeves/Triumph in progress |
Posted By: Buzzer
Date Posted: 13 Nov 2022 at 13:32
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I needed to make some brackets out of alloy tube, but of you squash the ends in the vice it looks crap… so I made this little die that profiles the ends round which also make them stronger.   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: Christy
Date Posted: 14 Nov 2022 at 09:06
Got rid of a bit more of that orange paint Lovely job.  ------------- Back on a Breva ... Again!! Breva 1100, Ducati Monster 900, Multistrada 950, 900SS Project |
Posted By: Buzzer
Date Posted: 15 Nov 2022 at 09:27
Its a magic tin... each time I open the lid its re-filled itself I made a speedo housing earlier in the build, but I was not happy with the result, so I tried again... this one is better... turning the dome took some doing! I have rubber mounted it as I always feel electronics need it…   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: johnno
Date Posted: 15 Nov 2022 at 16:00
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Don't forget the bolt lol.. ------------- 1100 sport corsa , Yam R1, guzzi 650tt rider |
Posted By: red leader one
Date Posted: 15 Nov 2022 at 17:13
| "Bernie" |
Posted By: Buzzer
Date Posted: 16 Nov 2022 at 14:11
I will try...
an indicator of your age there I wanted to add some custom detail onto the bike, in particular on the valve covers... So I tried the technique of etching alloy... have to say it worked rather well! Oh, and although those indicators are small, they are amazingly bright!  ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: red leader one
Date Posted: 16 Nov 2022 at 16:53
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" Yes I'm 102. I don't look it do I." |
Posted By: Buzzer
Date Posted: 18 Nov 2022 at 18:37
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Onto for me what is the most enjoyable part of a build... the wiring. I have a process for this I stick to. First I draw out the wiring diagram in Microsoft Visio, and colour code the wires. Then I order the wire in, which is quite cheap and any connectors I need. So often the standard of the electrics is what make a bike trouble free in the future. I then build the loom actually on the bike, circuit by circuit, wire by wire, which I hold temporarily in place with some Velcro cable ties. When its all in place I use that braided sheathing and close the ends with heat shrink tubing. it make a neat job. Rather than connect the main battery leads up, I use a fly lead with a 10 amp fuse just in case I make a mistake. I crimp, and if needed solder every joint. I have rubber mounted the coils and put them on an alloy heat sink. I also like to make my own HT leads out of solid copper lead, so I can get them to fit perfectly... I have also used up the last of the Tygon fuel tube I had in stock... Its 8mm ID and I am unable to source any more without buying a large quantity, which is really annoying.   ------------- My blog! Www.jtccc.Wordpress.com |
Posted By: rbt1548
Date Posted: 22 Nov 2022 at 09:56
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Oh, and although those indicators are small, they are amazingly bright! They do indeed look neat!, what make are they? I was thinking of adding indicators to my 1968 Triumph Tiger 650 and those look as if they may do the job without affecting the lines of the bike. Cheers ------------- 1975 Honda CB750 K5 1958 Wife It wisnae me, a big boy done it and ran away! "I was so much older then; I'm younger than that now!" |
Posted By: Buzzer
Date Posted: 22 Nov 2022 at 14:26
They do indeed look neat!, what make are they? I was thinking of adding indicators to my 1968 Triumph Tiger 650 and those look as if they may do the job without affecting the lines of the bike. Cheers [/QUOTE]
funny you should say that... my mate has just bought some for his old Royal Enfield as they don't look out of place... here is the eBay link https://www.ebay.co.uk/itm/155056432168" rel="nofollow - https://www.ebay.co.uk/itm/155056432168 ------------- My blog! Www.jtccc.Wordpress.com |