Been a while so time for an update:
Having fixed the leaky fuel tank, I am quietly pleased with the outcome but remain on notice to buy a new one in case it leaks
https://zclub.net/community/index.php?threads/fixing-a-holy-fuel-tank.27282/
Once painted with 3 coats of chassis paint and a few coats of gloss Hammerite, the tank came up very nice
The fuel lines were an utter pain to make in a single piece front to back given how many kinks there are ...
https://www.merlinmotorsport.co.uk/p/goodridge-6-aluminium-hardline-tube-per-metre-g-hl836-06d
But I’m happy with the outcome at the rear ...
The supply line is in two parts as I was routing for an electric fuel pump that I will do another time.
The BSA bike gaiters worked very well also so the strut assemblies are ready to go now. On that note, MSA kindly replaced the damaged ones but left the full price on the invoice, so I’ve been landed with another £78 of import duties! Grrrrrrrrr. However, MSA did offer it as store credit for my next order so less grrr.
Unfortunately a 5 minute job of putting the assembly together turned into a nightmare of the nyloc nut welding itself onto the shock absorber threads and subsequently turned into a 5 hour swearing session. I had to dremel grind out the bit on the flat side of the shaft, the opposite side to weaken it and then break it loose with a chisel.
The hand brake mechanism looked a bit sorry for itself and there appeared to be rust under it so it had to be rubbed down...
...and like all other parts of the underside, as I take off the underseal and surface rust, I find totally solid metal. So that is something to be happy about.
Yesterday it all got put back together and looked like this ...
BTW, lemon juice and salt + time, my new go to absolute favourite rust remover - just check out the before and after photos + the line where my dish wasn’t deep enough to submerge the handbrake mechanism fully:
Before
After an overnight soak ...
No wonder lemon juice is used for home teeth whitening - it dissolves off a layer of tooth!!!!
One of the hand brake cable hanging hooks on mine was missing and the PO had done a hack with exhaust hanger rubber ...
So I spent an hour probably making one out of aluminium I had laying about, original on right.
On the handbrake cable front, I finally received my Bangkok handbrake cable
https://www.ebay.co.uk/itm/151459145571
Here it is for comparison ...
I am going to write to the chap to say that the rubber gaiters need to be changed around (as per the original) to have the long ones on the wheel end of the cable to reduce dirt ingress.
Some thoughts: the protective over sheeth as you can see does not go all the way up the cable. I also had to heat the rubber up to pull it over the crimped bit - see the pic below, left side done, right side as it came.
I made up an alternative to the serrated washers on the moustache bar with some hard rubber washers. 12mm seemed optimal with 6mm and a 3mm washers glued together, both having 60mm OD and 24mm ID.
Having fixed the leaky fuel tank, I am quietly pleased with the outcome but remain on notice to buy a new one in case it leaks
https://zclub.net/community/index.php?threads/fixing-a-holy-fuel-tank.27282/
Once painted with 3 coats of chassis paint and a few coats of gloss Hammerite, the tank came up very nice
The fuel lines were an utter pain to make in a single piece front to back given how many kinks there are ...
https://www.merlinmotorsport.co.uk/p/goodridge-6-aluminium-hardline-tube-per-metre-g-hl836-06d
But I’m happy with the outcome at the rear ...
The supply line is in two parts as I was routing for an electric fuel pump that I will do another time.
The BSA bike gaiters worked very well also so the strut assemblies are ready to go now. On that note, MSA kindly replaced the damaged ones but left the full price on the invoice, so I’ve been landed with another £78 of import duties! Grrrrrrrrr. However, MSA did offer it as store credit for my next order so less grrr.
Unfortunately a 5 minute job of putting the assembly together turned into a nightmare of the nyloc nut welding itself onto the shock absorber threads and subsequently turned into a 5 hour swearing session. I had to dremel grind out the bit on the flat side of the shaft, the opposite side to weaken it and then break it loose with a chisel.
The hand brake mechanism looked a bit sorry for itself and there appeared to be rust under it so it had to be rubbed down...
...and like all other parts of the underside, as I take off the underseal and surface rust, I find totally solid metal. So that is something to be happy about.
Yesterday it all got put back together and looked like this ...
BTW, lemon juice and salt + time, my new go to absolute favourite rust remover - just check out the before and after photos + the line where my dish wasn’t deep enough to submerge the handbrake mechanism fully:
Before
After an overnight soak ...
No wonder lemon juice is used for home teeth whitening - it dissolves off a layer of tooth!!!!
One of the hand brake cable hanging hooks on mine was missing and the PO had done a hack with exhaust hanger rubber ...
So I spent an hour probably making one out of aluminium I had laying about, original on right.
On the handbrake cable front, I finally received my Bangkok handbrake cable
https://www.ebay.co.uk/itm/151459145571
Here it is for comparison ...
I am going to write to the chap to say that the rubber gaiters need to be changed around (as per the original) to have the long ones on the wheel end of the cable to reduce dirt ingress.
Some thoughts: the protective over sheeth as you can see does not go all the way up the cable. I also had to heat the rubber up to pull it over the crimped bit - see the pic below, left side done, right side as it came.
I made up an alternative to the serrated washers on the moustache bar with some hard rubber washers. 12mm seemed optimal with 6mm and a 3mm washers glued together, both having 60mm OD and 24mm ID.
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