Matchless G3 assessment and a rather large surprise!

After playing with the new matchless single for a month, an update and initial assessment is quite overdue!

Let's start with the good.

Unlike almost everything else I have ever bought this bike is 95% complete.  This is a huge help as I want it back together within a few months rather than a few years.  The engine has excellent compression and turns over freely.  This, combined with the other pieces I have accumulated will make this a much less expensive project.

Now the Bad.

When I say 'bad' it really should be taken with a grain of salt.  If I didn't have the aforementioned parts at hand these line items would certainly be a pain.

-The rear wheel.  I am not sure what has been done to the rear wheel,  it turns freely (decent bearings) however the spindle cannot be removed due to rusted on components.  In addition, the wheel is coated in some sort of silver paint (complete with grit) that paint stripper won't remove.  I'll get tough with it later.  For now, I have a spare wheel ready to go.

-Front forks.  The lowers have hairline horizontal fractures.  Looks like someone landed quite hard!
Enter spare set of forks.

-Front Wheel.  Has a bent rim but very good for spares.

-The Frame.  The swing arm was junk, with an agricultural repair.  The bushings were incorrect, forcing me to carefully cut through said bushing to remove it.  I picked up the swing arm from the other '58 frame we acquired and switched it out.

The left side of the frame also had some extensive damage.  I was able to do a primitive but clean enough repair.

The first step was to bend the piece straight with heat and leverage.

The 'open wound' was beyond straightening.  I cut off the excess fold and
found some material to replace it.  I also sandwiched some steel in between to
 strengthen up the piece.  

After the first weld and grind.

Shot from the side.

Shot from the top.

I then cleaned up the frame and brush pained with Chassis black paint, which I had used previously on the VW.  I should have bought semi gloss, but so it goes. 

The painted frame as it sits now. 

I did some massaging to the hind quarter of the frame which was also a bit bent.  I had a set of girlings from the GMH (Great Matchless Haul) of 2016 which were the right size.  The incorrect items were put in the spares pile.  

In my excitement, I went and ordered an exhaust pipe from Walridge.  To my shock, the pipe was far too small.  The little G3 was hiding a big secret.  It had been converted to a 500! 

As far as surprises go, this was a pleasant one.  Fortunately the too small pipe found a home on the AJS and I ordered another.   The other arrived and was about 1/32" too small.  The P/O had done some sort of modification that removed too much surface from the exhaust port.  What to do?  I thought of getting/making and adapter or filling some surface with JB Weld.  Fortunately, I took the head and pipe to a local muffler shop.  Initially reluctant as he thought the pipe would crack, the manager agreed to flare out the end to fit.  After a few attempts it was near a perfect fit.  I could see some stress marks and decided not to push my luck further.  With a good exhaust sealant, all should be fine.   Best of all, I was not charged for the work. 

Eagle-eyed readers may have noticed something else unusual about the engine.  1958 models were originally equipped with a combination of  coil and points ignition and alternator to charge the battery.  The P/O modified the engine to run off of a Magneto while retaining the alternator.  Not the worst idea in the world as one can still run the engine with a flat battery.  

I can either convert to stock with side covers I found on Ebay or use an old Fairbanks Morse magneto to provide spark.  We shall see.  

Coming soon; Wheels, tank, seat and mudguards.

Until Next time! 

I've done it again....

Swap meets have become a weakness of mine over the last few years.   I get untold pleasure from rooting through bins and boxes and exchanging conservative amounts of money for rusty treasure.

I started the first day of my week off visiting the last CVMG meet of the season.

I was doing fairly well, securing a very good 3.25 x19 Dunlop K70, some handlebars, wrenches and a big box of AMC suspension parts (jampots and a set of Candlesticks).  Then the beaten up white pickup truck pulled up.

I immediately recognized the familiar shapes in the back,  a pair of singles (Matchless and AJS respectively) and a pile of parts.

The bikes were both rolling,  The AJS being an early model ('49 Model 16) and the Matchless a later one (1958 G3LS), identifiable by the larger, more square toolbox and oil tank. 


The cheerful owner mentioned the price for everything and the inner conflict began.  We chatted for a few moments and I politely excused myself before I could get drawn into the dark vortex of another project (or two).

I bumped into the owner twice more, who each time tempted me with a lower price;  I reluctantly accepted his card, repeating the mantra 'I will not call him, I will not call him, I will not call him...'

I spent the rest of the day and next in a sleepy, charming Ontario town not thinking about AMC heavyweight singles. 

Fortunately for me I had plenty to keep me busy, namely sanding down and repainting an otherwise lovely Honda Civic suffering from extensive clear coat issues.

As I sanded in the sun, listening to the 'Once upon a Time in Hollywood' Soundtrack (fantastic film by the way) my thoughts kept returning to the two forlorn singles.  Maybe I do have a problem, I thought to myself.

*I should mention that the G9 has not been forgotten,  I am waiting on some hardware and working out some rear wheel spacing issues.  Henceforth she will be referred to by her Christened name 'Mary Jane'.

By Wednesday my curiosity got the best of me and I called the owner of the bikes.  I was certain that someone had snapped them up;  This would put to bed the question of  'What if?' forever.

Surprisingly, they were still available.  "Damn it." said I over the phone line.

"What's the problem?" he asked.

"Now I must help re-home them." was my response.

I knew my good (dare I say old) friend Chris had been toying with getting another bike project.
After 25 years of on and off persuading, he had finally come around to the idea of English Iron.

He and I had worked on some projects simultaneously over the years and did some flipping of bikes in the late 90's and early 2000's.  At one point we both had vintage Minis.  His was completed beautifully and sold off,  mine was sold off unfinished.

After a brief phone conversation and some google image searches,  He was in!

A few days later, we were off to the country to the seller's home/garage which resembled something from American Pickers.

Cash was exchanged, the bikes and parts loaded up.   It was apparent that Chris had his sights set on the '49.

Not needing two bikes, what would become of the '58?

Yes, she is sitting in my garage.  Thankfully I had just cleaned up and cleared some floor space!

A full assessment will be forthcoming.

Stay Tuned!

It's starting to look like a bike......Finally!

It's been a while since I have updated the blog, however I have been very busy behind the scenes!

The biggest development happened this past weekend when I assembled the front end and frame of the Matchless project.  For the first time, it looks like a proper motorcycle.  As each piece gets bolted on, I find myself filled with satisfaction and pride.  I was especially pleased with the way the steering damper came together with existing parts and a cut down spring from the hardware store.  It works very well (on the bench at least) and I look forward to testing it on the road, along with everything else of course.

Without further ado (as Paul and Craig would say) here is how she currently sits.

The seat pan is a recent acquisition, picked up for $20.00 plus shipping from Ebay.  I had built my own as I couldn't find a pre-'55 pan or a used seat anywhere.  I am happy that I did the fabrication, it was a great exercise and the end product fit the frame perfectly.  That being said, it is heavier and as an original is at hand, I will use it.  The later headlight was also bought for very little but required new captive nuts to be welded inside and some paint.

When I assembled the frame, I realized very quickly that I was dealing with a hardware deficit!  Fortunately for me,  Mr. Partridge has most of the required bits and a package is en route.

The engine is on the bench to the left, just on the other side of the headlight.  That should be assembled sometime this month and placed into the rolling frame.

This brings me to a quick note about the wheels.  When I got the bike it came with a full width '55 only rear hub laced to an 18" rim that turned out to be bent.  The front was of the single sided, early variety that I really like the look of.   I sourced an early rear hub and had both early wheels rebuilt with fresh spokes and rims by a local shop.  I attempted to get it done myself, but to no avail.  I am happy that I at least dove in and gave it my best.   Seeing that a professional found these to be a challenge I don't feel too badly!

I have mounted Duro tires to the front and rear as my budget (now tantamount to pocket change) couldn't accommodate the price of new Avon Speedmasters.  Hopefully I can upgrade them in a couple of years.  I have to say, Duro does make a nice looking tire that looks the part on a vintage bike.  I am sure that they are reusing old molds, though I am not sure who from.  I am told that Shinko reuses Yokohama Molds from the early 70's.

In other news, the 1973 Triumph has been sold and is out of the garage.  I bought the bike as a project in 2007, shortly after my sister passed away.  I never 'bonded' with the bike and I would work on it periodically over the years and spent quite a bit of money on the way.  A loss for me but a gain for the new owner who is retired and has lots of time on his hands.  I am very happy it found a new home where it will be appreciated.  As much as I love Triumphs, the OIF bikes just don't do it for me.

Last but not least,  I decided to treat Katie to a fresh chain and sprockets.  I could have held out, as the stock sprockets still looked good, but the chain had seen better days.  I had been taught that it was false economy to not change sprockets with new chain, so I bought a kit from Volar.

I was disappointed that the master link was of the rivet variety, not a clip as I am accustomed to.  My attempt to put on said rivet master link was a failure and my chain gently rolled off the bike two miles from home!   I  ordered two (one for back up) links with the clip, size 525 in order to remedy the issue.  To my surprise, I discovered that Volar pins are thinner than the standard size by .005 mm.  I called the company and placed an order for the correct parts which I expect to have tomorrow.  The young lady I spoke to was very friendly and helpful and shipped for free (to my US address) very quickly.  Hopefully I will be able to ride by Friday.


Until next time.....

Matchless Mock ups!

This post is long overdue.

Back when I acquired the Matchless parts lot (Feb of 2016)  I had a steep learning curve to figure out just what I had and what could be done with it.   Part of a G12, part of a G9/Model 20 and lots of miscellanea that I am still sorting through.

Since then I have picked up a plethora of new and used parts to fill in the gaps.

Did I also mention the seized 1949 AJS model 18 bottom end that I picked up at Christmas?

I saw the sad little 500cc single motor under a table at the Paris Rally last summer.  Unfortunately I had to leave and didn't get to talk to Mike Partridge about it.  I never forgot the engine and always wondered what happened to it.  Turns out it has been collecting dust since and he was more than happy to part with it.  I also acquired a lovely sleeved barrel and an iron head.  I had no idea what I was going to do with it of course, but I always admired and wanted a British single.  Even if it was just part of one.   Sometimes I just get that feeling when I see something I like.

I am getting a little ahead of myself.


Here is a sneak peek of the Matchless G9, that will be wrapped in the '55 AJS frame.  The motor, which is in very good shape is on the bench being rebuilt.  New sludge trap screws, Conrod and main bearings have been used in the bottom end.  The top end has been treated to a full rebuild.  New valves, vale guides and springs.   It was my first top end rebuild and I found it to be very rewarding!

My top tip is to have an extendable magnetic wand at hand to help place the collets when the springs are under load.  This also helps you retrieve a collet if you drop one.

The seat frame is homebuilt, based on the plans from Christian's Archive.  I used my spare tank for most of the mock ups (in case it fell).   I really like the look with these bars ($5.00 swap meet find) and this tail light (I have a post coming with the genesis of that home made special).  I will be using the 18" QD rear wheel seen on the truing stand.  That wheel came with the parts lot,  but the rim was badly bent.  I sourced a NOS Hap Jones WM2 18 on Ebay for $20.00 and laced it up.  The chrome mudguard is intended for a Royal Enfield Bullet and fits in perfectly.

With the G9 more or less sorted, I wanted to figure out what to do with the rest.   I brought the G12 stuff from the rafters and assembled it loosely.  I looked over the components and realized that re-building the 650cc engine up would be quite expensive.

The solution?

I decided to pair the '49 motor with the 1960 frame and fittings.  I have to say, it looks very correct, very right.

I foresee something like this, but in AJS trim and colours;  Making it a 'Southerner' apparently.

That is a project that will have to wait a while, but I do love it when a plan comes together.

Until next Time!

Silhouette printer paper review (make your own decals and stickers)

As I near my 100th post, I find myself busier than ever with hands on work.  I had hoped to document more of the Matchless build but find it difficult to stop and capture everything on film.  I have chosen to do an extensive write up once rolling and include the photos and notes that I have taken.

In the meantime I wanted to quickly review a product I picked up last year but only started playing with.

I am not a always a fan of decals/stickers on vehicles, but sometimes they work well.  That vintage 'STP' on an old desert sled oil tank can add the right level of character.

Ebay has lots of old stickers and water slide pieces, however these can be a gamble.   I have been lucky a few times (the one on my Matchless tank worked out well) and unlucky on other occasions where the decal disintegrated.

That was when I thought about making my own and decided to do some research.  What I ended up investing in was something called Silhouette Paper acquired from Hobby Lobby ($9.99 for 8 sheets).

This is a clear vinyl sticker paper that can be used with any home laser printer.  I gathered a few random vintage images and put them all on the same screen in MS Paint (I like things kept simple!)

As you can see, I foolishly wasted a good portion of the first sheet.  Next time I will load every inch to get the best bang for the buck!   I would also recommend running a test page on regular paper to make sure everything looks right.

I am impressed by the quality of the end result;  The paper holds colour well and there was no bleeding at all.  The fact that it prints onto a clear sheet is a huge benefit.  My 'Made in England' decal was the only disappointment, I did a test fit on the frame and it could barely be seen.  On a brighter background it works well but the edges can clearly be seen.

Where this product really shines is with more 'solid' images such as this BA sticker.

For the money, this is a great product.  Perfect to produce a good number of stickers for a toolbox, project bike, etc. 

Until Next Time......

I finally built my own wheel...! (Bonus feature: Tusk Truing stand review)

Wheel building.  The Dark Art.  Those who dare to broach it risk subjecting themselves to a madness from which there is no return.

Of course, I jest. 

Barely.

I have shied away from this type of work for a very long time;  Mostly on account of hearing horror stories of jobs gone wrong.  Some things however, you just can't escape from.

If we go way back to February 2016,  I had purchased a big pile of Matchless parts in the hopes of building 'Something'.  In that lot, there were two wheels,  a pre '55 single sided front and a full width post '55 rear.   Knowing that this combination would look strange on a finished bike,  I secured a full width front hub,  a single side rear wheel (without ancillaries) and complete rear hub (sans rim and spokes).  

I cleaned up my early style hub (for my early-style bike) purchased the spokes and a fresh rim.  

I watched a number of videos online, read articles to understand how to do the job.  

My first attempt looked good, however I was still out by a country mile.  Spoke ends were sticking out much farther than they should have been;  I took it apart again and again (and again).  I couldn't honestly say how many times. 

It should be noted that I had kept the assembled wheel for reference and had it sitting right next to me on the bench.   Here are some helpful tips I can pass on.

-Never cut the spokes off if they can be disassembled.  Extra spokes may come in handy at a later date for reference or even replacement should one break.  This takes time and patience but is worth the effort.   I was quite surprised by how well some of them cleaned up on the scotch brite wheel.  

-Take pictures, videos, draw a diagram. Make sure to measure the offset.

These are the straight spokes from the full width hub

My frustration was wearing on me and I decided to farm the work out to a professional.  I found a local firm, gave them the old wheel, the newly cleaned up hub, new spokes and rim.  The shop owner was friendly and the rates fair so I gave it the go ahead.   

About a week later he called me with bad news.  He was unable to build the wheel with the items provided.  To his credit, he emailed various sources and did research beyond the normal scope;  I don't think many customer walk in to have 60 plus year old wheels built.  

The biggest issue was that  the rear hub I provided for rebuild and the hub on the assembled wheel (so he could see the pattern)  were two different sizes!  While they looked identical, one was 3.1" wide and the other 4" inches wide.   He thought that perhaps the hub from the assembled wheel could be used with the new spokes and rim but wasn't 100% sure.  I paid the fee, took everything home and told him I would be in touch.  

I took my pictures,  took everything apart, cleaned up the hub and hand brushed it with POR15.  That last step worked out exceptionally well.  I was impressed by the thick, durable coat once the piece cured.  

I decided to ditch the self-defeatist attitude and take this job on myself, before wasting any more money.  It bothered me deeply that I couldn't build this wheel now that the mystery had been solved.  I set myself up, used pictures for reference and started again.

I did this five more times, to the point where I actually developed a decent pace and rhythm.  I started to see where all the spokes belonged, the pattern became obvious.  When I did make an error, I caught it quickly and recovered.   

Finally it happened.  A completed rear wheel!  A frustrating road with an exceptionally proud moment at the end of it.  Tenacity and faith yielding just reward.

I mounted on the truing stand and it looked very good!  There are a couple spots that need attention, for that the shop services will be engaged again.   

Now on to the review of my newly acquired stand.  I picked this up for $99.99 CDN plus tax (shipping was free) from Gnarly Parts in BC.   Website

It wasn't the cheapest or the most expensive, however the reviews were very good (4 out of 5 stars) and seemed a bit more solid than the other options. (Amazon and Harbor Freight) 

Assembly was extremely simple and quick, despite the lack of instructions in the box. As a matter of fact there wasn't any paperwork at all provided.  My biggest complaint about this item is the manner in which it is packaged.   The little level (an item lacking in the cheaper models) is plastic and was not wrapped separately.  Mine was broken, as it had been bounced around with metal pieces with no protection.  

Bugger!

Fortunately all the pieces were present and I was able to save some hassle by fixing it with epoxy.  The level is a handy feature to ensure that you are working on the right type of surface.  Mounting and dismounting wheels is simple and painless, requiring only a provided allen key to tighten or loosen the mounting pieces that hold the wheel in place.  Another nice feature is the center line indicator at the front of the stand.  This helps a great deal when measuring offset. 

All in all I would certainly recommend the product.  I honestly don't have much to measure against but for price and features, it seems to have the competition beaten.  

Until next time.....

Friday Inspiration.....

Brazenly stolen from  Legend Motors;  I hope that my Father's G11 is still out there and looks this good.....


Until next time...

Evolution of the G9 petrol tank

I originally picked up two tanks on the cheap last year (via Ebay) and had them shipped from California to Niagara Falls NY.

These were bought to practice on and hopefully use on the project if things worked out.  There was lots of sanding, some accidents, some welding, filling and painting.   This one still requires some clean up before clear coat is applied and my pin striping leaves much to be desired;  However I am very pleased with it!  The decals came from a company in England with a very wide array of products with excellent prices and service to boot!  I highly recommend them.  

https://www.isaydingdong.co.uk/

Surface rust! 

A good soak in a wood bleach and water solution removed the worst of it.

However sanding was required to remove the pitting...

Bugger!  The aforementioned repair of the badge screw mount.

Primed

First coat of pearl white paint

My first attempt at pin striping by hand 

fourth coat of black paint....

Application of decal and tape removed!  Not perfect and not factory, but I like it! 

Until next time......

Weekend Swap Meet pick ups

With other priorities dominating much of 2017,  I didn't visit many shows or swap meets.
At the 11th hour on Friday,  I happened to be cruising the CVMG page and saw the Kitchener branch would be holding court at the Paris Fairgrounds the next morning.  I figured I should start making up for lost time.

I set out early, as one does to find the best items;  Armed with a modest cash budget and list of essentials in mind, I kept my expectations low.  

Despite the intermittent heavy rain, the number of vendors was fairly high and diverse.  What did surprised me was the lack of project bikes for sale.   Not a concern for me, as the Inn is currently beyond capacity! 

There was one exception and it was certainly something not seen very often, this 1929 Harley Davidson JD project.  Considering the age and how much of the bike is present, someone should be able to restore to former glories.

At the end of the day, I made out quite well and far better than expected.  Below, I humbly present my 'haul'. 

It may not look like much, however these are all items that I had hoped to find and more importantly, needed.  

2 x Shorty/cocktail shaker mufflers (purchased for $2.00!)  I have never seen shorties with flared ends before.  The chrome is actually quite decent.

12 x Tools:  Several slimline wrenches, a NOS American made chain tool, Dunlop tyre spoons, Craftsman wrench, home made Triumph clutch tool, very old flint for welding and a mystery tool.  

1 x Bag of random British fasteners with nuts, always handy.

3 x original handlebar switches, all in excellent shape.  1 x Ducon, 1 x Miller and 1 x Lucas.

2 x Ewarts fuel taps with new components.  I was really surprised and delighted to find these as mine are but trash.  

All in all, a very worthwhile Saturday morning and I will be sure to attend next year.

My next post will reflect some project updates, until next time! 

Tank repairs...

Sometime last summer I picked up a couple of bargain Matchless/AJS tanks from a vendor in California to experiment with.  Both had traces of original paint and chrome, the latter of which was the subject of said experimentation.  I had dropped both in wood bleach, which cleared away a considerable amount of rust from the chrome surface however the pitting was too extreme.

I can't seem to find the photos from that specific test, however I will post them when they turn up.

I shelved the one tank for later as it had a poor repair to the bottom.  The second one was a much better prospect, having few dents and a lone screw broken off in the thread for one of the badges.   I decided that removing it wasn't a big problem and I needed the practice to perform the same operation to a 1966 Triumph tank waiting in the wings.

Unfortunately I was mistaken.  While I started off with a small drill bit, I somehow ended up punching a hole right through!

With no welder at the time, it joined the other tank on the shelf.

As the ice storm was hitting hard outside,  I needed to feel some sense of achievement inside the garage.

I fired up the old Becca Mig and began to build up some material around the hole.  This was then ground down flat.  I became ambitious and began to lead fill the tank.  This probably would have worked out better in warmer temperatures as you fight the ambient temperature to keep the metal hot enough.  I will need to add a bit more lead to finish, but overall I am pleased with the results!

With an all metal tank, this opens up to another planned experiment I am saving for the summer.

A true bugger up.

Some build up of material 

After some grinding 

Some lead filled in

After the smoothing out

Until next time!