My 4th MT

[William]

I have slowly begun to tidy up all bike parts in my sheds, i thought it would be easier and take up less space if it was in an assembled form, so i put some of it together. And remembered how easy and fun it is to work on these bikes, so its going to get built, as its my fourth and i have built the other 3 to pretty standardish spec i want this one to be a bit different so it will consist of the most practical parts opposed to what it should have. But have no fear it will all be olive drab at the end.

The shopping list so far is;
Rear Hub- i have one but the threads are sh***ed beyond repair and the sprocket is missing a few teeth.
A Chain
Kickstart + Gearlever
A less rusty fuel tank- A norton commando one may fit however
Set of exhaust hedder pipes- i plan to have exhausts like a norton commando as i have a set

The list of bits to make
Inlet manifold-aluminium
Inlet manifold-Rubber pipe
Rear wheel spacers

[William]

Update, started getting it put together and discovered how many parts i lack . . . but on the plus side alot of the stuff i thought was scrap was serviceable. The rear brakeshoes had no abrasive material on them, but we had some rivet on ones, first the shoes needed cleaning and then they were glued on, and when that was dry they were riveted.

After that they were fastened in place onto the brake plate fitted to the lathe and reduced in diameter till they fitted into the hubs, as the rivet on abrasive shoes were very old we worried they may have asbestos, so rigged the vacuum to suck the smaller inhale able particles up.




The rear sprocket had a tooth missing so it was arc welded up and filed into the correctish shape.



I ordered a chain offa ebay and then fitted it, the small shaft that holds the rear drum assembly together had its threads severely battered so after many hours with a junior hacksaw and a file i managed to get them back in a usable form.



I also have begun to fabricate an inlet manifold, i firstly took a drawing of the mounting point on the head, then found a similar sized washer. Then i measured the distance from the center to the mounting holes, and drew a ring on the washer at that radius. Then i drilled 3 holes 120* apart.





And thats where i am at now, just need to sort out the rear brake mechanism and source some exhausts and it will be usable!!

[ellrider]

I like your style.

Mark

[TDIPower]

Whats the front end?

Pete

[William]

The front end is from a cg 125 copy, i think it was a lifan 125, i think it will be strong enough and provide enough stopping power!

[William]

Small update; The inlet manifold has been made up from a large washer and a piece of turned bar. They were then braised together checked to see if it would fit and then painted and refitted with hylomar as a bonding agent to ensure an airtight seal. If i had had the time to do it properly i would have turned a o-ring grove into it.


I have managed to get a set of front pipes from eBay and will modify them when i have time, unless i can find a full system. Has anyone else noticed the silly money MT stuff is starting to go for?

[Minter]

Great looking project.. Be interesting to see how it runs with the 40mm Delly... Keep us all posted..

[William]

Done a bit more this week, got the chain slipper on the swinging arm fitted, throttle cable made, and both chain guards fitted. Also made a speedo and kill switch bracket out of aluminium. Fitted all the oil pipework and filter and contemplated what else i need before i can fire it up. i came to the conclusion that as i have none of the lights i shant fit the loom. Hence just fitted a switch which earths the coil unit as a kill switch.


Here is another picture of the inlet manifold prior to fitting.

And this is where the bike is now up too, the tank is very rusty inside but may be fine once cleaned out and coated with tank sealant.

[appyarry]

Small update; The inlet manifold has been made up from a large washer and a piece of turned bar. They were then braised together checked to see if it would fit and then painted and refitted with hylomar as a bonding agent to ensure an airtight seal. If i had had the time to do it properly i would have turned a o-ring grove into it.

What a great idea, what o/d and i/d did you use for the manifold?

I have been thinking about how I could manufacture a solid manifold and then join with a short rubber rather than the long one that pulsates ATM. Then it would be no problem to use any airfilter I like as it will be bolted to the carb. This would be fine for most use with a RAM Air filter. The only change would be in the depth of water it could go through. I must admit I'm amazed at the water I've been through and the old girl just keeps on going.

Ta,

[William]

The internal diameter was 40mm and the external diameter was the same as that of the carb which was 50mm ish. But just use the same external and internal as the carb that you intend to use. The inlet into the head was also 40ish mm so i think it should be less restrictive than the standard amal and inlet manifold. What carb do you have?