DO THE TON

Blood Sweat Tears and Grease => Projects => Restorations => Topic started by: swan on Dec 17, 2010, 17:28:51

Title: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: swan on Dec 17, 2010, 17:28:51
1962 BSA DBD34 Gold Star Restoration

Someday…How many times have you told yourself “Someday, I will find the bike I have always wanted?" Well for me, “someday” finally arrived and I feel like the luckiest bastard in the world. After 10 years of patience, perseverance and pure luck, I found a barn fresh 1962 DBD34 Gold Star that I could afford. My goal is to restore her from the crank up to full UK clubman specs and then will ride the hell out of her this spring.

My bike arrived from Texas and I am the one who found it in the first few minutes it was listed on Craigslist and snapped it up. I feel like a I won the f%#@ng lottery…
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5029-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/NSWcatalogeimagecopy.jpg)
Original US Clubman Specification
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/BSADBD34VSL242098.jpg)
My goal is to bring it to UK Clubman specs like this bike.

The Sale

As many of us often do, I was searching Craigslist for vintage British bikes and parts. The following listing popped up in Dallas/Fort Worth “Barn find BSA 500!!!with title!!!” It was listed 20 minutes earlier, my mind raced to thoughts of a Gold Star, though it was probably an early 1970’s Gold Star, a Royal Star or another 500c BSA. A man named Brad answered my call and I asked him a few basic questions. He is a Harley guy working for American Cycle Traders and knew little about BSA’s, except they were old.

I asked “Does it have one or two exhaust pipes?”

“One” he replied. My pulse quickened.

“Could I have you walk out to the bike and read the serial numbers on the left side of the crankcase beneath the cylinder to me?”

“Sure, it is right outside on my trailer”, “Let’s see, DBD34 GS 6XXX..”
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5113-Version2.jpg)

I have the BSA Gold Star serial numbers committed to memory for an imagined moment like this. My head was spinning and I wanted to scream out in joy, but forced myself to play it cool.

“Could you read the numbers on the frame near the neck atop the gearbox on the left side?”

He said “CB 32 10XXX”. Wow, this cannot be happening…

Then I asked “Now could you read the numbers and letters atop the gearbox on the right side?”

Brad wiped off the dust and dirt and said “ RRaT2”

Hmm, Is this the legendary close ratio RRT2 gearbox or not? Maybe, but I still own a standard box in great shape I could use…
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5053.jpg)

“Does the motor turn over?”

“Nope, motor is frozen.” Grrr….

I ask a few more questions. “Broke fins, damage to cases, solid frame?

“Yes, the top one. No, Yes.”

“I need your e-mail address to send your full asking price. Consider it sold and pull the ad”
 
“Really?, OK.” Brad replied.

With my head spinning and my fingers typing as fast as possible, I sent a Paypal payment to a complete stranger 1100 miles away, gulp, a big leap of faith and the adventure begins…

The next hour was spent researching my bike and I called Brad back.  “What the hell, I have had 75 calls in the last two hours! People are offering a hell of a lot more than you paid, what is this thing?”

I explained this “thing” is 1962 BSA Gold Star 500cc single cylinder US spec clubman motorcycle.  The Gold Star is one of the most sought after, important, powerful, fast and beautiful motorcycles ever to roll out of Birmingham during the 1950-60”s. I have been dreaming of this bike for 10 years. He honored our deal despite much higher offers. (One of the  things I liked while in graduate school in Texas was your word or handshake is a contract, paperwork is just red tape.)

The next day I called to arrange and pay for shipping my bike to Minnesota. A BSA “expert” showed up at his shop with $5000 cash more than I paid for the bike. He wanted to part it out on E-bay. “No sir, it is already sold.” You are a good man and a man of your word Brad Van Horn.

Brad bought two bikes from the original owner in New Mexico. He and his wife are alive and well and expressed a desire to see this bike restored. Brad and I agreed not to disclose his purchase price or my purchase price, so I will not. The original New Mexico title was included and I agreed to send photos and report progress of the restoration to the original owner.

We contracted Steve Loken of Lokenmotive Transport to haul my bike straight up I-35 to my doorstep. With his leadfoot, I had the bike 5 days after I found it. Now the fun begins.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0403.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0404-1.jpg)

First Things First…

Before I could really spend any real time working on the Gold Star I needed to liquidate three other project bikes I had scheduled for the next year. First up was my 1966 Triumph Bonneville project. This really hurt, but told myself I can always find another 66 Bonnie in the future for a realistic price. It sold to a nice guy in the Anoka, MN for a $1700 and I felt good he is going to bring it back to stock as I had planned. Ouch, but I keep telling myself I have a Goldie. Next, I E-bayed the Rocket Gold Star replica I was going to start this spring. I had collected a 1956 A10 frame and 1958 Super Rocket motor, forks, hubs tool box, oil bag etc was sold for a total of $1500.  I kept the standard gearbox and came out a head on the deal. The motor went to a man in Indonesia building a RGS replica and the frame to a member on the Britbike forum. Sir Lucas’s magneto and dynamo went to Australia and forks to the UK. Twenty-four hour a day global society.

The next victim was a 95% restored 1975 Honda CB400F Super Sport. I have built three and sold two of these and am sitting on a fourth, so one had to go immediately, while the other will go in the spring once complete to fund the Goldie. She went to a cool dad in Minneapolis who wanted simple classic bike for his daughter. He paid me to finish the restoration, to lace new rims, mount new tires etc for him and I will make a little extra on the deal so I ended up with $1800. Yikes, I am going to spend more than that amount for a crankshaft and other motor parts…

First Impressions
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5069.jpg)
Steve Loken dropped off my new bike on my day off. It was a beautiful warm Indian summer day and I got to spend some quality time photographing, assessing and breaking the bike down. The bike may look terrible to most people, but to me, it is a shining jewel. The good news is nearly everything is there: tank, clocks, 190mm front drum brake, transmission kicks through and shifts, etc. The bad news is the motor is seized (frozen rings?), the cylinder head has a broken top fin, no Amal GP carb, the clocks are cores for rebuilds at best, no side or center stands, one of the centerstand tabs is broken off the frame, spokes and rims are bad, seat pan has rust holes, broken Lucas head and tail light lens, dented tool box and oil tank and a few other minor things. So what, the frame and motor match and every missing part is available in the US or UK. I have my Goldie at last.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5046.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5074.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5035.jpg)
A broken clock gives the correct time twice a day. My clocks tell me I will be spending hundreds of dollars to restore them.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5120.jpg)
Anyone home?
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5039.jpg)
My dirty kinky girl

Restoration Method

I have built and restored a 1966 BSA Lightning, 1974 Norton 850 Commando, 1976 Triumph T140 and my current ride, love of my life, a 1966 Triton (Triumph/Norton hybrid café racer). Also, I have been restoring and selling several 1970’s Honda CB 400, 550 and 750’s for cash to support my vintage British habit. So, I know bikes, what to do (and not to do), where to get parts, find information and have tools and am well prepared to plunge into the mysterious world of the single cylinder Goldie.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triton%20Cafe%20Racer/DSCN6461-1.jpg)

I have worked as a museum curator, archaeologist and archaeological conservator and have graduate degrees in Art History and Anthropology. My training and work experience has me handling objects centuries and millennia old, some extremely valuable or priceless, so restoring a 50 year old motorcycle is easily manageable.

My goal is to restore the bike to UK Clubman specifications and ride the hell out of her. I would like to retain and restore most of the existing parts, rather than replace everything. The concept of motorcycles as blue chip investments or part of an investment portfolio or the concept and practice of building “show” bikes drives me absolutely crazy. I think the concourse people need medication. Why spend all the time, energy and money to create something you will never ride, let alone even start? To me, riding bikes hard, as designed, is most enjoyable. To each is their own.

Since I have a beautiful Triton, a second bike is a luxury, not a necessity, so I made a deal with myself that I would not go into debt building the Goldie. With all that needs to be done, I am on track and budget to have this running next June. Yes, I realize motorcycle projects take three times as long and twice as much as planned, but this is a realistic goal for me.

I already owned Mick Walker’s Gold Star Book and ordered a factory parts list and service manual as well as The Gold Star Book from George Prew.

The Breakdown

My bike spent 30 some years in storage in the dry New Mexico climate. I sprayed all the hardware, fasteners and moving parts in PB Blast penetrant and nearly everything came off easily. No drilling or easyouts, no snapped bolt heads, no impact driver. The only parts that gave my grief were the dreaded swing arm bolt removal and the fork sliders. I had Winona Welding and Sandblasting try and press out he swing arm bolt, but they needed to cut it and press out the remaining part. The fork sliders were siezed beyond belief and I have spent many frustrating hours trying to free them. No luck, so I found a used pair through the www.britbike.com (http://www.britbike.com) forum. Everything else was photographed, cleaned, removed, labeled, bagged and boxed.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5117.jpg)
Weapons of Mass Deconstruction

The frame appears to be straight, rust free, and without repair. The only damage was a missing centerstand mounting tab. (http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5595.jpg)
Missing centerstand tab.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5168.jpg)
Goodnight Goldie

I will document the individual components in following posts. Stay tuned!
Title: Re: 1962 BSA DBD34 Gold Star build
Post by: swan on Dec 17, 2010, 17:36:13
Here is more of my project:

The gearbox shifts easily through all gears and the kickstart is smooth. On the other hand the motor is frozen solid. I have been soaking the rings and bearings in PB Blast, ATF and acetone, Sea Foam Deep Creep and Marvel Mystery Oil for more than a month. I need to weld up an engine stand so I can bring the motor into a machine shop to press down the piston and remove the cylinder. Once I get the motor broken down, Peter at Mods and Rockers in Mankato, MN www.modsrockers.com (http://www.modsrockers.com) is going to vaporblast this beauty back to foundry fresh.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5238-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/Primarysidebefore.jpg)

Provenance

My bike came with the original title with correct frame and engine numbers. The original owners signed it for me-I am the second owner! My local DMV had never seen a 1962 New Mexico title, but the women behind the counter know me and my penchant for weird old motorcycles, particularly those without titles.  They remember me well after titling my Triton. This time, I handed over the title, signed a check and walked out with license plates and my title is on the way. Simple. My dating record and dispatch record arrived from Stephen Foden of the BSA Owners Club in the UK and I am the proud owner of a 1962 BSA DBD34 Gold Star dispatched to Hap Alzina.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/BSAOC-document-for-web.jpg)
The real deal!

Time and Money

With my Goldie and transport paid, I still have a bit of cash to get started buying overpriced motorcycle parts, rechroming, cadmium plating etc. My goal is to make her a complete roller first and then work on the motor last, after I scrape up the funds for a cylinder rebore, piston, rings, Pearson crankshaft, Carrillo rod, bearings, unleaded valve seats and valves etc. Money, money and more money, but you need pay to play with this thoroughbred.

I ordered a replica 4 gallon tank from S&M Motors on E-bay and tank badges, cap, clips, hardware etc from Domiracer. A quick call to Buchanan Rim and Spoke got my two 19” WM2 and WM3 flanged Excel rims punched to my hubs with stainless steel nipples and spokes. This is the same set up as my Triton and I love it. A pair of Avon AM26's arrived recently from Dennis Kirk as well as my full front end (tubes, springs, cover shrouds etc) from the UK. Seat kit from Leighton in Birmingham is on the way. I saved a pair of unused UK made rear shrouded shocks from my RGS replica.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5500-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5538-Version2.jpg)
Flanged rims and stainless spokes
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5626-Version2.jpg)

All the black bits were sandblasted at Winona Welding and Sandblasting and they had to listen to me babble about how great this bike is, what a rare find it is etc. They did a great job and I took everything down the road to Custom Powder Coating in Minnesota City, MN.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0512-Version2.jpg)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5580-Version2.jpg)
 


Chris Evanson at Custom Powder Coating had to listen to me babble about this bike, but he has a few old bikes in his stable, so he understands and appreciates my passion. I paid him extra to do a great job, take his time masking and plugging and make to look as good as possible. I normally paint my bike with catalyzed auto paint but for some reason I went with powder coat and opted for “jet black”, one step below gloss black.  Everything is done and looks great.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5820-Version21.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5846-Version2.jpg)

I prepped and primed the tank and will post images soon.
Title: Re: 1962 BSA DBD34 Gold Star build
Post by: BigRedButton on Dec 17, 2010, 17:43:31
Epic!
Title: Re: 1962 BSA DBD34 Gold Star build
Post by: tWistedWheelz on Dec 17, 2010, 17:51:00
HOLY SHIT!..........You have my full attention!


I am ready to see this thing come around, and it looks like you have a lot of work to do, but it sounds like you have what it takes to get it there!

Good luck, I will be watching this one for sure!
Title: Re: 1962 BSA DBD34 Gold Star build
Post by: DBC on Dec 17, 2010, 18:09:11
wow, I hear rumors of barn finds such as this this, but never actually witness them.  great job on your marvelous find and I look forward the all the progress you will be making!
Title: Re: 1962 BSA DBD34 Gold Star build
Post by: loudest143 on Dec 17, 2010, 18:23:36
I'm tuned in for sure!
Title: Re: 1962 BSA DBD34 Gold Star build
Post by: beachcomber on Dec 17, 2010, 19:06:12
If you have any problems getting parts [ like the clocks ] let me know. LOADS of BSA and Goldie stuff at the UK's 2 main Classic Bike shows - spring and Autumn [ Fall ].
Title: Re: 1962 BSA DBD34 Gold Star build
Post by: GoBears0305 on Dec 17, 2010, 19:22:21
wow...i can't wait to see this one

Title: Re: 1962 BSA DBD34 Gold Star build
Post by: teazer on Dec 17, 2010, 19:43:40
Nice catch.  Looks like it will be a really nice bike when it's done.  The small tank and high bars are like the Catalina Scrambler model so I guess the US version was made to look like that.

are twittering goldie silencers still available?
Title: Re: 1962 BSA DBD34 Gold Star build
Post by: swan on Dec 17, 2010, 20:03:23
Thanks everyone for the kind words and offers!

I am going to rebuild the clocks (or have Nisonger or Joel Levine do so and I cough up the cash) and have found the correct twittering muffler/ silencer in the UK. Every other single part is available in the US or UK and I am going to re-zinc or cadmium all the existing hardware.

I cannot wait to hear this bike thump and twitter as she once did. For now, I keep geeking out on Youtube videos like this BSA Gold Star Fly Past. (http://www.youtube.com/watch?v=9F20jsbpQ3A#)
Title: Re: 1962 BSA DBD34 Gold Star build
Post by: IndieSol on Dec 17, 2010, 20:09:06
Often times luck like this doesn't fall on those who deserve it.  I think this bike met the right owner.  Good luck on your build.  I'll definitely be watching.
Title: Re: 1962 BSA DBD34 Gold Star build
Post by: dcmspikes on Dec 17, 2010, 20:33:54
sounds like the beggining of a great story.  im tuned in
Title: Re: 1962 BSA DBD34 Gold Star build
Post by: Rocan on Dec 18, 2010, 11:53:29
my lord...


I am beyond jealous.

you deserved it man! absolutely amazing story!  :D
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: crazypj on Dec 18, 2010, 12:44:42
Saw the title and wasn't going to look
 Thought it may be another ** yr old who's grandfathers bike was going to be hacked up 2010 'cafe style'  ::) without having a clue about history of Goldie's
 Kudos for your patience and plan, going to be an expensive restore but worth it to get exactly what you want.
 Guess you'll have it around for a long time  8)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Dec 20, 2010, 12:27:25
My new seat cover kit arrived this weekend from RK Leighton in the UK http://www.rk-leighton.co.uk/ (http://www.rk-leighton.co.uk/) and this is how I transformed an ugly rusty pan to a new seat.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5476-Version2-1.jpg)

The original seat was missing its foam, had shreds of the original cover, was deeply pitted on the top with many small holes but was generally solid overall. I originally ordered a replica seat with white piping from S&M Motors through E-bay but they sent a seat with black piping, so I sent it back, It was cheaper for my to restore my original pan and recover.

The holes and pits were apparent after sandblasting, so I had a local welder friend fill the holes in trade for our favorite fermented and hopped beverages. After grinding down the welds, I filled some of the deeper pits and remaining pinholes with Lab Metal, a high temperature resistant body filler that will withstand the heat of powder coating. The powder coating looks good, the holes are gone but nobody will ever see it since BSA seats do not flip up like Triumph seats. It does offer protection from future rust.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5802-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5808-Version21.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5872-Version2.jpg)

Andrew Leighton recommended glueing the foam to the pan, so I sprayed it with some adhesive, let sit until tacky and then pressed them together.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5879-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5881-Version2.jpg)

The cover slipped on easily, fit very well and I tapped on the clips. I started at the back then clipped the front and then worked up the sides. Inverting the pan and putting a knee on it made it easy to pull the cover to the correct position.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5883-Version2.jpg)


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5887-Version2.jpg)
Looks much better!

On to the tank tonight…
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: tWistedWheelz on Dec 20, 2010, 13:00:43
First off, great work, seat looks perfect! Second, I love that all your photos have a nice white background...sweet touch!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: two wheels of hell on Dec 20, 2010, 13:20:33
Great story and I have to say the bike could not be more deserving. I have saved a couple of British bikes from Ebay doom. I meet a guy last year that was a Goldstar freak. He used to race them in the early 80's. He showed me 13 Goldies in his barn. Most in various forms of decay. He had good intentions for them and had a garage full of pallet shelving to restore them. He said in the early 80's they were pretty easy to come by and very cheep to todays prices.

Most of have a list of bikes and women in our head. This bike is on the list for me. Glad to see you marked it off yours!

Congrats! l look forward to your updates
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: VonYinzer on Dec 20, 2010, 13:21:43
Beautiful stuff so far. Really great story as well.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Dec 20, 2010, 13:37:14
Thanks all!

13 Gold Stars in the barn?? For real? I need to see a photo!

I have no problem with parting out some bikes on E-bay for those parts will eventually end up in running bikes. With Gold Stars, nearly everything is available including brand new motors from ABSAF in Holland and motor parts from numerous sources in the UK and USA. It is the frame and the original cases that are elusive and expensive. My Goldie was too complete to hack up into pieces. It may look bad, but all I see is potential for next summer. I have no interest in every selling this bike and going to ride her hard.

A nice, near stock 1960 US Clubman Gold Star just went for $20,100 on E-bay. Multiple that by 13! http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=140488711266&viewitem=&sspagename=STRK%3AMEWAX%3AIT#ht_500wt_1182 (http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=140488711266&viewitem=&sspagename=STRK%3AMEWAX%3AIT#ht_500wt_1182)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: pawn on Dec 20, 2010, 13:53:17
this is such an amazing thread. Great find, great write-up, and awesome photos. I'm happy for you to have found your dream bike, that's really cool!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Garage Rat on Dec 20, 2010, 14:51:47
Thanks all!

It is the frame and the original cases that are elusive and expensive.


Why not replicate the frame? You have a frame, make a jig from the frame and detail everything... Shouldn't be hard with your archeological back ground.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Dec 20, 2010, 15:01:19
A replica is a replica. It can only be original once.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: dewjantim on Dec 20, 2010, 15:29:52
Congratulations on your excellent find and in progress build  ;D ;D ;D.  I, too, have always wanted a Goldie..... but, so far, haven't found one for cheap  ??? ??? ???. I am glad you will be actually riding your bike instead of putting it away somewhere in a dark garage or your living room as some kind of perverted center-piece. I have several rare bikes , keep them in showroom condition, and ride the hell out of all of them. I have had several BSAs and think they are highly under rated motorbikes. Currently, I have a A50 R with a 650 Lightning engine. I swapped a $225 Yamaha scooter for it. Going to do it up in cafe style with Goldstar paint, and mufflers, and a cafe style seat. It is # 4 project down the line..... So, keep up the good work and keep us informed......
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: IndieSol on Dec 20, 2010, 18:32:14
Excellent work on the seat.  And the write-up was very informative.  Can't wait to see the finished tank!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: 03rangerxlt on Dec 20, 2010, 18:58:05
this defines cool
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Dec 20, 2010, 21:33:57
Just finished some work on my tank. The consensus is there is no set factory pattern for the main tank color (BSA silver sheen) and the shape of the exposed (unpainted chrome sides). I studied dozens of historical photographs or modern restorations to get an idea of the layout then started with some thin 1/8" 3M brand plastic tape to get the shape to look right to my eye.  Once I was satisfied, I measured and marked the pattern for the opposite side, taped again and then covered the chrome sides with more masking tape.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5853-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5856-Version2.jpg)

Next, with a deep breath, I took 400 grit sandpaper to all that beautiful exposed chrome. I scuffed in an "X" pattern to create some valleys so the primer could make a mechanical as well as a chemical bond to the chrome. I sprayed three coats of VHT brand Self-Etching primer (green), let it dry, lightly sanded with 400 grit, then layed down a few light coats of a sanding primer (grey).

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5859-Version2.jpg)

I bought the correctly matched OEM paint from Don Hutchinson (http://www.triumphman.com (http://www.triumphman.com) ). He is known for Triumph paint but does BSA's as well. Great guy, very friendly and helpful.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5557-Version2.jpg)

I sprayed three coats of Silver Sheen, then three coats of catalyzed clear coat to get this:

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5894-Version2-1.jpg)
 
I could not find the formula for BSA Gold Star Silver Sheen floating around the internet or the britbike forum so I went with Don. It is a metallic silver with some small flakes in it. In the UK they recommend using VW Beetle Silver as a match, but I could not find a formula for it in the US. Here are some details of the Silver Sheen and the red pinstriping color:

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5896-Version2-1.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5902-Version2.jpg) test strip

Hopefully tomorrow night I can sand the clearcoat, pinstripe and add more clear. Stay tuned...
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Tim on Dec 20, 2010, 21:37:35
You are a brave, brave man ;)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Dec 23, 2010, 10:11:58
I found this Goldie on Craigslist and someone should jump on it for $1250. (maybe a typo? $12,500?) Here is your chance for your own Gold Star project. It is probably a 1963 DBD34 sold it late in 64 and titled as a 1965 BSA (?).

http://losangeles.craigslist.org/wst/mcy/2126576746.html (http://losangeles.craigslist.org/wst/mcy/2126576746.html)

The ad:
"65 BSA DBD 34 500 cc, This is an unmolested example of 1965 motorcycling, it is known as a scramble or dirt bike, this bike is a little rough but all there, the trans moves throught the gears fine, the chain is rusted some as are the wheel, handle bars and the chrome shocks, please notice the inside of the fuel tank....how clean it is....but also notice the tank is ALL Aluminum and with no dents so it could have the paint removed and ploished to a mirror finish.This is a great bike for restoration of a correct period piece.
If you are a serious buyer and want to see more pictures email me and I will send more, but hurry its on ebay too and Im already getting calls.

I have ALL the original paper work, including the title and the original invoice from the Dealer to the Buyer, from 1964, the Califorina title is is good condition as well, this is just a cool bike great for a winter project, with lots of dollar potential when its done, im doing house cleaning now and need to get rid of some of my 5 motorcycles.

thanks and hope to hear from you. 1-714-456-6509 "
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: crazypj on Dec 23, 2010, 13:33:05
Posting deleted by author.
 Guess he realised it was too cheap after the first 500 calls?  ;)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Dec 23, 2010, 14:33:09
UPDATE on the CL Goldie mentioned above.  A member on britbike.com forum spoke to the seller and he wants $9000 + for it :    The motor is stuck, no fenders but he has the tacho. It is still worth half his asking price.

The ad was posted in the middle of the night and I am sure had many, many calls. Here is his new E-bay auction:
http://cgi.ebay.com/ebaymotors/BSA-DBD-34-CATALINA-Scrambler-dirt-tracker-500cc-/160522786654?pt=US_motorcycles&hash=item255fe7575e#ht_2144wt_950 (http://cgi.ebay.com/ebaymotors/BSA-DBD-34-CATALINA-Scrambler-dirt-tracker-500cc-/160522786654?pt=US_motorcycles&hash=item255fe7575e#ht_2144wt_950)

This would have been nice to pick up for $1250!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Dec 29, 2010, 12:42:47



Thanks everyone for your kind words! I have been a busy boy with my job but have eeked out a few moments to work on my Goldie. I spent Christmas Eve preparing and tweeking the CB400F I sold to a cool dad in the Minneapolis. He drove down in a snowstorm to pick up the bike for his daughter. It now has new rims, spokes tires etc but I still need to polish the tank for him.
 (http://i170.photobucket.com/albums/u272/66triton/CB400f/IMG_5907.jpg)


With my bike I am still struggling with the swing arm spindle, so I walked away for a while and built the front end so I can determine the offset for the front hub.  Britbike.com member Goldstarfreddie hooked me up with a nice pair of fork lowers. My original pair was seized beyond belief. Here is the carnage of my original pair I butchered in order to get the nuts and washer off the fork stanchions.
 (http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5958-Version2.jpg)


I meticulously cleaned, prepped, primed and painted the fork lowers with catalyzed single-stage gloss black paint and bought all new UK made fork tubes, bushings, seals, circlips, seal holders, springs, shrouds, headlight holders, hardware, fork seal tool etc from Leigh Classic Motorcycles and classicbikeshop.CO.UK. Both are great people to work with, good communication and fast shipment to the US.


I oiled the bushings and inserted the tubes into the fork lowers and added the circlips, no shims were needed. The first circlip went in with two screwdrivers in under a minute, but the second took me more the than ten minutes. I next lubed the inner portion of the seals and slid the down the stanchion with the SPRING SIDE DOWN. I wrapped the fork lower threads with PTFE tape (aka Teflon, thread sealant tape) and hand and tool tightened the chrome fork sealers. Originally, a wrap of twine or hemp was used to seal this connection.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5950-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5949-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5953-Version2.jpg)


Next, I sprayed my fork springs with a light coat of WD-40 for rust prevention and inserted the fork shrouds. Everything looks much better and slides freely and evenly.
New tapered bearings from Germany via Britbike.com veteran David Kath were pressed on the lower yoke and I have a new front end. I am using clip-ons and black Gold Star headlight holders as well.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5954-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5634-Version2.jpg)
Tapered Races and Bearings
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/Race.gif)
Roger Race Bannon


Next will be the front hub, stay tuned…
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5419-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: chris73cb175 on Dec 29, 2010, 13:00:21
that tank and forks look amazing. can't wait to see what the finish product will be. and that is some determination for the pops daughter she will be pumped. keep up the good work
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Rocan on Dec 29, 2010, 13:04:53
amazing man! i need to get a white backdrop for my pics ;) looks amazing.

what are you shooting with? lighting set up?
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Dec 30, 2010, 22:43:56
The Front Hub

BSA Gold Stars came with a variety of hubs and rim sizes for both the home and export markets. My bike has the 190mm front drum brake which many seem to like while others prefer the BSA 8" brake. I have both brakes, but am going with the 190mm for now. The outer covers and interior drum were sandblasted to bare metal, primed with etching primer and painted. I have seen the inner ring either silver or black and I started with silver but changed my mind and went with black high temperature caliper paint. It looks more balanced with the color scheme of the bike. The has been much discussion on the forums as to the original exterior silver color and its modern equivalent, most people recommend Hammerite Smooth Silver which I used and you can see for yourself.


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5923-Version2.jpg)
Breakdown

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5918-Version2.jpg)
Hornets’ Nest

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5889-Version2.jpg)
Started with Silver

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6025-Version2.jpg)
Changed my mind and went with black paint on the drum

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6030-Version2.jpg)
1640 RS sealed bearings

The bearings were kept in the freezer, the area where the bearings are placed was heated and lighted coated with grease. I placed the bearings with some washers, threaded rod and nuts and tightened them into position. NEVER pound your bearings. Find a bearing press or do as I did.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6047-Version2.jpg)
Polished bearing retainer rings, proper service tool and anti-sieze compound

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6051-Version2.jpg)
Right hand thread on both bearing rings. Interior bearing ring has the larger inner diameter opening and a cotter pin.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5917-Version2.jpg)
Original paint

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6053-Version2.jpg)
Hammerite paint

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6060-Version2.jpg)
Hammerite paint from http://www.tcpglobal.com/ (http://www.tcpglobal.com/)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6059-Version2.jpg)
Much better! On to lacing and trueing the spokes and rims, lathe turn the drum and new brake pads and arcing from Vintage Brake. http://vintagebrake.com/ (http://vintagebrake.com/) The hardware will be blasted and cadmium plated.


 
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: pawn on Dec 30, 2010, 23:50:49
i love this thread!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Dec 31, 2010, 23:22:31
Happy New Year!

After some frustration, I finally figured out the swing arm spindle problem and am now starting the new year off right by going clockwise on this project!

The spindle was too big and I determined the zinc coating would not allow for a press fit into the swing arm. After some hand sanding and wire wheel on the bench grinder it was the right tolerance. This was such a bitch I drilled, tapped and inserted a grease zerk fitting to the bottom of the swing arm so I never need to remove the spindle again.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6063-Version2.jpg)


I saved a pair of UK made rear shocks from my former Rocket Gold Star replica project and installed them with new hardware. Also the front tapered races and bearings and yokes went on. Forks, clip-ons, headlight holder etc will go on tomorrow so I can figure the offset for my front hub and lace it up.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6070-Version2.jpg)

A final coat of paint went on the oil tank and tool box and they will be sanded and polished tomorrow too.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6042-Version2.jpg)

Time for a well deserved pint. Happy New Year and be safe!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: cafePete on Jan 01, 2011, 12:40:55
Great project going on!
I'll be tuning in. ;D
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: alpinaclone on Jan 01, 2011, 16:47:26
Nice progress, this bike is going to be a beauty.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Jan 01, 2011, 20:25:42
Thanks guys! I put a few hours of work in to my bike today.

The tins are original. The tool box was bad and the oil tank had one big dent. I used a hammer and dolly on the tool box and was able to push out most the oil tank dent. The tool box needed some body filler and I used a bit of Lab Metal (high temperature body filler) on the oil tank. I polished the tool box today but need one tiny paint touch up on the oil bag. Here they are:

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5094.jpg)
Original tool box

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5049.jpg)
Original oil tank

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5653-Version2-1.jpg)
Blasted and pounded

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_5914-Version2-1.jpg)
Filled, primed and sanded

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6080-Version2.jpg)
Polished tool box

I used single-stage gloss black auto paint on both tins, wet sanded with 800, 1000 and 1500 grit sandpaper then polished 3M Perfect polish, machine and final glaze. No wax and I am going let them sit and off gas their solvents for a few days before applying the graphics. Last year I found a used heavy duty Dewalt 849 polisher and it makes all the difference in the world. This thing is a beast, but has the power and torque to polish and buff like glass. I use small 3.5" pad kits on motorcycle parts and they work great! The larger auto sized pads will destroy your paint job in a split second if you slip up. You need to be mindful of the leading and trailing edge of the rotating pad so as not to catch on any edge or detail and wreck your paint job. Beg, borrow or steal (not mine) a heavy duty polisher for your next paint job.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6043-Version2.jpg)
The beast

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6044-Version2.jpg)
small pads work great on motorcycle parts


I rebuilt the rear hub and pressed in two new 1620 2RS bearings. Note the shorter shoulder of the spacer goes on quick detach side and there is a thrust washer behind the bearing.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6075-Version2.jpg)

The bearing retainer is a LEFT HAND thread.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6078-Version2.jpg)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6087-Version2.jpg)

With the forks on and the hubs done I can mock them up on the frame and determine my spoke and rim offsets so I can lace my wheels this week. Stay tuned!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: tWistedWheelz on Jan 01, 2011, 23:24:16
Damn, you are moving QUICK! Nice work though!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: marsupialwoe on Jan 02, 2011, 17:29:49
Thanks for all the great photos.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Jan 07, 2011, 23:25:04
I finally found a couple of hours free time, so I laced my front and rear hubs.

The front 190mm brake took quite a while to lace while the rear quick detach hub was dead simple and quick.

The front hub:

The Buchanan spoke kit consisted of 40 spokes, 20 interior and 20 exterior spokes. The BSA factory parts manual shows the same part number 42-5552 for all 40 spokes. Each nipple was lubricated inside and where it meets the rim to prevent future galling. This is an alloy Excel WM2 19" flanged (shouldered) rim.

The interior spokes (end showing to the outside) are obtuse and the exterior spokes (ends to the inside) are 90 degrees.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6109-Version2.jpg)
(top) exterior spoke 90 degrees
(bottom) interior spoke obtuse angle


Buchanan Spoke and Rim marked the rim making it easy to identify the right and left side of the front rim.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6096-Version2.jpg)

The interior spokes went in first on the right hand (brake plate) side with the spokes pointing forward in the direction of travel as per original. Everything was placed on a large piece of foam to protect the paint and rim.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6106-Version2.jpg)

I flipped the wheel and laced the left hand side (drum side) interior spoke going the opposite (towards the rear) direction.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6111-Version2.jpg)

Next were the exterior spokes on the left side. They were a tight fit and it was necessary to remove the drum ring from its plate in order to get the spokes in. The angle was difficult and I need to use a punch in order to get the spokes to sit in their seats. The right hand exterior spokes went in easier. I left all the spokes loosely laced .

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6116-Version2.jpg)

The rear hub.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5391-Version2-1.jpg)
Chomp.

The BSA rear quick detach hub has 40 identical straight spokes and could not be easier to lace. I did one side and the other, following photographs of my original wheel. This is an alloy Excel WM3 19" flanged (shouldered) rim.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6117-Version2-1.jpg)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6118-Version2.jpg)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6121-Version2-1.jpg)
Done.

I am going to mock the wheels up on my frame this weekend so I can determine my offsets and then true my wheels.  DO NOT FORGET to measure the offsets of your original wheels like I did!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Jan 20, 2011, 09:13:50
A short update:


After two weeks of intense work demands I finally got a chance to work on my Goldie. (I missed my girl!) I mounted the loosely laced front hub to work out my offsets.


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6129-Version2.jpg)


The rim was centered between my front forks. The offsets from the rim CENTER (not the sides of the rim since they will vary from brand and style) are:


 2.043" drum side (left)
2.461" brake side (right)


2.542" WM2 Excel flanged rim width
4.800" distance between forks


I transferred the hub to my fancy new truing stand and brought it to truth. Previously I trued my rims on an old swing arm in a vise. A truing stand is sooooo much nicer to work with. Next, I'll figure the offsets for my rear rim in line with my front wheel and true it. Then the front wheel and drum will be turned by a local machine shop, I'll mount the tire and have another shop balance it. 


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6193-Version2.jpg)


As anxious and excited as I am to make my bike a rolling chassis, I am going to be patient while I gather and prep all the hardware to be cad plated. Once the brake hardware is cad plated I'll send the brake plate to Vintage Brake for new brake pads and arched to match the specs of my freshly turned drum. There is much like and dislike for the 190mm brake, but with a true, round drum and matching new modern compound brake pads I should get some stopping power out of it. I still have a BSA  8"  front drum if I decide to switch.


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5038.jpg)
Before: dusty, rusty and crusty.


Another busy weekend so more updates next week.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Flugtechnik on Jan 20, 2011, 10:09:28
Wow!
 
"Uptown"
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6193-Version2.jpg)

 
 
"Ghetto"
(http://4.bp.blogspot.com/_-tpnHj70SbA/TEyu-EA1ZdI/AAAAAAAAAsA/dPW1q_Nd21A/s320/DSC00183.JPG)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Slice on Jan 20, 2011, 12:40:30
This thread is fantastic so far, I love it... great work!
-slice
 
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: treitz on Jan 20, 2011, 13:25:12
I get so excited when this thread moves to the top of the list. Makes me feel like a little kid with a awesome picture book!

Can't wait for more!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: dewjantim on Jan 20, 2011, 15:57:09
Cool build...... lots of detail  8) 8) 8) .....
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: bikeboy on Jan 20, 2011, 18:14:55
Wow!

wow is right. I'm not sure I'd want that needle indicator that close to my painted brake plate unless I was confident it was not going to hit. I'm guessing you've had a few passes at it by the time the pic was taken  ;)

nice work so far. Going to be a great bike by the looks of it.

cheers
ian
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: IndieSol on Jan 20, 2011, 18:43:14
Now THAT is a truing stand!  Where did you buy it? 
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Jan 23, 2011, 16:22:25
Thanks all! Back after a few days in the woods and off the grid for some well deserved time off.


I have previously trued rims on my frame and with a old swing arm in a vise with acceptable results. I bought the truing stand off E-bay from Sportingforless and love it. They do not have it listed on their web store, but there are several on e-bay from various sellers at a wide range of prices. Truing rims is one of my favorite parts of any build, but with a new stand it is so much easier. On to the rear wheel tomorrow night...
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 01, 2011, 21:30:48

Well, it ain't much but I made a couple hours of progress.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6315-Version2.jpg)
 
With the front rim laced and trued, I mocked up the rear rim and as per advice from senior Gold Star owners on the Britbike forum, used straight edges to determine the offsets of my rear rim in line with my front. Two 5" lengths of steel channel bar were clamped to the front rim (with spacers to make up the difference between my WM2 rim front to the wider WM3 rim rear) to align the edges and center of my rear rim.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6317-Version2.jpg)


I then started tightening up the spokes once I determined the correct offset. I will finish it on my fancy new truing stand. My front rim is true to .003" radially and axially, excluding the "hump" where the rim is joined during manufacture.


That's it until next week, stay tuned...
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: thirsty 1 on Feb 02, 2011, 14:51:44
Right on man that's some sweet stuff! ;D
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: dgrady77 on Feb 03, 2011, 02:41:26
It's great to see another BSA on here.  Your Goldie is everything my little C11G wants to be when she grows up!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 03, 2011, 11:38:37
Thanks guys!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: kparrott on Feb 04, 2011, 11:38:40
You're attention to detail is amazing! I can't wait to see it complete!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: bradwsm on Feb 04, 2011, 12:23:41
That is a absolute gem!!! fantastic work!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: kookie31 on Feb 04, 2011, 13:17:28
had to steal my son's bib to wipe the drool away! my god thats amazing! excellent work. you got my full undivided attention on this one
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: bikeboy on Feb 04, 2011, 18:44:11
That's it until next week, stay tuned...

nooooo. you can't leave it that long  :'(
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: 50gary on Feb 04, 2011, 19:51:00
Nice job on the truing, .003"  Do you find they hold true, do you have to touch them up after running them for a bit?  I would expect some settling?  How do you get the tension equal?
  Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 05, 2011, 12:04:30
Thanks again everyone for your nice words! I wish I could work on my Goldie full-time, but a very busy work schedule and an out of state girlfriend get in the way of my fun. I'll post more next week.


The front rim is as true as I can get it and is going to a machinist this week to lathe turn the inside drum. I'll double check for truth, tweek, mount tire and have another shop dynamically balance it on their machine. I did the same for my Buchanan spokes and rims on my Triton and they have held true for more than 3500 miles. I do check my wheels after 50 miles of shakedown and have never had anything terribly out of truth.  Do it right the first time and you will not have to do it again.


The front brake plate and shoes are going to www.vintagebrake.com (http://www.vintagebrake.com) to be relined with modern brake compound and arched on their lathe to match my freshly turned front drum. This will provide more stopping power than when it left the factory.


(http://i170.photobucket.com/albums/u272/66triton/1966%20Triton%20Cafe%20Racer/DSCN6423.jpg)
Ye Olde Triton
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: IndieSol on Feb 07, 2011, 19:24:29
Was at a show this last weekend and saw the bike below.  Immediately thought of this build.  Gave the bike a good look.  You've really got something special there.

(http://img683.imageshack.us/img683/5642/21805959.jpg)

(http://img189.imageshack.us/img189/2156/21674682.jpg)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: wfo guy on Feb 07, 2011, 23:45:11
This is fun watching you. I owned a 68 BSA 441 Shooting Star in the early 80's. I traded a Tiger Cub 200 for it. It wasn't a Goldstar but I understand the love affair. I've had my share of Triumphs also.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: racewiththedevil on Feb 08, 2011, 03:22:18
great score on that goldie! they are wonderful machines!
 
I woulld suggest skipping the extreme long wait and expense of using vintage brake's services and picking up a pearson duetto replica 2ls plate for your 190. it will far outperform even the best set up sls 190.
 
also do you have the bgss eddie dow catalog tip book?
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Almost_Vintage_GS on Feb 09, 2011, 21:38:57
An inspirational thread, keep up the good work and we are all looking forward to the outcome.  Also, your documenation is phenominal.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: diesel450 on Feb 09, 2011, 22:08:10
Nice find! I've got a buddy with a Gold Star, not sure which year. He wins awards at shows all the time and it seems like he rebuilds the motor every winter. fucking limey bikes!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 11, 2011, 12:13:10
Thanks everyone! Thanks IndieSol for the images.


Well it is official, my Minnesota title arrived today and I am the second owner of this bike, free and clear!


I finally have some free time and will work on her this weekend.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: diesel450 on Feb 11, 2011, 12:33:12
Nice! Big hurdle crossed there! Congrats!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Jonny on Feb 11, 2011, 13:15:43
wow great job on the bike so far swan!! cant wait to see the bike completed! :)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Sfightercafe on Feb 11, 2011, 21:40:33
Love the write up........I also managed to find a DBD 34 in a water filled basement many moons ago ( late 70s/early 80s)..........price was a princely 100.00. Guy that had it knew absolutely nothing about it, just wanted the junk outta his basement.........Was real hard to keep a poker face when a friend and myself went over to pick it up........Bout the same shape as yours but  the engine ran tru and more complete. Ended up trading it off as I had several Nortons, a Trident and my Rickman CR at the time. My thoughts were to pull the engine/trans and slip them into a Seeley framed rolling chassis that was available at the time. Bike ended up going to a guy that was restoring one and I ended up with another triple.........That DBD 34 and my CR are the only bikes that I have regrets for letting go.......Hope you enjoy yours, they were made to be ridden and a big single in proper tune is a unique experience!.... ;D

Regards....................Bart
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 11, 2011, 23:21:15
Thanks all, Sfightercafe, I very few regrets in life, but most involve two wheels...

Well, a few small steps forward tonight.
I finished sorting out the alignment of the rear hub, trued the rim and mounted the tire.


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6322-Version2.jpg)(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6327-Version2.jpg)


I have several hours of play time tomorrow and am going to gather all the hardware, photograph it, bead blast, file and prep everything so I can send it all to be re-cadmium plated. I am going to take my time and get every single bit done, even the stuff you will never see such as the bolts inside the rear brake drum.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6328-Version2.jpg)


I am still trying to find a decent regional chromer who understands old bikes and is willing to do small batches.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6330-Version2.jpg)


The front hub is going to the machine shop on Monday to be turned and then both wheels will be machine balanced.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6334-Version2.jpg)
Before lathe turning the brake hub.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Goggles Pizano on Feb 12, 2011, 00:09:00
I am still trying to find a decent regional chromer who understands old bikes and is willing to do small batches.

Consider Brown's Plating (www.brownsplating.com (http://www.brownsplating.com)).  The are generally regarded as the best in every aspect.  I realize that they may not be regional, but I can see that you're definitely going all out with the restoration. I know they're service would be more than fitting.

Can't wait to see the rest of the build come together.  You're doing a great job so far.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: jay_kent on Feb 12, 2011, 20:14:44
what a great thread, just read it through.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 15, 2011, 21:35:23
Thanks GP, Browns is pricey, but you get what you pay for. I may buy new from the UK for it is cheaper on some items.



I started preparing all the hardware for cadmium plating so I finally tackled the gearbox and finally solved the mystery of the "RRAT2" stamp.


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6344-Version2.jpg)


I cleaned the exterior of the gearbox and removed 40 + years of New Mexico mud, grease and who knows what. The good news the gearbox turned over easy with no discernible lash or play.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6342-Version2.jpg)
Clean at last, clean at last...


I cracked the inspection cover was encouraged to see oil, no foreign matter or chucks or specks of metal. Pulled the front covers and all looked clean and good and it seems I am the first person to get in here. Everything was pristine and beautiful. Flawless!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6353-Version2.jpg)
Oily goodness.


 After pulling the lay and main shafts I started counting gear teeth to determine exactly what I have.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6370.jpg)


With the aid of the BSA Service Chart listing all the A and B group gearbox ratios found here http://bsa-a10.hailwood.com/images/gearbox/chart1.jpg (http://bsa-a10.hailwood.com/images/gearbox/chart1.jpg) (Courtesy of our BritBike's David Kath, thank you!) I started counting teeth.
It turns out this is an "ARRT2" gearbox used on B34 Gold Star Clubman and 1963 Gold Star Twins aka Rocket Gold Star. It does have two Torrington needle bearings. This is NOT an RRT2 extra close ratio road racing gearbox. So what to do?
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/Bsagearchartedit.jpg)


For now, I have decided to restore this ARRT2 gearbox along with my STD gearbox while I research and choose which one I am going to use on my Goldie. Who knows what the factory was thinking when they slapped this together. I do not need a RRT2 gearbox for I will be riding in light traffic and the hills along the river. I may use my Standard gearbox and sell the ARRT2 box to anyone looking to restore their Goldie or Rocket Gold Star. Maybe I will ride both then decide which to keep.
 
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6376-Version2.jpg)
The patient on the operating table.


I need to finish breaking everything down, cleaning and the proper hardware is going to be cadmium plated, new bearings, seals, gaskets etc along with vapor blasting the cases and polishing the covers and caps. Same for the STD tranny and both will look good as new.


Picking up the front wheel tomorrow from machine shop so I can mount and balance the tire and get one step closer to having a roller...

Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Midcoastcustoms on Feb 16, 2011, 02:17:13
Hey Swan bike is looking awesome.  I am also from MN and have been referred to this shop before but never have actually used them.  I believe they do small batches and custom work specializing in automotive and motorcycle restorations.

JR Custom plating
John Colton (owner)
1391 11th Ave. SW
Forest Lake, MN 55025
 
651-464-0761

 www.jrcustomplating.com (http://www.jrcustomplating.com)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: andrewm on Feb 16, 2011, 03:01:10
great great thread. love the detail and great photos.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: beachcomber on Feb 16, 2011, 08:19:07
Swan,

the ARRT2 boxes were standard Rocket Gold Star fodder - I suspect that it may have been a parts bin raid at the factory! IE - they ran out of the stock Goldie box and fitted from the RGS. I had three RGSs - all with ARRT2 boxes. ALL of my 5 Goldies [ 2 x 350, 3 x 500 ] used RRT2s and I never saw a Goldie with anything else fitted.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 16, 2011, 08:53:42
Midcoastcustoms thank for the plating reference, I'll check them out. Thanks Andrewm.


Beachcomber, I think you are right. They factory may have used up what was left or dump the crap on the Yanks. The stamp looks like a RRT2 inner casing with an "A" added later. How does the ARRT2 gearbox ride?


I am not willing tp pay retail for a RRT2 cluster or a Nova 5 speed so I may go with my STD until I get lucky again and find a close ratio gear cluster.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: beachcomber on Feb 16, 2011, 09:12:08
Hey Swan glad to pass the info. on.
 
There were MANY anomolies in the day - on brand new showroom floor bikes. Bear in mind the British Bike industry was spiralling downward at this point - no investment in new technology - a blinkered attitude to the new threat from the East. The spares situations during this period was also chaotic. I had 2 pals who worked at the BSA plant in Small Heath in the 60's / 70's - the stories ..................... I remember once our local dealer had 10 Super Rockets in his showroom - all awaiting dynamoes before they could be sold on !
 
The ARRT2 box was much more user friendly and was in fact the box of choice in my Manx / Gold Star. I also used the same box in one of my Tribsas that I had as a race bike. The box was ideally suited to the power delivery of the twins, but was a very pleasant box in the Manx chassis.
 
Love your build BTW
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 16, 2011, 10:52:32
Beachcomber, thanks for the input! I am familiar with all the strange happenings at Small Heath, particularly during the dying days of the early 1970's. I have read varying things about the ARRT2, good and bad. I appreciate your review and I will have to try it for myself and decide.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: johnu on Feb 16, 2011, 15:00:22
Swan, nice bike you're restoring.  Excellent workmanship.
 
My ten cents worth regarding you're choice of gearbox internals; my dad (in the UK)has a 62 Goldstar with the close ratio box and I can tell you that for normal street riding (in town, stop lights etc.) it is a bugger with that high first gear, actually it is miserable (a lot of clutch slipping).  He also has a Rocket Goldstar that has a standard box in it and it really is a sweet bike to ride, I choose that over the Goldstar any day if we are going out for a ride.  Now if you were out on a track or have nice roads with little traffic the cr box would be the way to go for sure.
 
I look forward to seeing the finished bike.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 16, 2011, 16:12:34
johnu, thanks.  I think I am going to try both the STD and ARRT2 boxes and choose the one best suited for my riding style. I generally ride the beautiful and empty, curvy and hilly country roads around my area of the Mississippi River and less time in heavy traffic. There is much folklore concerning the RRT2 gearbox and I understand its shortcomings for riding in the real world.

I too am looking forward to seeing my bike finished, but I am taking the time to do it right.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: johnu on Feb 16, 2011, 16:44:36
Sounds like where you will be riding, the cr box could be the right choice.
 
Nothing wrong with taking your time on the restoration, you are definately doing this bike right .  My dad is the master of taking his time on resto's, luckily some of it rubbed off on me. 
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 17, 2011, 23:19:57

Three steps forward and two steps back...


Finally got the front drum lathe-turned and sorted out after quite a bit of effort and running around. My local machine shop does not have a lathe that would fit the front wheel, so I went to a couple other places and ended up at a local O'Reilly's Auto Parts store. Employee Jake was extremely helpful, patient and his Dad and uncle are British bike fans.  My wheel fit in their brake lathe but I had to first remove the bearing covers, but that did not work. Then had to remove both bearings for their spindle was 1" and the ID of the bearings are 7/8".  We could not get the wheel to run true on their spindle and cones. Hmmmm... I thought about inserting bearings with the same 2" OD and a larger ID to slip over their spindle but that would not work for the bearings would just spin when it was ground. I came up with a $5 solution from Fastenal-two spindle collars with an 2" OD and 1.25" ID and we were able to run the wheel true on the lathe and make the cuts.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0130.jpg)


Looks much better, I double checked the spokes and rim for truth back on the truing stand and ran a dial indicator on the inside drum and I am good to go!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6381-1.jpg)
Turned drum and spindle collar in bearing holder to fit the lathe.


The front tire was mounted and tomorrow I am having both wheels computer balanced. One more step towards a rolling chassis.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: tWistedWheelz on Feb 18, 2011, 09:31:17
This build is absolutely amazing! Your attention to every little detail, the quality of the work, and your knowledge and skill will really set this bike FAR apart from any other! This will certainly be a very fine machine when you are done. You are truly a member that DTT is very proud to have!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Garage Rat on Feb 19, 2011, 23:37:51
Whats a good tolerance for a wheel? Ive spent about the day messing with it.

Side to side I'm around .02, but top to bottom I'm a little less then 1/8" and this thing is kicking my ass... Is this good or am I running around in circles?

Thanks
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 20, 2011, 11:25:03

Thanks TW! You have a beautiful project as well.


Basement rat, truing wheels takes patience and you must know when to walk away sometimes. It is one of my favorite parts of any build, but I must be in the right frame of mind to do it. Beer is helpful. Check the factory service manual for tolerances on your bike. Are you using a stand, a swing arm or the rim mounted on your bike? Get your rims as true as possible for any wobble or hop will add up, particularly at higher speeds. New bearings are cheap and help the rim run more true.


With new rims, spokes and bearings I was able to get within .004" radially and axially on my fancy new truing stand. Remember the welded area where the rim is joined to itself will always have some hop and can never be as true as the rest of the wheel. Tighten on low and loosen on high, tighten to pull to one side while losening the corresponding spokes on the other side. I finger tighten all spokes evenly to start, then work on the axial runout (up and down) and get it as close as possible, Next, I work on the radial runout (side to side) and get as close a possible. I'll go back and tweek the axial then the radial again. All spokes should be tight and have the proper sounding ping when plucked. Proper oil in the nipple and and anti-seize lubricant between the rim and nipple is absolutely necessary.


I have a local shop dynamically balance my wheels on their machine after I true the rims and mount the tires. They charge about $30 for the pair and it is more accurate than I can do on my own stand. I pick mine up tomorrow!


Here are two references you may find helpful:
Dan Jones at SOHC.com http://forums.sohc4.net/index.php?topic=368.msg205745#msg205745 (http://forums.sohc4.net/index.php?topic=368.msg205745#msg205745)
John Healy Triumph Sage http://www.tioc.org/lacing371007rim.htm (http://www.tioc.org/lacing371007rim.htm)


I hope this helps.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 23, 2011, 00:00:37

A few more steps forward...


Got my wheels back from Gary Russel's Powersports yesterday. Gary is great guy, rode a Norton back in the day, runs a small local shop on his farm and he balances all my wheels. Front wheel came out great but the back took some effort and needed a good sized lead counter weight, but they are balanced and true.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6453-Version2.jpg)


I have been slowly gathering, inventorying, photographing and cleaning all my hardware so I can send it off to be cadmium plated.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6392-Version2.jpg)


Almost done and I dissected my magdyno tonight to prepare its hardware for cad plating. The dynamo does put out some power but it took some effort to spin it and I soon found out why. Somehow insects got inside, shat and died, leaving it full of crud. The armature cleaned up nicely but I am leaning towards a full Hawker Electric replacement kit http://www.hawkerelectrical.co.uk/items/17-1_14-lucas-e3lm-dynamo-rebuild-kit-.htm (http://www.hawkerelectrical.co.uk/items/17-1_14-lucas-e3lm-dynamo-rebuild-kit-.htm) . The magneto was much cleaner and I am going to have it professionally rebuilt, after it is vapor blasted.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6454.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6455.jpg)
Yuck!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Garage Rat on Feb 23, 2011, 01:44:50
Sorry for the hijack, just wanted to let you know I got mine sorted out after about four days on and off...

(http://i29.photobucket.com/albums/c276/Ed_Guy/DSC_0099.jpg)

Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: teazer on Feb 23, 2011, 02:14:52
That's the same stand I use. Got it second hand in Chicago years ago and it does what it needs to.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 23, 2011, 12:07:49
Garage Rat, Glad you got it sorted. Your extra wide rim and heavy gauge spokes probably made it more difficult to run true. I love the old style cast iron stands, many are Harley or Indian items and therefore way overpriced on E-bay. Bonus points for the chest freezer /workbench!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: kparrott on Feb 23, 2011, 13:23:37
Swan,

I've always looked around the site, but joined after seeing your build. You are doing awesome!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 24, 2011, 22:45:47
Thanks kparrot!

FREE AT LAST, FREE AT LAST!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6467-Version2-1.jpg)

As I gather hardware to be cadmium plated I finally tackled the cylinder tonight. The piston, cylinder and rings are frozen after 40 years of no use and they have been soaking in different solutions of ATF and acetone, PB Blast, Seafoam Deep Creep, DOT 3 and Marvel Mystery Oil for several months with no movement whatsoever. Next, I tried Naval Jelly, which is a gelatinous phosphoric acid, to attack the rust on the frozen pistons. Still no movement.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6384.jpg)
Frozen solid



It soaked for another week in Marvel Mystery Oil and I was going to set up an electrolytic reduction to remove the rust and free the piston, but stumbled across another technique, tried it tonight and it worked! From an antique motor forum I found the 12 steps to removing a frozen piston http://www.smokstak.com/forum/showthread.php?t=37566 (http://www.smokstak.com/forum/showthread.php?t=37566) and it recommended scrapping away as much rust as possible (which I had done) and use a 50/50 mix of ATF and gasoline with a bit a cloth as a wick and ignite it. The heat warms and expands the whole cylinder and sleeve while the ATF works its way down past the rings. I let it burn for an hour and pounded with a large wooden drift and a dead blow hammer and I finally had movement.  Several more whacks pushed the piston down and I was able to finally release it from its rusty prison. Going to finish cleaning and breaking her down tomorrow. A major step forward...
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0149-Version2.jpg)
Fire and Ice

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6465-Version2.jpg)



(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6470-Version2.jpg)
Rebore or resleeve? I'll get out the internal micrometer tomorrow after cleaning.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: bikeboy on Feb 25, 2011, 05:10:28
Fire and Ice

That sure is a cool tip. And it works by the looks of it.

great build you've got going.

cheers
ian
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: tWistedWheelz on Feb 25, 2011, 09:50:50
Seeing that fire in the top of that cylinder outside like that.....If it had been me there, I would have pulled up a lounge chair and opened a few beers around it! That is a true gearhead firepit!

Nice trick and thanks for sharing! That needs to be in the $50 mod thread!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: jay_kent on Feb 25, 2011, 12:03:48
Seeing that fire in the top of that cylinder outside like that.....If it had been me there, I would have pulled up a lounge chair and opened a few beers around it! That is a true gearhead firepit!

Nice trick and thanks for sharing! That needs to be in the $50 mod thread!

I know know what I'm going to make my fire pit of.

And that tip is the bees knees. I've got a cb750 that is locked up. Guess I know what I'll be doing on sunday shop time.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 25, 2011, 12:20:02
Thanks guys, I did have a couple of pints last night to celebrate my victory over the frozen piston.


jay-kent, good luck on your CB750. I hope this technique works for you and please post your results in my thread in the "1-800 cafe-help" section for others to use. http://www.dotheton.com/forum/index.php?topic=23057.0 (http://www.dotheton.com/forum/index.php?topic=23057.0)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Rocan on Feb 25, 2011, 12:34:57
awesome man!  agreed with having a few beers around that pit.... heck, even roast a few hot dogs...

the kerosene and marvel mystery oil add to the flavor.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 28, 2011, 14:31:15
Thanks all!

Ha! yes, it feels good to make progress. I normally do not use a hammer any where near my bikes, but after several months of soaking the rings and piston it was "hammer time".


A quick update with many photos.


I spent several hours breaking down and cleaning my motor, taking my time, doing it right, using the right tools and techniques while learning every square inch of this beautiful beast. All the bolts, studs, spindles, misc hardware were pulled, bearings and races drifted out, valves, seats and springs removed and the cases were cleaned with parts washer solution and then 3M red scrub pad for metal, Simple Green and elbow grease.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6472-Version2.jpg) (http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6476-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6480-Version2.jpg)


The cases cleaned up well and no major surprises, chucks of metal, cracks, repairs etc.  One of the cylinder studs was a complete bastard and required a lot of heat, lubrication and patience on my part.  The crankshaft, rod, bearings and races are all in excellent shape as were the valves, springs, guides, valve seats and pushrods.


The only drama was with the tappets, tappet holders and camshafts. Take a look:
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6485-Version2-1.jpg)
Intake 65-2442                    Exhaust 65-2446
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6493-Version2.jpg)
Worn?
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6491-Version2.jpg)


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6483-Version21.jpg)


The exhaust tappet was sticking due to rust and corrosion at its top and the inlet camshaft and tappet are trashed. Perhaps this is why my bike was parked all those years ago? Looks like I'll spending more money on new tappet holders, tappets and a new cam.
 
 Tonight, the continued saga of scrubbing, cleaning, documenting and photographing parts.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: jay_kent on Feb 28, 2011, 14:36:04
the photography is really outstanding. Just a great photo journal. should be made into a coffetable book once you're done.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 28, 2011, 14:38:54
Jay_Kent, it is going to be a motorcycle when its done!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: bikeboy on Feb 28, 2011, 16:17:37
... it is going to be a motorcycle when its done!




 ;D ;D ;D ;D ;D
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: jay_kent on Feb 28, 2011, 16:51:43
zing.

I think for a collector or bike enthusiast, a collection of images of your rebuild would be spectacular.

Carry on.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Feb 28, 2011, 16:56:01
Thanks!
As I said before, as popular as Goldies are, there is relatively little, actual and usable restoration information online. By documenting my build it will help others on their builds.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: VonYinzer on Mar 01, 2011, 15:00:50
Spectacular work so far Swan. She will certainly be a thing of beauty.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: MBellRacing on Mar 01, 2011, 15:05:24
Oh look, a REAL cafe racer! Looks incredible and great pictures to go along with a great build. Can't wait to see it running and riding!!!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Mar 01, 2011, 15:13:51
Thanks guys for the encouragement!  One of the many reasons I love the Goldie is that it is nearly ground zero for all cafe racers. A stock Gold Star looks so lean, fast and ready to race the streets.



Today was better than Christmas! Look what just arrived, a new UK made exhaust and proper silencer, correct refurbished Smiths chronometric tachometer and the long out of print book "Goldie". Purchased from a Britbike.com member and Goldie fanatic.


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6495-Version2.jpg)
vrooom, vrooom...


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6497-Version2.jpg)
Thump, thump, thump....twitter
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: jrknecht on Mar 01, 2011, 15:20:53
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6495-Version2.jpg)
vrooom, vrooom...


Haha, this would freak me out on my bike, at 2000rpms I would think I was redlining it. ;) I really love how clean it is.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Greg-NWO on Mar 01, 2011, 17:29:06
I absolutely love this thread....   keep up the great work Swan.  The quality of your work is incredible, thanks for sharing the journey with us!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: SpottheDogg on Mar 01, 2011, 18:53:19
Love it!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: scroggins5000 on Mar 01, 2011, 19:58:11
I just read this whole thread, and I think this bike finally found the perfect owner for it. Amazing work. I can't wait to see it finished!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: wfo guy on Mar 01, 2011, 20:49:57
Does anybody when the reverse rotation on the gauges was used? The shelby cobras use this but all my Triumphs and BSA's from the 60's were standard rotation.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: racewiththedevil on Mar 02, 2011, 12:05:14
1963 was the last year of the smith's chronometric for BSA and the switch for most mfg's to the magnetic type spedo's and tach's.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Jonny on Mar 02, 2011, 21:07:59
wow swan! your blowing through the clean up of this bike! and now that the pistons free! cant wait to see the progress you make now! haha can tell that you have been waiting for this bike :) ! and great work thus far!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Mar 06, 2011, 13:21:49
Thanks again everyone for the kind words.
On this week's installment of lunch hour update I worked with my friend Pat the welder to repair the broken cylinder head fin, cut and fill a 4” hairline fracture on my inner primary cover, press out my rear brake arm spindle and create a motor stand. I traded shop time with his boss Pete for my labor on Pete's 1971 Honda CB750 which I will get running, timed, tappets adjusted and tuned up after sitting for ten years. No problem, for I have built 5 CB 400, 550 and 750’s and know the motor and carbs well.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0166-Version2.jpg)


Their shop is 160 years old, one of the first buildings in Winona and began as a saloon facing the river, a whorehouse up top and a blacksmith in the back. (welding, whiskey and women-all require warning labels). It later became a Winona Boiler and Steel and the building is filled with ancient machinery, leather belt driven cast iron machine wheels, mammoth brakes, shears, presses etc along with beautiful Miller and Lincoln welders and all the shop toys we lust after. Pat is young, very knowledge, creative and a great guy. I hooked him up with a Honda CB750 that he is going to customize in to an old school bobber.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0171-Version2.jpg)
master at work
The inner primary cover under Pat’s magic hand:
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0173.jpg)


I broke off some donor fins from a trashed Triumph 650 barrel weld to my cylinder head using Heliarc (TIG) and 4043 welding rod. Guess what, cylinder fins have iron in them and will not weld to my alloy head… All part of the learning curve. I tried several local options but ended up buying a broken BSA cylinder head on E-bay, so the repair is delayed to the end of the week.


 (http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6500-Version2.jpg)
Pat welded an engine stand from shop scrap and I beadblasted my hardware. It is so nice to use a monster industrial compressor that cycles every 20 minutes instead of my small compressor that cycles every couple of minutes. We also pressed out my frozen rear brake spindle without destroying the spindle or plate using their 50 ton press. Always nice to have the right tool for the job.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0170.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6521-Version2.jpg)
With a busy work week, I will try to find time to finish preparing hardware for cadmium plating and wait on the donor cylinder to finish my head and get the motor parts off to be vaporblasted. Stay tuned…
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: wfo guy on Mar 06, 2011, 19:19:11
I am well aware of the value of friends with equipment that I don't have. I remember alot of welded parts on my 441. I feel your pain in this project.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Mar 10, 2011, 13:56:50
wfo guy, yes it is good to have friends with nice equipment, Beer is one of my favorite bartering tools.

A minor victory, my cylinder barrel was at stock 85 mm bore with the severely frozen piston and rings. I had the Engine Store of Winona (http://www.theenginestore.com/index.html) bore it to just under .030” over standard. There is still a tiny bit of pitting, so I will order a .040” piston and rings and have them bore to match the new piston and that should clean up the last of the pits. No re-sleeve necessary! The Engine Store is a local full service machine shop, do great work at reasonable prices and took extra care and time do it right. Thanks guys.


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6549-Version2.jpg)
Before
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6555-Version2.jpg)
After


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0213.jpg)


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6556.jpg)
Tiny pitting that should clean up at the next size overbore (.040”)


I have freetime this weekend to move forward on the fin repair and hardware prep.

Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: haplo_84 on Mar 10, 2011, 17:39:13
god i love reading your updates. Beautiful, beautiful work. done with painstaking care.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: dewjantim on Mar 11, 2011, 21:01:23
I wish more of my friends had some of those machines...... making stuff by hand using Harbor Freight tools gets a little difficult sometimes. None of the machine shops around here are interested in doing little jobs. Most have a $100 minimum which is way too much to have something pressed out or a broken bolt removed.... Excellent build, by the way..... lots of info and pics. I can't wait until it is done.....
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: .jordan on Mar 11, 2011, 21:13:59
sweet trick with the motor. Glad you were able to get it free.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Mar 13, 2011, 13:05:33
Thanks all!



Progress. The cylinder head fin  (http://www.dotheton.com/forum/index.php?topic=23229.new#new)and the inner primary cover are repaired, frozen dynamo screws removed, more bead blasting and prep for vapor blasting and cad plating. I love working on my bike.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6498-Version2.jpg) Before
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6569-Version2.jpg) After
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0243.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0246.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0279.jpg)
Whitworth tap from British Tools and Fasteners
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6566-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6567-Version2.jpg)





Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: lassenc on Mar 13, 2011, 13:08:34
Love it! How did you clean up the fins? Wirebrush?
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: haplo_84 on Mar 13, 2011, 14:33:10
Everytime you post something new its like being a kid and walking into the candy store with a hundred dollor bill in my hand!
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Mar 13, 2011, 14:36:41
Thanks Haplo_84, every time I touch my bike I spend $100....
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: haplo_84 on Mar 13, 2011, 15:20:26
Oh i can beleive it, just doing little mods on my bike is costing me more than i was thinking. But it'll all be worth it in the long run. I'm excited to see the outcome of the beauty, your attention to detail is just awesome.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: 50gary on Mar 13, 2011, 15:25:54
Swan, looking very nice all the way through good work.  To backtrack just a bit, could you fill me in on the Vapor blasting?  I read about it in "Classic Bikes" but I don't know any details.  I been looking for a local shop that does this but no luck thus far.  Thanks.
  Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Mar 13, 2011, 15:43:01

50gary,
I will write up a complete before and after page on vapor blasting once my parts are done. It is highly popular in the UK for restorative work, the results are simply stunning and have many advantages over traditional media blasting. Two people offer vapor blasting small orders for motorcyle parts:
Mods and Rockers (http://www.modsrockers.com/index.html)
Bikesalot (http://www.vaporblasting.biz/index.html)




I am going with Peter at Mods and Rockers for he is only 2 hours away, he rides British bikes and understands how important this motor is to me.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: 50gary on Mar 13, 2011, 20:00:45
Thanks I'll watch for that write up.  I live in Saginaw, Michigan USA.  I'll keep looking.  Mods and Rocker where are they located?
  Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Mar 15, 2011, 10:40:53

Another step forward: The motor parts, two gearboxes (STD and ARTT2), two monobloc carbs and the inner primary cover are all repaired, cleaned, prepped and packed for vapor blasting. I crated everything for transport to Peter at Mods and Rockers (http://www.modsrockers.com/about.html) vapor blasting in Mankato, MN.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6655-Version2.jpg)
Precious cargo


I have never had anything vapor blasted before, researched the pro's and con's and decided to try it. I will post my results in a separate thread when all is done.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6618-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Goggles Pizano on Mar 15, 2011, 12:11:15
Interesting.  I've heard of similar results with glass beads (not cut).  Supposedly, the round beads close up the pores of the metal unlike cut glass which leaves pits.  Very interested to see how it comes out.

Per the site you listed, it seems the rates are pretty reasonable as well.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: teazer on Mar 15, 2011, 13:38:56
Vapor blasting is more or less glass beads in a water stream.  I first used it on Aero Engine turbine blades when I worked for Rolls Royce a couple of life times ago.

It leaves a really nice clean satin finish.

Phil Pilgrim in Melbourne has a set up, and there have to be some in the Midwest.

Search for AQUA BLASTING in teh US
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: IndieSol on Mar 15, 2011, 15:37:08
It really is looking great, sir.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: jrknecht on Mar 15, 2011, 16:10:41
What setup are you using to shoot all your stuff? Pictures look amazing ;) . I would love to shoot everything on white but I no longer have my studio so every time I want to do a backdrop I have to get everything out and set it up at home  :P .
Keep up the great work.


JR

Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: jonnyTHUNDERmaker on Mar 22, 2011, 00:51:47
You sir, are ridiculous (in the best way of course). I can't imagine the excitement when you got this old girl.


Fantastic job so far. What great work. I think you and this bike were meant for each other. Keep up the great work, and the great updates and pictures. Good luck, and happy wrenching



Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: stik70 on Mar 22, 2011, 01:04:13
Swan, your work is inspiring. Me, living just two hours south of Mankato, and having a B44vs to finish, thinking will have to meet up for coffee in Owatonna or Austin some Sunday morning. Your bike is cool!!
Kev
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Mar 22, 2011, 10:09:27
Thanks everyone! I have been extremely busy with work and travel and unable to spend  time on my bike.  Stik70, I rarely get out of bluff country but would consider a high speed burn up along I-90 to meet up...


I am slowly collecting, documenting, cleaning, filing and prepping all the metal hardware for cadmium plating. It is a time consuming and detailed process which could drive a weaker person freaking insane. Every single nut, bolt, screw, washer, spring, stud etc needs to be processed, including new hardware which is zinc plated. My order for a Whitworth tap and die set from the UK weeks ago has not arrived and is holding up this process. I am also adding all the hardware from a Norton gearbox, Triumph T110 motor and Lucas K2F magneto for version 2.0 of my Triton as long as I am it. Tedious work, but I am making the time do it right.


Also I am patiently awaiting my motor and parts from vapor blasting. Quality work takes time.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6674.jpg)
One of many bags of parts being prepped for re-plating. Extra credit points for anyone who can identify where these parts belong.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: 50gary on Mar 22, 2011, 10:33:20
Swan, in this photo you have a portion of the hardware in small plastic bags with the labels.  Will the Cadmium plater do these bits one at a time and re-insert them into the labeled bags, or simply do them en-mass and return to once again be sorted?  The biggest "tool" you have at your disposal appears to be your methodology, organizational skills.  I admire your abilities in this area.  Early on you mentioned you are an archeologist by day and a motorbike Maven by night?  This is a learning thread.
  Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: swan on Mar 22, 2011, 11:05:01
50gary,


Meticulous documentation and notes are necessary because everything will arrive in one big box, plated in a large container and returned as a large jigsaw puzzle. Platers will not do small batches or keep things separated. Since I am mixing two motors, two carbs, two gearboxes everything from my Goldie etc organization is a must.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted-wow)
Post by: swan on Apr 01, 2011, 10:44:42
WOW..... I picked up my parts in Mankato, MN from Peter at Mods and Rockers Vapor Blasting last night and am simply speechless. Stunning.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6782-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6787-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6808-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6827-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6772-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6816-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6793-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6806-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6818-Version2.jpg)
Before
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5238-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: jay_kent on Apr 01, 2011, 10:50:45
That is a stunning unit
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Goggles Pizano on Apr 01, 2011, 11:07:55
That definitely cleaned it up. I'm not sure how it looks in person, but in the pictures it almost looks like it's been painted with silver paint.
Title: Re: 1962 BSA DBD34 Gold Star barn find restoration
Post by: Keogan on Apr 01, 2011, 12:19:14
This thread is amazing, and I'm inspired by your knowledge and passion for your bike. That engine looks better than new!

Be  careful, as my grandfather always says, don't spend too much time making it look perfect because you'll never want to ride it. Allthough i've seen your perfect Triton and i doubt you'll have any problem riding this soon to be beast.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: saywhat on Apr 01, 2011, 12:28:09
That engine looks sooo fresh now. Are you planning on recoating it, or leaving it raw?
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Greg-NWO on Apr 01, 2011, 13:18:22
I love this thread....  it kills me waiting for updates though!!  :)

Looks great, can't wait to see more!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on Apr 01, 2011, 13:20:49
Thanks guys! Everything is clean as the day it was born in the foundry nearly 50 years ago. This is the final finish, British crankcases were not painted except some cylinder barrels were painted black.


Here are a few more details of vapor blasted parts:
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6834-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6848-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6850-Version2-1.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6853-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6851-Version2.jpg)


I had a great time talking with Peter and his buddy Shades34 at Mods And Rockers. They have a garage full of old bikes, tools, parts, photos etc and we talked for several hours about bikes and I could not stop looking over Shade's Triton project. He has all the right bits and is doing it right.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triton%20Cafe%20Racer/IMG_6769-Version2.jpg)
Peter is a true craftsman who is passionate about old bikes and treats his customers' parts like his own. This is the first time we have met face to face, I highly recommend his services and the results speak for themselves. I could not be happier.


I am still waiting for my Whitworth tap and die set to arrive so I can finish cleaning and prepping my hardware for cadmium plating.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: diesel450 on Apr 01, 2011, 15:30:28
Very nice! I'll be looking for that service on the east coast for sure.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: beachcomber on Apr 02, 2011, 11:39:54
Swan,
 
just got back from a short break and  the latest artwork from John Hancox [ for the DTT calender ] was waiting for me..............BSA Gold Star .....oh boy.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Jewbacca on Apr 03, 2011, 12:21:49
Wow, this thing has come full circle my friend! Those vapor blasted parts sure are puuurty. I may be showing my dumb newb side here, but in the last pic of the engine fins, are those just casting seams in the middle of the fins? Looks like they are almost separated? Like I said, just my curiosity coming out a bit. Bike is coming along great, can't wait to see the end product! Good luck brother!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: bikeboy on Apr 03, 2011, 20:22:59
that motor looks awesome swan.

can't wait to see it together.

cheers
ian
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: jonnyTHUNDERmaker on Apr 04, 2011, 15:32:56
Wow,
That vapor blasting really cleaned up those parts. They look perfect. Thanks for the pics and the update. Good luck
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Jonny on Apr 05, 2011, 01:48:42
wow engines looking great! bet you cant wait to get the hard wear back from plating so you can put it back together!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on Apr 12, 2011, 22:12:00
Thanks all! It is pure torture staring at this motor case while I finish hustling up the money for a new Pearson crankshaft, Carrillo rod, bearings, piston, camshaft, tappet and guide. (USD $1800)

The bad news is I have been slammed at work and managed to sprain my ankle screwing around on a bicycle so I am on crutches and have had little time to work on my bike. The worst part is the weather is beautiful, the snow is gone, my Triton is rearing to go and I have not ridden yet this year. My goal is to ride on Easter but with a tender right ankle kicking her over may be a challenge.

The good news is I bought a decent set of UK made CEI taps and dies to finish preping my hardware for cad plating and found a vintage Craftsman British Standard Whitworth 1/2" drive socket set on Craigslist for $50! I have two complete sets of Koken sockets and sets of open, combination and ring wrenches by Everest and other Eastern manufactures, but some how got it into my head I need vintage Snap On or Craftsman wrenches. Recent E-bay auction results brought me back to reality and I will use what I have until I find older tools at realistic and affordable prices.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6993-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6999-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6973-Version2.jpg)
Money well spent.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: bikeboy on Apr 12, 2011, 22:21:09
Money well spent.

good tools are always an investment.

heal quickly, and jump on that triton. even if you've got to get someone else to start it ;)
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on Apr 15, 2011, 12:29:01
Thanks BB, tools are an investment, I love them, (don't we all?)


Another step forward... I worked at my friend Pat's shop to fabricate some simple tools to finish breaking down my magdyno. The hardware is going to cad plating, the body shell will be vapor blasted and the coil will be rewound with a new modern condensor by Joe V's Cycle. (http://www.joesvcycle.com/page_08.htm) In order to remove the large mag gear you need two non-existant Lucas service tools: a generator drive locking tool and locking plug for the drive gear.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/locking-tool.jpg)(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/locking-plug.jpg)


Some shop scrap (1/4" rod and 13/8" rod ) and a bit of quick fabrication yielded these two tools:
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7016-Version2.jpg)
These two tools allow the nut on the shaft to be removed.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0639.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0640.jpg)
We pressed out the rotor and the inside components look pretty clean after sitting for 40 years. No rust or major carnage.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7015-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7017-Version2.jpg)


I found the Lucas Magdyno workshop instructions here. (http://www.bolsover.com/lucas/sectionL5partB.pdf)
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: bikeboy on Apr 16, 2011, 09:42:58
Some shop scrap (1/4" rod and 13/8" rod )

hang on a minute swan. It's been a long time since I've had to work with that crazy imperial system, but 13/8" just does my brain in! Did you just make that up?

Oh, and nice work on the tools. what ever you used  ::)


ian
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: frogman on Apr 16, 2011, 10:05:26
Prolly means 1 3/8" rod, that's a big hunk of steel too.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: 50gary on Apr 16, 2011, 11:20:29
Yes-sir, the comma was left missing I'd suspect?  Here, borrow one of mine ,,,
1,3/8"
   Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on Apr 16, 2011, 11:47:03
Yes, my bad, typo... 1 3/8" ( 1 inch 3/8, 1, 3/8" 1.375"). Thanks guys.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on Apr 19, 2011, 17:09:09

A quick little update: I picked up a few final small bits from Custom Powder Coating in Minnesota City on my lunch hour. The magdyno straps and cap look absolutely beautiful as do the brake parts and spacers. Not much, but it makes me happy and is another small step forward!


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7218-Version2.jpg)

Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Sonreir on Apr 19, 2011, 17:10:31
Slow and steady wins the race, man.  Any short cuts on this project and you'll only hate yourself later.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Erskine on Apr 19, 2011, 20:29:00
I covet your Craftsman Ebay bargain.
Well spotted!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on Apr 26, 2011, 19:13:40
Another small step forward: My dissembled BSA magdyno and K2FC magento for my Triton version 2.0 sent off to Mods and Rockers for vapor blasting.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7268-Version21-1.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on Apr 27, 2011, 19:13:43
Wow, a very nice thing happened today. Limeyrider, a member of the Britbike forum, sent me a set of Torrington needle bearings for my RRAT2 gearbox rebuild. I tried to offer him money, he refused, I tried to pay for the postage, he refused. I like to give and have a hard time accepting gifts, that is how I was raised. He had an extra set of bearings and said he was 'following my progress closely". Well Limeyrider, since you are following closely, thanks again, what a kind gesture!


Does this mean my bike has groupies?


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7272-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: saywhat on Apr 27, 2011, 19:49:27
I can't get over how clean those cases are, I spent all weekend scrubbing mine down, and I can't come close to the vapor-blasting goodness.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Garage Rat on Apr 27, 2011, 19:50:33
I know id give more then bearings to your bike...
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: haplo_84 on Apr 27, 2011, 20:12:55
Thats a great thing about an enthusiast, they will give if they have it and are not using it. Especially with a build such as this. There are going to be things hard to find and someone who loves that bike will put something forth towards it. Thats enthusiast of any kind (Car, motorcycle, boats). Its a tight knit community for different things and when they feel its for something like your bike where it will be a super clean example and used for what it was made they willing give to the effort. As apposed to a collector or an afficianado who thinks it should sit and never be touched and spends thousands just to do so.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: 50gary on Apr 28, 2011, 00:19:18
Does this mean my bike has groupies?

          More than you know. 
  Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Goggles Pizano on Apr 28, 2011, 00:37:31
I'm a groupie.  I love this build.  The only thing I don't like about it is that it's not moving fast enough :-)

I can't wait until you get to the body work.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: rjz5400 on Apr 28, 2011, 11:50:46
yes groupie here also,
 ;D

dont tell anybody here though, they think i am a "don't give a f*#k" motorcycle speed demon. not some weepy eyed vintage BRITISH bike restorer guy.   so help a brother out.  8) 8)


and keep up the good work, as if it hasn't been said enough I am inspired to ditch the three half assed builds i have going and get down to business on one and do it right!!!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: thirsty 1 on May 02, 2011, 00:32:51
Again nice work on doin' it right for the right bike. Sweeeeeeet.......
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Sonreir on May 09, 2011, 13:01:44
Come on swan, no more slacking!  We want updates!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on May 09, 2011, 14:55:29
Thanks all, I too am a hopeless groupie of this bike. Small update, outer transmission bearings arrived from Simply Bearings UK (http://simplybearings.co.uk/shop/) (cheaper than buying them in the US) and my magdyno body for the Goldie and magneto body for my Triton version 2.0 arrived today from vapor blasting. WOW! Peter at Mods and Rockers (http://www.dotheton.com/forum/www.modsrockers.com) vapor blasting did it again.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7352-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7354-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7357-Version2.jpg)




Sonreir, I was not slacking, but moved into town last week and put the project on hold because my entire life was in boxes, including three motorcycle projects. I now have a small workspace and space in a garage for my Triton. My ankle is slowly getting better and I have ridden my Triton for the first time this year. She is running well and happy to be out. Some laws were broken, but nobody got hurt... Still trying to find the time to finish prepping hardware for cad plating. That's it for now, slow and steady...
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: haplo_84 on May 09, 2011, 15:08:38
So fresh and so clean!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Sonreir on May 09, 2011, 18:36:29
Seriously... that vapor blasting looks so good I'm looking at my next project being a restoration of a more valuable bike just so I can rationalize getting it done.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on May 17, 2011, 12:28:22
An important update: my tax return arrived and I can now order my new crankshaft from Phil Pearson in the UK! Pearson cranks are masterful precision works of art capable of taking any abuse thrown their way. Carrillo rod, new bearings and precisely balanced to a new forged piston. Oh yeah. It is like a heart transplant but better, stronger, faster....
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/Pearson-carnkshaft.jpg)
Heart of the beast (only GBP 800, $1300 USD)


Also, I took a call from the producers of "American Pickers" last night and through some more calls and e-mails it looks like Mike and Frank are going to call me as a "phone a friend" portion of their show. Unfortunately it is not motorcycle related and in line with my position as a curator, but I told the producers to tell the guys I found a BSA Gold Star in a barn and to watch their eyes go big and mouths open. I'll keep you all posted after it happens, should be fun! I have seen the show a few times and nothing wrong with anyone with a passion for old bikes.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: JustinLonghorn on May 17, 2011, 12:34:35
That's awesome, man!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Garage Rat on May 17, 2011, 21:43:56
Love watching that show.
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on May 17, 2011, 21:50:06
Bummer, after a day of texts, e-mails, photos and phone calls I found out I will not be on "American Pickers". They guys were looking at an old woodstrip canoe in Minnesota and wanted my professional advice and appraisal. It turned out to be in very poor shape and are not going to film or buy it, so I am out. The producers were very appreciative for all my work and advice and will contact me in the future for other finds. They also know I am a vintage motorcycle freak too. Something may come up again.


Making a phone call to the UK tomorrow for my crankshaft!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Jonny on May 17, 2011, 22:08:10
thats a bummer swan, what type of canoe was it? Peterborough? hahaha
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on May 17, 2011, 22:55:38
It was an older cedarstrip/ fiberglas canoe, most likely garage built from popular plans (early to mid 1960's). Not an older cedar canvas (EM White, Gerrish, Old town et al) or a very old cedar strip such as a Lakefield or Peterborough. It was rotted in places with holes and after further inspection the guys decided not to buy it or include it in their show. Oh well, I gave them a link to my Gold Star restoration so maybe they will pop up on this forum!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Sonreir on May 18, 2011, 11:55:57
Thank crank looks like a work of art, swan.  How does it differ from a stock model?
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on May 19, 2011, 12:47:00
Sonreir, the stock crank in a DBD motor was the Gold Star's Achille's heel. It could not handle the power of the motor and many broke a rod, holed a crankcase, loosened crank rivets and worse. Pearson's cranks are indeed works of art using the best modern materials, pressfit, bearings, Carrillo rod etc made to a tolerance of .0002. He has been working on Gold Stars for more then 40 years and one of the most respected names in the business. I ordered my crank and it is the 550th crankshaft he has made for Goldies. It will be the heart of the beast and will offer peace of mind when I really put the spurs to my bike. Phil said it will be done it 2-3 weeks. I cannot wait!

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/lathe.jpg)
(Pearson in workshop, photo Mike Loper 2003)
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Bob G on Jun 14, 2011, 12:53:05
Hey Swan,  Just found your postings, great series - great progress!  Curious who you found to do your cad plating.  I need to send a bunch of hardware out for a couple of my Brit bikes.  Platers are drying up in SoCal these days...
 
Thanks!
 
Bob
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on Jun 14, 2011, 15:16:08
Bob, I am using Aero Propellor  (http://cadplating.com/)in Colorado for my cad plating. I am still trying to find the time to finish cleaning, prepping and documenting all my Goldie hardware and extra gearbox, as well as a Norton gearbox, my Triumph T110 and a few other British bits for plating. Aero is good, I spoke to the owner and he understand old bikes. $125 minimum and it is about $5 a pound to cad plate. Everything needs to be CLEAN. I hope to ship everything on Friday.


A few more steps forward while I wait for my crankshaft. I ordered all new bearings from Simply Bearings UK (http://simplybearings.co.uk/shop/) (C3 clearances available in RHP, SKF and FAG bearings), a replacement 65-2442 camshaft and tappet as well as a new gasket set. I need to get my hardware out and start polishing the covers so I can put the motor together. Soon!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Greg-NWO on Jul 12, 2011, 17:43:51
Need update.....  soon!!  :D
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on Jul 14, 2011, 20:35:59
Minor update, bearings arrived from UK and new gasket set is here. Have not heard from Pearson so I will call him soon.

My girlfriend is visiting me for 6 weeks so I have been busy with her and have little to no time to wrench...
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: swan on Jul 15, 2011, 10:23:57
Just spoke to Phil and he finished my crankshaft last night. He will balance it to my new piston, ship early next week and I should this within a week. Cannot wait!
Title: Re: 1962 BSA DBD34 Gold Star restoration (UPDATE vapor blasted!)
Post by: Ethanol on Jul 16, 2011, 02:15:12
I am totally in love with this entire build. Just spent an hour looking through all 19 pages and am blown away. Awesome.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: swan on Jul 19, 2011, 13:30:09
Thanks Ethanol, it has been quite a ride...

WOW! I spoke to Phil Pearson on Friday July 15th and he said my crank was done, he would balance it over the weekend and ship on Monday. I sent a thank you e-mail to his wife Linda this morning and FedEx showed up with my crank! One day delivery from the UK. WOW. Here is my beautiful Pearson crankshaft #550, Carrillo rod and new piston and rings awaiting its new home. I am stunned, it even smells good.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7866-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7868-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7882-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7869-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7880.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7879-Version2.jpg)
note the date stamp "14/7/2011", today is 19/7/2011. It was GBP 800 or USD $1290.00 and worth every cent for the peace of mind it offers.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: Maritime on Jul 19, 2011, 13:41:00
That is a thing of beauty!  Congrats, now the engine will likely outlive you.  Hope you enjoy the hell out of it!  Can't wait to see all the good stuff put back in and please post a vid of the engine running when cpmplete.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: Sonreir on Jul 19, 2011, 16:42:24
Absolutely gorgeous.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: swan on Jul 19, 2011, 19:18:32
Thanks guys! I brought it home and CANNOT STOP STARING AT IT...
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: JustinLonghorn on Jul 19, 2011, 20:29:43
It is kind of sad, knowing that such a beautiful piece of machinery will be hidden away inside of a motor. However, there is something absolutely heartwarming knowing that beautiful piece of machinery is going to keep that same motor happy. And, in turn, keep you happy as well.

I love this build.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: 50gary on Jul 19, 2011, 23:18:12
This is what we call "man jewelry"
  Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: ROCKO on Jul 20, 2011, 09:13:11
Mr Swan ,your photos,comments,attention to detail (attempts at humour) have truly inspired a first time builder,i've now stripped my modest cb100 cafe project which was nearly half arseddly finished(that's a technical term)and am starting again-semi properly this time-----thankyou-------can't wait for more of yours
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: Maritime on Jul 20, 2011, 09:19:12
Thanks guys! I brought it home and CANNOT STOP STARING AT IT...

You know, I could sit that on my coffee table and call it art.  I would look at it all day and smile. But then the bike would never get finished!  I think you need to frame a picture of it and hang it in the grage so you can see it after you hide it away in the belly of the beast so to speak.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: VonYinzer on Jul 20, 2011, 09:20:39
Dear god that is stunning. Cant wait to see this bike back together.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: Greg-NWO on Jul 20, 2011, 13:33:07
Absolutely beautiful!
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: swan on Jul 20, 2011, 16:56:16
Thanks all! I am going to photograph it well and hopefully never need to look at it again. Pearson told me a customer wanted acrylic crankcases so they could see their crank.

To me it is beyond fine craftsmanship, but true art. Highly functional, utilitarian, industrial and kinetic sculpture...I am going to abuse as hard as I can, knowing it will take anything I throw at it.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: 50gary on Jul 20, 2011, 20:15:46
Whoa now, I'll bet those BSA cases can't take as much stress as the crank Pearson crank and the Carrillo rod (& probably a forged piston) can dish out?  The cases may flex enough to cause damage not born of the crank, rod or piston?  A man has got to know his limitations.  heh heh.
  Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: jonnyTHUNDERmaker on Jul 22, 2011, 12:01:48
That truly is a piece of fine art. What amazing craftsmanship! Congrats, and thanks for the updates
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: martyman on Jul 22, 2011, 21:27:01
I just went through this whole thread and it stopped...can't wait for the next post, fantastic build.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: dean owens on Jul 22, 2011, 21:48:55
holy mackerel!  absolutely AMAZING!!!!!!!  thank you so much for sharing.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: swan on Jul 25, 2011, 11:24:30
Thank you everyone for the kind words and encouragement. I still cannot believe this is my bike, I own it and this abstract pile of parts will someday soon become a living breathing machine. Slow and steady will win this race.
Off to the machine shop this morning to hone my cylinder to match my new forged piston.



(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7889-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7890-Version2.jpg)
+.040 over
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: edhaeuser on Jul 26, 2011, 11:56:59
One of these days I will have to ride up and see it in person!....outstanding work!!!!!

Ed
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: swan on Aug 01, 2011, 11:49:47
Thanks Ed!


Another minor step forward. Cylinder is honed to match piston (great work Engine Store, Winona!) and I will file the rings to factory specifications tonight.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7915-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: Greg-NWO on Aug 01, 2011, 19:55:46
I love your photography work!  Every picture is eye candy :)
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: 11400MilesAway on Aug 23, 2011, 11:12:24
Swan..i signed up cuz of your (this) amazing thread while searching different forums for information about B31's..

You are doing a fantastic job and I can't wait for more updates!

I'm gonna start my B31 thread and hope you and others will be give me advice as I have limited knowledge (first time) and resources where I am..

Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: swan on Aug 23, 2011, 16:03:08
11400, thanks, welcome aboard and it looks like you have a diamond in the rough.


As I have said before, despite the popularity of Gold Stars, there is little, real usable build information on the web. By documenting my restoration (and mistakes) it will help the next person restoring a BSA like yourself.


My girlfriend is gone, I spent several hours cleaning and organizing my small workspace last night and will finally finish prepping my hardware for cad plating this week. Stay tuned.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: Greg-NWO on Sep 30, 2011, 22:17:22
I'm dying here....  we need an update!
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: dean owens on Oct 01, 2011, 16:35:16
tell me about it.  this is one I look for every time i come here.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: BigRedButton on Oct 04, 2011, 22:00:41
and I keep hoping....
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: joea on Oct 18, 2011, 02:07:20
(http://i24.photobucket.com/albums/c28/v-cycle/Picture343-1.jpg)
ok to hijack and give 11400 miles something to get him going on his project.....here is my 53 b33 500 in a goldstar frame.(the way i bought it). i restored it about a dozen or so years ago-really nice machine to ride...joe
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: kieferocks on Oct 18, 2011, 14:02:23
EPIC build. Keeping an eye on this for sure.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: 03rangerxlt on Oct 18, 2011, 16:51:36
Yeah, I keep checking in to see updates... :(
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: bikeboy on Oct 19, 2011, 02:56:45
My girlfriend is gone, I spent several hours cleaning and organizing my small workspace last night and will finally finish prepping my hardware for cad plating this week. Stay tuned.

When you say 'gone', I hope you just mean she's nicked out to her mum's for a visit, and it's not permanent?? That would be a pity.

Now get on with it slacker ;)


cheers
ian
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: swan on Oct 19, 2011, 16:48:13
All,
rumors of much death are exaggerated... I am alive and well and so is my girlfriend.  Sorry for dropping off the radar and leaving you hanging.


A perfect storm of professional, civic and social responsibilities, lots of travel, restoring my newly found shop equipment and helping friends on their projects have kept my from my Goldie. Any free time I have is spent wrenching and riding the Triton, but now that it is getting cold and the sun is going down earlier, I'll give my full attention to my project. I am burning a vacation day next week to finally finish prepping my hardware for cad plating and I plan to finish polishing my tank and tins too.


My life will slow down in November and am eagerly looking forward to working on the Goldie in my tiny, but warm workspace.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: bumpthump on Nov 12, 2011, 14:44:18
I am late to the thread, . A sleepless night last night, and I guess that has been a blessing. It allowed to read the entire thread over a couple of hours, so the ups and downs stayed with me.

Living in Scotland, I kind of caught the tail end of the Brit bike meteor in th early 70s, and the full blast of the Japanese hurricane that followed. In those cheap and cheery days, I owned and rode many a Brtish bike,,,,,,and sent a few to the scrapyard too. I think I managed rides on all my dream bikes (Laverda SF, RGS, Goldstar, and Vincent Black Shadow.....and yes, a marvelous hour on a Brough SS100 featuring the Matchless engine.

As to owning.........well the Goldie and RGS were always the ones I wanted and were always the ones that stayed tantalizingly out of my budget. The Vincents and Broughs were things of love, but my appetite settled itself for magazine features and day dreams.

The particular Goldie has rolled out like the first reel of what will eventually be my favourite bike thread of it. So far, it's a dream bike found in the way we dream of finding one, and attacked with the precision and control that we'd love to think we'd apply to the work ourselves.......but most don't.

So this whizz bang thread has dropped off the radar a bit.............family responsibilities stand aside for no bike, and it's a couple of months committing to that side of life that can buy you six months over where you want to be.

There's got to be a lot of pressure to push it on to completion, but trust me, the journey, the imagining is always better than the ending. In many ways, owning an immaculate DBD 34 can be less life enhancing than wanting to own a DBD 34.

I remember a miraculous build on a 67 Bonnie I took part in, Getting the bike, looking at the sum of  the parts and working out what to do..........those were the moments I will treasure far more than riding the finished bike,,,,,,,,,weird, but true. The rescue of the bike, the engineering, the hassle,,,,,,,,all great. With few exceptions, the end result turns into a motorcycle,,,,,,,,just a motorcycle.

I think this one will be different. each phase is detailed and consigned to memory. I wish you well when you come back to show us all more. In your heart, it might well feel like it's a burden that you carry, but see it through.j
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: jbrtwork on Nov 12, 2011, 15:20:23
Ah... never too late. You appear to be a rather good writer, bumpthump. Welcome to DTT and I look forward to seeing you share some of the stories of those fabled bikes.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: bumpthump on Nov 13, 2011, 10:50:11
It's been a cracking thread to read almost as a journal. What has impressed me the most is the standard of the work carried out on the bike. Some of it has been a real memory jogger, and some of it has been "hell, I wish I'd had the patience, money and connections to do mine that well". Up to this stage in the game, this looks very much like one of those bikes that is going to be built to a standard way higher than the original factory finish. Personally, I love it, because (like the Pearson crank), it elevates the bike to something akin to art.

The early pace of the work was breathtaking. I so well remember the way that the early enthusiasm gene works...........the bike gets your every waking moment, and you give it your heart and soul. For most of us mortals though, familiarity breeds contempt (a strong term, but you know what I mean), in that the build (regardless of the bike) can slowly fade from being your demon lover to the thing that is an endless drain on your time and pocket. The amazing thing is, it can strike at any stage of a project. I've seen two bikes for sale where the owner has tired of the project, and all that needed to be done is maybe three or four days of work and $200 or $300 worth of cash..........yet the owners have given up.

I don't think that's what is happening here. The front end of the project seems to have been tackled with such determination, that this one certainly isn't going to wither on the vine. I'm confident that in a day or a week or a month,  we are going to see this project spring back into internet life, and a bike which I think has the potential to be one of the world's best Goldies is going to knock our collective socks off.

The bike's owner is kind of living out our collective dream, and I think everyone who has followed the thread is willing this thing to the conclusion that we all want to see.
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: joea on Nov 13, 2011, 11:36:44
alright swan you better get the ball rolling we natives are getting restless-......
          i probably know the answer since we are practically neighbors-nice fall weather in mn is nothing to take for granted so he is probably enjoying the warm days before he has to seal the doors for a long mn winter...joe
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: jbrtwork on Nov 13, 2011, 12:25:44
alright swan you better get the ball rolling we natives are getting restless-......

Don't make us come over there and complete this project ourselves!  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: 50gary on Nov 13, 2011, 13:38:34
I'll give you $500.00 for the project right now.  I'm on my way over with the van, see you in a bit.  I've always thought a Gold Star would make a cool a$$ choppa,.. fair warning.
  Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: jbrtwork on Nov 13, 2011, 15:04:55
50gary, that is sooooooooo wrong!
Title: Re: 1962 BSA DBD34 Gold Star restoration (New crankshaft arrived!!!!)
Post by: swan on Nov 14, 2011, 19:36:05
Bumpthump, thank you for the kind words. Everyone else sorry for the delays but Joe is right, I am eeking out every bit of riding before the snow flies (any day now). To the rest of you, (50gary) no one is going to touch this bike... I stare at it everyday, it is my screen saver on my phone and computers and I have not lost enthusiasm. Work, travel and life leave little to no free time for me, but again things will slow a bit starting this week.

Finding the time to prep the hardware for plating is kicking my ass. I made improvements to my POS bench top blasting cabinet with some additional lighting, new seals, silicone, filters and a $15 craigslist shopvac. I am slowly tackling the hardware in sections (tonight one of the gearboxes). Sending all my hardware out to be cad plated is making me nervous and I may zinc plate it all myself. If the box was lost, stolen misplaced etc it will sink the project. I have copy-cad chemicals from Caswell and a really cool vintage DC power source from a neighbor (former BSA and Triumph shop owner and a Goldie fanatic), have plated hardware for other motorcycles and my vintage Schwinn bicycle and may end up doing so for the Gold Star. Additionally, if I miss the odd piece or need to re-plate in the future I can do so myself. Hmmmm, should I go zinc or cadmium....

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8654-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8655-Version2.jpg)
Freshly blasted.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: wfo guy on Nov 14, 2011, 20:59:15
In regard to what you just said: I agree. If you know the plater and can hand deliver the parts, it's a great scene. When you're dealing with almost unobtanium parts, I don't trust many actions to have the desired result.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: joea on Nov 14, 2011, 22:45:42
hi swan..well we had another nice day outside in mn! ha ha
anyhow i would suggest you go with brite cad plating. i can give you a place (and persons name) in pa who does nice work and has not lost any of my parts and lets face it anything you need for a bsa g/s is available, it's far from unobtainiam..
         i lay it all out and then take photo's(3 or 4)call them, tell them to expect it, box it and include a note/contact information and ship....quality zinc is ok but that era bike had cad not zinc. cadwell kits do not hold up good enough. real cad lasts...
       the other thing is cleaning i hate to do it also but one of the best ways is to wire wheel most of it (6 or 8 inch wheel) . when i worked at nwa i would glass bead it(as they had great equipment)  and then go right to the plating shop, that was nice .but now  i use a combination of glass,aluminum oxide blaster,a parts tumbler and a wire wheel since my shop equipment is not great .if you blast them leave the dust on it as it keeps it from rusting(a little) and keep everything dry or spray them with a rust preventative..
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: bikeboy on Nov 14, 2011, 23:43:03
when i worked at nwa i would glass bead it(as they had great equipment)  and then go right to the plating shop, that was nice

I get the best result (zinc plating) by glass beading, then running over the parts with a wire wheel. It puts a nice smooth finish on them, and gives the zinc a nice shiny-smooth texture.

Zinc plating at home is a no-brainer, but I'd personally be reluctant to try any of the other more complicated finishes.

keep plugging away at it :)

cheers
ian

cheers
ian
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: 50gary on Nov 15, 2011, 00:27:59
HAHAHA, to quote my favorite English comedy duo Armstrong and Miller, "it's a joke can't you guys even take a joke"
  As if any sane person would ever molest this classic?
  Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: joea on Nov 15, 2011, 01:49:51
bike boy,same with cad and actually any plating, the better the prep work the better the final plating looks..
    cad is the prefered plating for vintage british machines as that is the way they were delivered unlike the japanese machines which had zinc plated hardware. cad is the superior plating also and why it is used for aviation and aerospace parts and probably the only reason it is still around in the usa....epa is trying to outlaw it due to it's a heavy metal and bad for humans and enviroment...
what ever way you go just make sure the plater has a good reputation, as that is the biggest concern- does he do a good job,perform each step correctly and give you a quality part.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: bikeboy on Nov 15, 2011, 02:03:18
cad is the superior plating also and why it is used for aviation and aerospace parts and probably the only reason it is still around in the usa....epa is trying to outlaw it due to it's a heavy metal and bad for humans and enviroment...

Yeah, I agree Joe, cad is much nicer. Didn't know it was OEM on brit bikes, but makes sense.  I was just musing on the relative merits of home-plating, and while I have a zinc kit that turns out great stuff, the cad and other metal platings are more involved and temp/chemical critical, and in the end probably not worth the hassle. It's fantastically conventient to be able to pull a few bolts out, clean them up and plate them, and have 'em refitted within the hour :)

Good quality platers are also a dying breed over here, but if you manage to find one, then that's a relationship worth cultivating.

cheers
ian
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: bumpthump on Nov 15, 2011, 10:12:50
My tuppence worth. Be patient, and go cadmium. I say this not (only) because it's superior, but because you have started this with such an eye wateringly high standard of detail and finish. Now, i can't really explain this, because it's something you kind of have to see side by side. A British bike of this period with cadmium fittings looks very different to the same bike sporting zinc plated fittings. It's hard to explain, but if you can imagine an old brass screw head that's tens of years old, and has been worn and polished through years and years of contact, it becomes a thing of beauty. Compare it then to a brass screw bought from Home Depot yesterday. Both are essentially the same thing, both have the same metal at their core, yet one is utilitarian, while the other has a tactile "rightness" about it.
When you see the same bikes with zinc and cadmium, both are shiney and new, but deep down inside, you know that one has a look of expediency to it, whereas the other has a look of authenticity to it.

This bikes deserves (ok, demands) that you go the cadmium route. You're not in a race with anyone but yourself. Take the time to stay true to the standards that you have set. When I said your bike was on the way to being one of the best Goldies in the world, I meant it. It's you who has plotted the course. Don't let the nerves get the better of you. You're seeing what looks like a little zinc shortcut here, but you need set it aside, accept that the prep work has driven you nuts, and stay on the track that will reward you for your commitment.......and it genuinely isn't going to be found in zinc! You have said that this bike will never be for sale........so there's neither the need nor the rush to cut corners to maximize profit. As you've found, the devil resides in the detail, and doing the prep work has been that little dance with the devil. You just need to remember that in the finished bike, God resides in the detail too, and something as simple as cadmium plating your fittings is the kind of detail that will make all the difference in the world.....you'll know it when you've assembled it, believe me.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: joea on Nov 15, 2011, 11:41:23
 i think they have outlawed cad in some parts of the world possibly for the general public and aviation is still exempt? .....the reason i say this is i service a lot of vintage brit bikes so i need to buy parts / hardware often and i hardly see any cad plated parts from england anymore....
.........joe@vcycle
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: swan on Nov 15, 2011, 11:52:00
"It's hard to explain, but if you can imagine an old brass screw head that's tens of years old, and has been worn and polished through years and years of contact, it becomes a thing of beauty. Compare it then to a brass screw bought from Home Depot yesterday. Both are essentially the same thing, both have the same metal at their core, yet one is utilitarian, while the other has a tactile "rightness" about it.
When you see the same bikes with zinc and cadmium, both are shiney and new, but deep down inside, you know that one has a look of expediency to it, whereas the other has a look of authenticity to it."

I get it. I use the term "burnish" to describe it. There is something about old metal that has been brought to a polish through wear and long use. Old brass handles, old copper and yes, cadmium plated hardware. I am going with cadmium plating and will send everything to Aero Plating in Colorado; in a moment of weakness I contemplated zinc as a shortcut. Cad just looks right and will last longer than zinc. I just need to carve out the time to blast, wire wheel, photograph and take notes for the rest of my hardware. As with my Triton build, patience is key and I learned to walk away when necessary.

Thanks all.

PS "One of the best Goldies in the world" ? I do not think so, but it will make for an incredible daily rider.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: bumpthump on Nov 16, 2011, 05:46:53
Your standard of work up to now has been exemplary......far better than 99% of the work out there. I've seen just about everything that the museum and concours d'elegance scenes in the uk has to offer, and believe me, your bike is on track to be right up there on the upper branches of that tree.

Daily rider? If that's how she ends up, then no complaints from me! Just don't be surprised if having stayed the course, you find yourself with a bike that has you smitten to the point where when it all comes together, you just want to freeze it in time, and keep her for very special occasions.

Glad you're going for cadmium..............it's worth the hassle.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: swan on Nov 16, 2011, 10:57:19
Thanks again Bumpthump for the kind words and encouragement. As I have said from the beginning, I am going to ride this bike as much as I can. There are plenty examples of museum, concours, trailer and living room queen BSA Gold Stars that are never ridden. For me the joy of discovery, the journey of restoration and the self-satisfaction and pride of owning and riding a true classic is what this is all about.

I have (had) a line on a Smiths chronometric speedometer that matches mine to the number. A person on Craigslist was wanting to trade it for another correct one for his restoration. He is still making up is mind what to do with it, but I am first in line should he decide to sell. I picked up a restored replacement tachometer a while ago, but have not found the correct speedo (that I could afford). Joel Levine gave me a rough estimate of $400 to restore mine based on some photographs. This morning I decided to open up my speedo and assess its condition.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/brokenclocks.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5473-Version2.jpg) Before
I used a few drops of PB Blast on the bezel ring and a rubber strap wrench and to my amazement it came off without much effort.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8657-Version2.jpg)
Everything on this bike was dirty, but had little to no rust due its long storage in the dry stable climate of New Mexico. It is dusty, dirty and filled with dead bugs but not as bad as I feared. I'll carefully clean it up and go from there.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8659-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8660-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8663-Version2.jpg)
Smiths chronometrics are absolutely gorgeous, made like Swiss watches and unlike the later magnetic gauges, have a jerky, mechanical sweep of their needles that looks so cool when they move.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: JustinLonghorn on Nov 16, 2011, 11:11:58
Your photography of this build is absolutely gorgeous, sir.

I think that Smith can be saved. They are indeed  a beautiful piece of machinery.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: joea on Nov 16, 2011, 11:41:09
swan reconsider ....i used aero plating in co three or four times and was not pleased with the quality.....parts were not bright and they were stained on more than one occasion plus he lost a few items once...
     go to jet plate in pa.
joe
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: swan on Nov 16, 2011, 11:47:27
Joe, thanks, I'll check out Jet Plate.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: bumpthump on Nov 16, 2011, 15:12:06
Chronometrics are another deep joy! Yours looks in remarkable condition when all things are considered. Three or four years in a damp British garage would certainly cause more deterioration than yours has suffered. Again, I think you have a bit of thinking to do before letting that one go anywhere!

I'm really glad you aren't going to mummify the bike. You're right............probably more than half of the Goldies still out there never ever turn a wheel. I know of one (a 350) that has sat in the (very large) kitchen of a friend's house since the mid 80s. He'd never part with it (he bought it for a pittance), and sees it as a bit of a conversation piece............if the bike could talk, it would be screaming "help me".

I'm going back to look at your chronometric again..............and chuffed to bits that people can still get pleasure from the mechanical imperfection of the way the needle moves across the face of the instrument. It's another bit of detail that enriches the sense of speed and travel. I can remember the oohs and aaaahs when people first experienced the super smooth movement of Japanese speedos. Chronometrics became yesterdays news very quickly. How things have changed...........

Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: swan on Nov 20, 2011, 17:42:06
"Mummify" great term for bikes that are never ridden! Ahhh, the mysteries and joys of chronometrics. I dissembled my speedometer and despite outward appearances it was not too bad.  What at first seemed like an ancient device akin to the Antikythera device, it is really a simple and beautiful work of precision machinery. I spent several hours carefully and meticulously dissembling and cleaning mine. I have the correct tools, patience and the ability to stop when I do not understand something and did not try to force anything loose. A clean bench, trays and good lighting and a large magnifier are essential. So far so good, except I broke a tiny screw which holds the leaf springs. Arrrrrgggg. Smiths are metric and I could not find drill bits, taps or fine screw smaller than 1.5 mm so I may have to use a #90 size screw as a replacement.  Also I cannot remove the stabilizer wheel to free all beneath it. More PB Blast and patience so I walked away for now.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/Smithsexploded2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8692-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/Smithexploded.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8701-Version2.jpg)
I am encouraged and believe my speedo can be saved. The number wheels were frozen and I managed to free them with tiny drops of solvent (away from the numbers to prevent them from smearing). Despite the fact my glass was cracked, there was no real rust, just a hardened layer of extremely fine dust over everything.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8708.jpg)

I also managed 4 hours of bead blasting and wheel grinding on my hardware. Tonight I should be get another 4 hours in. Making progress and am still researching places to cad plate everything.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: wfo guy on Nov 21, 2011, 19:38:31
I think you might try evaporust for the speedo. I used on my 160 and was pleased with the results. I would try it before anything that could damage it.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: jonnyTHUNDERmaker on Nov 21, 2011, 20:20:03
I second evaporust. I used it a few times and it always did a great job.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: joea on Nov 21, 2011, 20:27:06
have you tried dynamite!
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: 50gary on Nov 22, 2011, 00:12:10
I used to work in the 'back room' of a family Jewelry store, a good clock shop would feel pretty close to  home on that speedo it has the look of a clock movement.  Ultrasonic cleaning may help?  Pity about the broken screw, again I'd check for a replacement at a good clock shop?
  Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: Garage Rat on Nov 22, 2011, 09:57:44
Try an optician for the screw.

I had a screw on my bobbin case on a 52 Singer industrial where the head was worn off from the thread tensioner. No jewelery shop in town had one close but the Wall Mart optician did!

Don't know what your resources are like but torque wrenches have little screws in the heads too, do you know of a Cal shop around?
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: swan on Nov 22, 2011, 11:04:05
Thanks all, but the small screw is BA standard (British Association) based on the metric system, but slightly different. I need to find a way to remove the tiny broken screw before I can replace with another. I hear good things about Evaporust and my give it a try.

Checking out for a week because girlfriend is in town and and I have some long overdue time off. Have a good Thanksgiving for those who celebrate it.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: Greg-NWO on Nov 22, 2011, 11:30:56
Looks like some model building companies stock BA nuts and bolts.   http://www.brunelhobbies.com.au/tools/bnd.htm

Not sure if that helps at all but that's what my Google-Fu came up with :)

Looks great!
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: Garage Rat on Nov 25, 2011, 10:18:35
... Are the Gold Star speedoes the same as others? I know a guy with some less famous BSA's.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: beachcomber on Nov 25, 2011, 10:40:58
Swan,

I just spoke to a guy here in the UK that manufactures "new" instruments from all new Smiths period components. A new speedo is £280 and he says there's nothing he can't rebuild.

If he can build one, I guess he also has all the parts !! Might be worth a contact if you need parts.
"Speedo Repairs" - website -  www.speedorepairs.co.uk.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: joea on Nov 25, 2011, 19:51:33
gauges are chronometrics not magnetics and there are a few different speedo's but i think only one tach for the bsa 500's.
     looking at the photo's i think you may have problems making it work correctly again since when dirty inside they do not work correctly, very sensitive.  once you remove the fair amount of corrosion you may have pitting which again may cause it not to function properly.
 try this for corrosion removale you will be blown away on how good it works..it's a toilet bowl cleaner called "the works".. put some in a plastic bowl and then your degreased parts, take out in about 15 minutes or once cleaned, then dip in water/baking soda mixed bowl to neutralize...i then spray them with something like lps 3 ...
there is a place in bloomington mn - apt, 952-881-7095 they do good work.
joe@ vcycle
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: bumpthump on Dec 02, 2011, 15:55:18
I guess we'll just have to wait and see what's encrusted and/or hardened dirt, and what's corrosion. I do agree that chronometrics are fragile, and don't care for dirt particles in and around the mechanism, but my past experience (I stress experience, and not skill), says that these things are very recoverable. Time will tell.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: swan on Dec 03, 2011, 14:24:49
I've put the speedo on hold and have FINALLY finished prepping my hardware for cadmium platting. All hardware is photographed, listed, boxed up and ready to go. Here is all the hardware to a BSA Gold Star plus hardware from an extra BSA gearbox, Norton gearbox, extra 8" BSA front wheel, BSA rear quick detach rear wheel and bits from a 1959 T110 motor for the Triton.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8879-Version2.jpg)
Wow, it was a lot of work to blast and wire wheel everyone to squeaky clean. Next time I will pay some one to do it or I will rent time professional blasting cabinet. My little compressor and crappy blasting cabinet took many, many hours. It will be worth it in the end.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8889-Version2.jpg)
Everything was noted and photographed in small groups (gearbox, motor studs etc) like this so I can put this giant jigsaw puzzle back together when everything is plated.  Commercial platers dump EVERYTHING into one large barrel to plate and send it back all mixed together, so good notes and photographs are a necessity.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8798-Version2.jpg)

Should be a quick turn around from the plater so stay tuned for the results, I cannot wait to start going clockwise, have a rolling chassis and build the motor and gearboxes!!!
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: Greg-NWO on Dec 03, 2011, 14:56:47
Stunning, I can't wait to see it all plated!!
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: joea on Dec 03, 2011, 21:15:27
hi swan....i don't think most platers tumble it all even though they have several size baskets (screened baskets attached to a motor that turns them in the tank).
  long, large,heavy parts are hung individually across a large basket (in case they fall off) so they get good plating coverage....the several shops i have used do both, small nuts, bolts, washers,screws, etc in the baskets, long,large, heavy parts hung individually...
 try a wire wheel on larger parts it does a good job and the finer the blast media(use glass for cad,zinc,nickel prep), and the better the cleaning finish the better the plating finish ,(like chrome,nickle etc.)..
joe @ vcycle
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: joea on Dec 03, 2011, 21:32:08
the problem with gauges is if a part is bad it is hard to source a part! and lets face it very few people have the capability to remake those small gears and i think if you have rust on just one tooth you may be screwed ....another option is to buy a used core and try to repair it as most guys will not tear into them they will just replace them. i have had good luck with both chrono's and magnetics doing some minor repairs so it may be an option, keep your eyes open on ebay.  good thing is you have nothing to loose so you may as well give it a go if you have time.
     and lets face it springs aways off..looks like s/e min may get 6-8 inches tonight....
have a good one,joe
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: two wheels of hell on Dec 03, 2011, 23:31:33
The work done on the hardware is outstanding and I truly understand how time consuming it really is. I really hate cleaning threads and have purchased new bolts in the past. Projects are made amazing by dedication on the little things. I guess this is why I am not a restorer. Seems like everyone is concerned about the clocks. What's too worry? Just look at that hardware!!! That's the hard stuff because it is a motivation killer. Nothing in the world that more money cannot fix and when it comes to Smiths Gauges they will shake you upside down till all the money comes out. Plenty of folks work on these chronometric gauges for this reason and I agree they have parts. I am getting ready to try and rebuilt a set of grey face Smith and recently purchased a very good book by Graham Blighe. Excellent book if anyone wants to tackle the later Smiths Magnetic gauges.
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: bumpthump on Dec 04, 2011, 16:09:02
Amazing dedication on the hardware front. That must have been a serious test of character to get through that much prep work. The first few bits can be a real blast (sic) to do, but the rest must have been an absolute chore.

Back (briefly) to the chronos. Someone mentioned much earlier in the thread that they were built like Swiss watches. That is true, but only up to a point (obviously). it's probably not directly comparable, but I think the following principle holds true.....my mate has an early Rolex Submariner, and he put it into Rolex for a service. A couple of internal parts were swapped out for new, but due to minor corrosion, they also changed the face of the watch. By all accounts, it wiped a fair chunk of it's commercial value as well as changing my friend's personal connection with the watch. In the case of this Goldie, if anything is kept, I'd side with two wheels of hell, and try to ensure that the original instrument cases and faces stay with the bike. Ultimately, changing the internals of the instruments is no different from changing the crank for the beautiful Pearson item. Even re-finished, it would good to keep the original visible stuff with the bike and if anything has to be sacrificed, it should be the internal bits. Opinions?
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: swan on Dec 05, 2011, 19:21:45
Joea, semantics. Basket instead of tumbling. I've never visited a commercial plating operation.

Chronometrics, still walking away from the speedo for now.

I am very happy to report my hardware shipped today and I chose Quality Plating (http://qualityplating.com/) to cadmium plate everything after several positive reviews from Britbike forum members. I spoke with Glenn, he was nice and it will take a couple of weeks but he is going to try and push the order so I have everything back before X-max, which would be great because I have several days off over the holidays, do not have to travel anywhere and plan to chill at home wrenching bikes.

In anticipation of a rolling chassis soon, I mounted my freshly powder coated center stand only to realize the right foot was bent.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8749-Version2.jpg)

So some quick work with an acetylene torch and wrench restored it to its original shape. Dropped it off at my powder coater today to have it blasted and recoated along with my engine stand.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG1060.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8917-Version2.jpg)

I am going to start polishing my engine covers this week so they are ready to go when I assemble my motor with freshly plated hardware. Onwards and upwards...
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: JustinLonghorn on Dec 05, 2011, 19:44:12
I know this has been said many times over, but the attention to detail on your build is quite exceptional. I really appreciate your detailed documentation, sir. I am sure this build will help folks with their respective Goldies time and time again.

Please keep it up.
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: jonnyTHUNDERmaker on Dec 05, 2011, 20:17:15
Awesome news! I can't begin to imagine how long it took to do all that hardware...Great job
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: joea on Dec 05, 2011, 21:00:18
hi swan
 just thought you may want to know how it is actually done ..
 the worst part is now over,  i never look forward to prepping parts for plating.
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: swan on Dec 05, 2011, 21:17:27
Thanks Joe and everyone else.

I do not want to say "never again", but I will prepare hardware with a better cabinet and compressor next time. I feel so happy and lighter now that the hardware is FINALLY shipped out. Looking forward to getting it back and to start going clockwise.
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: bumpthump on Dec 05, 2011, 22:00:39
I have visions of some 300 pound guy astride the bike and kicking it over and over and over again, and eventually the right leg of the centre stand begins to give under the sheer load pounding away above it I plead guilty to a similar crime on a Velo Viper a decade or three ago, but to my credit, I was much closer to 200 pounds.

The way you have simply shrugged it off, fixed it and got it away for coating with the minimum of fuss all bodes well for what comes next. You've found the site, you've done the archaelogical cataloging, and your now into preservation. When you get into the assembly phase, keep zillions of pictures coming. I am sure I am not alone in picking up an unexpected emotional attachment to this journal and to the bike itself.

It has also given my two current projects a new lease of live. I have a tidy Super Rocket that was destined to become the ubiquitous RGS replica. This thread has changed my mind, and now its simply going to be a stonkingly good Super Rocket.........I have decided that i;ll re-inforce what it has always been,  and I shall shy away from making it  a replica of anything at all. A good lesson for me,
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: swan on Dec 05, 2011, 22:16:55
Bumpthump, I am 150 lbs wet and sent off the center stand to powder coat without actually looking at it in the context of the whole, and failed notice the obvious fact it was bent. Two steps forward, one back...

There will be zillion (or less) photos coming soon. Engine build, gearboxes, wheels and the pivotal moment she becomes a rolling chassis. It is humbling to be an inspiration to you and your bikes. I love Super Rockets and A10's in general and sold a Bitsa A10 I was going to make into a replica Rocket Gold Star when I found my Goldie. In the future I would love to find an A10 and restore it to factory stock. Start a build thread on this forum for you project(s).
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: bumpthump on Dec 08, 2011, 15:05:48
I certainly will! It just goes to show how we all influence (and can be influenced by) others. I guess I've always held Gold Stars, Rocket Gold Stars and Velo Venoms as the pinnacle of my bike world (setting aside the fiscal madness that is now Vincents and Broughs). The Rocket Gold Star has long been the replica of choice simply because it's so achievable...............a chrome tank here, a frame tweak there. In a sense, it has done down the Super Rocket, and in another sense, it has elevated it, because comparitavely few now exist which haven't been sacrificed at the altar of RGS reps. I'm kind of glad that I woke up to the "idea" that keeping a Super Rocket as a Super Rocket is a worthwhile thing to do!

Slightly off topic, but a friend in Glasgow is toying (well, he's gone a little further than that), with the concept of using a Harley engine and gearbox to create his own homage to a Brough Superior...........bespoke frame and all. He's got it going on under the working title of a "Rough Facsimile". His madness makes me smile.
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: bumpthump on Dec 17, 2011, 05:05:13
Any word on the plating progress?
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: swan on Dec 17, 2011, 13:34:18
Hardware arrived safely at the plater and I will call on Monday for an update. Hopefully I have a pile of freshly plated hardware just in time for X-mas.  I ordered many missing bits of hardware, fiber washers etc as well as new tappets from Phil Pearson. Waiting (im)patiently to start going clockwise, build the motor, gearboxes and have a rolling chassis soon! The center and engine stands are back from my powder coater and I had them redo my front engine cover for there was a flaw in the coating. I also polished and buffed the timing cover to a mirror finish and started the primary, but am out of town this week, so I will get back to them on Wednesday.

Bumpthump, have you spent time on the Super Rocket pages? http://bsa.hailwood.com/
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: bumpthump on Dec 19, 2011, 08:34:26
Thanks for the link to the Super Rocket stuff. I've come across some of it previously, but I had a good look over it last night. I hadn't realized that the nacelle was virtually compulsory in the uk, and that a tach (if optioned), was kind of just bolted on to the side. Mine has (a very ropey) nacelle but no tach. Pretty original, but needing much work. Thanks for the steer to the pages.
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: swan on Dec 21, 2011, 14:29:26
Still waiting to hear from Quality Plating. Another small step forward, my new light-weight tappets just arrived from Phil Pearson in the UK. Of course they are beautiful, machined by the man himself.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8958-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: jbrtwork on Dec 21, 2011, 19:59:07
Beautiful... perhaps even sexy. This thread is becoming the Victoria's Secret catalog of Brit bikes.

Merry Christmas and happy holidays, Swan, et al.
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: swan on Dec 22, 2011, 12:39:29
Thanks jbrtwork. I just spoke to Quality Plating and my hardware will ship tomorrow so I will have it late next week. A photo of my newly plated hardware will be the centerfold!
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: IndieSol on Dec 24, 2011, 02:18:45
Top notch as always.  Happy holidays.
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware going to the plater!)
Post by: bumpthump on Dec 24, 2011, 08:25:03
Mr Pearson never seems to disappoint does he? That's just a function of a man who knows the engineering required, and doesn't then indulge in commercial scale cost cutting in order to lower manufacturing costs. He charges what it costs to make it right, and in the long run, that's what matters. She's still shaping up to be one hell of a Goldie!
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: swan on Dec 25, 2011, 00:46:16
Bumpthump, you are so right.

Happy Holidays everyone!

I am very happy to have 3 days off, not having to travel or do anything but wrench my bike, listen to music, drink and eat. I have a fridge full of fantastic Minnesota beer (Summit Pale and Black IPA, Surly Furious and Bitter, local home brews and growlers from Fitgers Brewhouse, Duluth and Town Hall, Minneapolis.) I do not recommend getting trashed and wrenching but I enjoyed a long leisurely pint while the music was turned up and was working on my Goldie. The sun was out and hell, even the Minnesota Vikings won today!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9007.jpg)

With the arrival of my new tappets and in anticipation of my freshly plated hardware arriving next week, I started rebuilding the motor. Here we go with lots of images...

All the lower motor parts were meticulously cleaned and inspected. My worked bench was cleaned and all the necessary parts, tools and lubricates were at hand. I heated my crankcases to 200 degrees F. in my oven and tossed the bearings, bearing races and camshaft spindles in my freezer.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8992.jpg)

I pulled the timing side case out of the oven, installed the tappet guides with some anti-sieze lubricant on the threads and touch of black oil resistant silicone on their tops to prevent oil leaks. New tappets (cam followers) were slipped in with plenty of engine assembly lube
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9025-1.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9030-1.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9024.jpg)
(here's to you John Healey).

Next the camshaft spindles were taken put of the freezer, lightly drifted in with a 5/8 extension socket so that the flat portion of the spindle is parallel to the bases of the tappets. The exhaust on the exhaust side and the intake on the intake side and they went in easily with a few taps.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_8991.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9026-1.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9027.jpg)

While the case was still hot, I pulled the timing side bearing race out of the freezer, lightly greased the exterior and tapped it in to place. It too went in easily. The trick is to warm the entire case, not just the area around the bearings, so they expend enough to accept the races and bearings.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9028-1.jpg)

The drive (primary) crank case was taken out of the oven, the factory shim was installed and held with a smear of grease then small outer ball bearing was drifted in with a smaller diameter collar tie and a gentle taps from a dead blow hammer. No problem and the retaining ring was installed.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9042.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9038-1.jpg)

The large roller bearing race was lightly greased, drifted in with the shouldered side toward the outside of the motor and set flush up against the case. The bearing retaining plate was placed over the drive side race and the screws were given a dab of blue Loctite and wrenched in with their locking washer orientated such that the arched sides were next to the bearing retainer, The washers were bent up, locking the bolts and bearing retainer in place. As far as I know, BSA only did this on Gold Star motors.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9048-1.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9055.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9058-1.jpg)

On to the crankshaft, that beautiful,beautiful crankshaft.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9011.jpg)
First the oil thrower/ spacer was fitted on the drive side of the crankshaft followed by an oven warmed bearing and distance collar spacer.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9012-1.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9061-1.jpg)

The timing side bearings were also warmed and drifted on using a 3/4" pipe and taps from a hammer until it was flush with the crankshaft. The races,bearings and other moving parts were all well lubricated.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9034.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9035-1.jpg)

Now it was time to fit the two crankcase haves together over the crankshift. This is a dry build because I am waiting for the engine bolts and magneto studs to return from plating and I wanted to check the endfloat of the crankshaft and ensure the connecting rod is perfectly centered in the cylinder opening. So far there is no detectable endfloat and rod is centered, but I need to torque down the engine bolts to factory specs and then accurately measure the tolerences. If anything is off, I will need to take the motor apart, remove the bearings and add necessary shims.Once everything is good, I will seal each half of the crankcase with Yamaha Three Bond and hopefuly will not need to crack my lower motor for many, many years.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9065.jpg)

 I added the camshafts and idler pinion and turned the crankfshaft-smooooth, so smooth!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9068.jpg)

I started on the cylinder head, cleaned the valves, springs etc. I am going to do a bit more research,  shopping and may decide to go with new valves, guides, springs and possibly new valve seats for unleaded gas. More money, but it will be worth it. I also need to clean and inspect the oil pump tomorrow.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9072.jpg)

Stay tuned and happy holidays everyone! Cheers!
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: Garage Rat on Dec 25, 2011, 01:02:58
This much care, love, detail and time was never put in to it when it was first being made. Very nice.
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: Kanticoy on Dec 25, 2011, 01:04:29
All I can say is....

(http://www.smileyhut.com/happy/clap3.gif) (http://www.smileyhut.com)
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: Greg-NWO on Dec 25, 2011, 01:31:16
What a nice Christmas present :)   Looking great!!
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: IndieSol on Dec 25, 2011, 13:14:21
So happy to see this update this morning.
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: swan on Dec 25, 2011, 17:09:03
Thanks all for the kind words, I hope Santa was good to you all. Looks like IndieSol got his present early this year with a beautiful BMW.

Did not get very much done today due to social obligations and playing outside in the sun.

Oil pump was very simple to clean and no drama whatsoever. The trick is to not over tighten the two bolts all the gears will run smoothly.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9086.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9089.jpg)

I cleaned the rockers, springs,washers etc and was surprised to discover one was copper plated ? Weird....
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9104.jpg)

Need to do more research on my strange small intake cylinder head and continue sanding the primary and gearbox covers. Onwards...
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: bumpthump on Dec 27, 2011, 03:22:50
Brilliant photos. Wish I could shed some light on the co,pper plating but I've never seen it before.............least, not so as I remember. I know some manufacturers did it to differentiate components of specific duty, but I don't get it with the rocker arms. I'm assuming of course, they are the same metal, and you don't have some weird PB hybrid one off!

This is going to be one amazing bike!
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: swan on Dec 28, 2011, 20:49:08
Thanks BT.
I finished sanding my gearbox and timing covers and have started on my primary cover.

Here is what I did:
Dremeled out the worst and deepest scrapes, gouges and casting flaws.
220 grit wet sandpaper on the Dremeled areas
320 overall
400
600
800
1000
1500
black, red and white compounds on sisal and loose wheels respectively on my buffer
A touch of Mother's Mag and Aluminum polish

I carefully inspected and washed the covers between grits to ensure all the sanding marks from the previous grit were gone. A strong light and running water made this easier.
The gear box cover took 4 hours...
It is not perfect, I left the original casting pits on the bottom and edges, but is shiny and looks better than it did before. It had be used off-road and there were some heavy rocks scars.

(http://i170.photobucket.com/albums/u272/66triton/IMG_8935-Version2.jpg)
Before
(http://i170.photobucket.com/albums/u272/66triton/IMG_9149-Version2.jpg)
After

On to the primary cover....
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: Ringo on Dec 28, 2011, 21:11:10
A fellow Vikings fan! You must love disappointment and resignation as much as I do...

Bike's looking great, Swan; your thoroughness is netting a lot of nice eye candy for us.  The before pic of that cover looks daunting, nice work!
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: Greg-NWO on Dec 28, 2011, 22:22:02
Looks great!  I think a few marks here and there just add character :)  I admire your patience....  I have a terrible time with sanding and polishing.  Good thing I don't do bodywork for a living  haha  I think I would go crazy.
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: paddlesat16 on Dec 29, 2011, 14:43:45
Fantastic build and write up very muchos impressed
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware is back from plater!)
Post by: swan on Dec 30, 2011, 18:34:14
Thanks Ringo, Greg-NWO and paddlestat16.
YES!!!!!!!!!!!!! My hardware just arrived from Quality Plating after being cadmium plated. Wow....
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9197.jpg)

I have two full days off to sort out this jigsaw puzzle and start wrenching clockwise!

Stay tuned, many images to come as she becomes a rolling chassis, the wheels, motor and gearboxes are built.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9200.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9199.jpg)(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9198.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor assembly!)
Post by: Ken on Dec 30, 2011, 19:13:46
swan,

The plating is beautiful! Can you give us an idea of the cost? I have a feeling after being inspired here, others may want to try similar restorations, checkbook permitting.

Also, do you have a photo of your buffing wheel setup? I see all kinds of information about machining, but very few about the art of polishing.
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware back from cad plating!)
Post by: two wheels of hell on Dec 30, 2011, 19:20:22
What a thing of beauty. This bike will be better than it was delivered from the factory. I wish I had the patience for this. You make it look so simple. The reality is few people have the ability to complete this project on this level. Happy New Year.
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware back from cad plating!)
Post by: ProSimex on Dec 30, 2011, 19:35:12
fap fap fap fap fap fap fap fap fap fap
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware back from cad plating!)
Post by: frogman on Dec 30, 2011, 21:15:22
fap fap fap fap fap fap fap fap fap fap

You'll shoot your eye out, you'll shoot your eye out!! HAHAHAHAA

Effing A that is geo-orgasmic-wonderfilled-awesome stuff! Its always the little stuff that blows the rest of the world out of the water when its touched upon and done well.
Title: Re: 1962 BSA DBD34 Gold Star restoration (rolling chassis!)
Post by: swan on Jan 02, 2012, 11:21:05
Thanks and happy New Year!
 I have been a busy boy and now have a rolling chassis. A major step forward.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9251-Version2.jpg)

More images and details soon...

Ken, cadmium plating generally is $5 per pound with a 15 pound minimum. Zinc plating (most Japanese bikes) is a bit less per pound. Quality Plating charged me $225 for 35 pounds of hardware and a baking process to reduce embrittlement. I threw in extra parts from different motors, multiple gearboxes, hubs etc so one bike will cost less. I plan to sell an extra restored BSA quick detach rear hub with fresh powder coat, cad hardware, new bearings etc which will offset most of my cad bill.

Unfortunately I have an extremely busy work week and will not have to time to work on my bike until Friday.
Title: Re: 1962 BSA DBD34 Gold Star restoration (hardware back from cad plating!)
Post by: Bert Jan on Jan 02, 2012, 11:28:08
It's so good to know and see that you're the best owner the bike could have ever wished for.
Skills and commitment make a porn bike, but add some dedication and you've got love. Top notch build mate!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: swan on Jan 03, 2012, 17:53:59
Thank you Bert Jan!

I eked a little work on my bike late last night and early this morning to mock up the engine and gearbox plates, studs, washers and nuts. What a mess. My bike originally had an odd assortment of nuts and washers that differ from stock, so it took some time to figure this out by using diagrams, thread gauges, micrometer and parts catalogues. Also adding to the confusion is the need for slightly different studs and hardware to switch to rearset footpegs. I have it sorted and will order some additional and missing hardware along with a few other little things so I can finish and install the gearbox and motor.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9261-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9263-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9267-Version2.jpg)

It is very nice to finally have a rolling chassis and everything looks sooooo much better than before!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9258-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5038.jpg) (http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9260-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: Sonreir on Jan 03, 2012, 17:57:10
Looking great, swan!  Keep it going!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: DreadRock on Jan 03, 2012, 20:11:19
My Gods man that is looking so sweet ! mind if i watch....
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: Ken on Jan 04, 2012, 01:01:39
I eked a little work on my bike late last night and early this morning to mock up the engine and gearbox plates, studs, washers and nuts.

With all that beautiful hardware, I figured there was no way you could wait until Friday!

Thanks so much for sharing craftsmanship par excellence!

BTW, how much white seamless background photo paper do you go through?!?! Offhand, I'd guess you have a pretty big roll.

It'll be a rider soon.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: 03rangerxlt on Jan 04, 2012, 22:25:53
I just want more and more of this restoration project!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: Garage Rat on Jan 04, 2012, 23:19:33
This is more than a restoration.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: bumpthump on Jan 05, 2012, 23:34:11
This is no ordinary restoration, this is an M & S  restoration.   Ok' only us Brits will understand That reference .  Anyone care to doubt my belief that this DB34 is headed to The very top of the Goldie tree?  I for one  am up for A 20 page signed booklet at the end of the job.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: jbrtwork on Jan 06, 2012, 00:16:43
This is no ordinary restoration, this is an M & S  restoration.

I'm a total Anglophile, but I don't get it. Please tell.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: swan on Jan 06, 2012, 02:06:03
This is no ordinary restoration, this is an M & S  restoration.
? M & S? Marks and Spencer??

Thanks everyone, I hope to make time this weekend to work on my bike.
Title: Re: 1962 BSA DBD34 Gold Star restoration (motor build)
Post by: swan on Jan 09, 2012, 13:28:58
"Work, the curse of the wrenching class..."   I ended up working both my days off this week but found time last night to wrench. Here is the lower motor with lots of photos:

Time to button up the bottom end. I dry fitted the crankcase ends together, measured for endfloat and there was no need to shim. Next I opened the cases again (hopefully the last time for a long, long time) and smeared a thin layer of semi-drying Yamabond sealer, bolted each half together and checked the endfloat of the crank again. All good.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9336-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9337-Version2.jpg)
Say goodbye to my little friend..
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9338-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9344-Version2.jpg)

Next, I inverted the motor and installed the oil pump, drive spindle, holder, gaskets, filter etc,
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9333-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9348-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9342-Version2.jpg)
I warmed the crank shaft drive spindle slightly and pressed it over the end of the crankshaft and key. It went together easily and it is so nice to work with precision made parts. I check all the rotation of the crank, spindle and oil pump and all is good.

My exhaust camshaft is new from Phil Pearson, but my intake camshaft is used and although the lobe is good, the outer wheel had a bit of corrosion, so it was hard to see the timing mark. I double checked, compared and transfered the mark from my old, worn intake cam. I deepened the timing mark with a dremel wheel and give it a dab of paint to make timing easier in the future.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9352-Version2.jpg)
Next I set the crankshaft at Top Dead Center and lined up the camshaft timing marks to the crankshaft.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9355-Version2.jpg)
I then finished up the timing side with the outer plate, oil feed and seals.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9363-Version2.jpg)
I also installed the magdyno pinion and new seal, but will need to open this back up and install the washer and bolt once my mag is rebuild ($400 later).

Next, I set the end gap of the piston rings.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9367-Version2.jpg)
I placed the top and second rings one inch down from the top of the cylinder and measured the gap with a feeler gauge.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9365-Version2.jpg)
The piston came with a formula sheet to calculate the proper top and second ring gap and it worked out to be .015 for the top and .018 for the second rings. I filed the top ring slightly to get the correct gap, but the second was good.
Next, I carefully slipped the rings on to the piston and aligned the gaps to the suggestion orientation.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9368-Version2.jpg)
I then compressed my rings with a high-tec specialty service tool (a hose clamp from the hardware store) and oiled and feed the piston and rings into the base of the cylinder. I find it easier to do it this way rather than trying to drop the cylinder on to the piston while attached to the con rod.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9369-Version2.jpg)

The cylinder bolts were installed next.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9371-Version2.jpg)
I stopped here because I am waiting for one special sized washer for the cylinder head bolt. The cylinder head bolts slide upwards from the cylinder and need to go in before I match the cylinder barrel to the bottom end.

Starting to look like a motor and should make more progress at the end of the week.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9375-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: Maritime on Jan 09, 2012, 13:37:44
I totally want to do high res prints of this assembly and use them for art work in my shop.  You are doing a super job on this. everytime I get an email that there is an update, I stop whatever I am doing to read it.

Excellent work.

Regards,

Mike
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: LuisN on Jan 09, 2012, 13:55:39
this has to be the BEST .. and i mean BEST step by step detailed take down of a bike i have seen.

I have a Norton 16H 1941 myself and its in running condition. I got it and had to put 3 years of slow work gathering original parts. Want to help me take apart engine and build it back up? just want to get it cleaned just like yours!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: Rocan on Jan 09, 2012, 17:54:33
*still drooling*

so nice man. SO Nice.

Definitely take you as an example as to the cleanliness I should have when building my own bikes...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: jbrtwork on Jan 09, 2012, 23:19:06
Definitely take you as an example as to the cleanliness I should have when building my own bikes...

No kidding. I've never had such a clean work space... nor done such precise work. Should I ever need a heart transplant, I want Swan as my doctor. :)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: jay_kent on Jan 10, 2012, 10:31:29
sign me up for one of those books. Pure mechanical porn right here.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: swan on Jan 10, 2012, 10:35:27
Ha, thanks guys. Trust me, my house is not that clean. I have no choice but to do the best possible job I can on my bike because it is a Gold Star, a rare bird indeed.

I cannot tell you how nice it is to work with clean vapor blasted parts, re-plated hardware and to be finally going clockwise. As I was wrenching I was thinking about the mechanics in Birmingham, England doing the same thing to my bike fifty years ago. I love B'ham and have been there many, many times and feel a personal connection to the city and its history.

LuisN, this is my hobby, not my profession, but I talking with the guy who bought my CB400F last year for his daughter and he wants me to repair and rebuild his 1970 Norton Commando project. I may take it on because need to raise more money to get my bike running not to mention $1500 for a new DBD cylinder head. Send your parts to Green Tree Scooters in Iowa (they bought some of Mods and Rockers' VB equipment) and have them vapor blasted, you will be amazed.

Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: ProSimex on Jan 13, 2012, 17:45:01
I second the using high res prints of these photos as artwork.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Rolling chassis!)
Post by: swan on Jan 14, 2012, 00:27:39
I've been a busy boy... Full story and LOTS of images tomorrow...
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/BSAGoldStarroller.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: IndieSol on Jan 14, 2012, 02:45:17
Thank you for this thread.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: ProSimex on Jan 14, 2012, 11:37:29
Pm me for my shipping address when its finished.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bumpthump on Jan 14, 2012, 16:13:36
It's all coming together beautifully. I think I have read the whole thread at least half a dozen times!
We are now getting that incredible alchemy that a build of this quality produces. Every single component brings nothing but approval. There's not been a single moment of "oh I don't think he's done that bit right". In some ways, this build is actually rewriting (or at least, redefining) the way a project like this should be planned and executed by anyone hoping to achieve top level restoration results.
I remain in awe of the dedication and single minded determination to see it through.

On a lesser note, my previous comment on this being an M&S restoration alluded to a very famous UK tv advert which in essence stated that their food wasn't, say, just a honey roast chicken, it was an M&S honey roast chicken......all voiced over in as sexual a way as possible by some husky voiced female. Basically it was saying that anything they prepared was a cut above anything anyone else offered. Hence the comparison with this restoration project!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Jan 14, 2012, 17:59:43
Thanks Bumpthump for the explanation and the compliments. I cannot overstate how nice and rewarding it is to build this bike with clean parts, re-plated hardware and new precision parts.

You guys wanted more images? Here you go:

With the arrival of a few spares parts the cylinder barrel could be installed.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9399.jpg)

Two small crankcase studs were installed with a hand tightened with a stud puller.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9403.jpg)


The cylinder head bolts and correct washers were threaded through the cylinder barrel and held in place with a rubber band (you all know this trick right?)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9401.jpg)

The piston is partially in the barrel and attached to the con rod via wrist pin and held fast with two circlips properly aligned and locked in their respective slots in the piston.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9404.jpg)


Barrel on, oiled piston slid smoothly and looks great.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9408.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9409.jpg)

Next, on to the rocker box. It looks simple but this quick a bit of time to ensure everything is correct, thrust washer, spring, washer o-rings etc were in correct order and the compression release assembly was tricky.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9416.jpg)

The old felt washer of the compression release was replaced for obvious reasons (left one), but the new washer was difficult to install.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9422-1.jpg)

I oiled it so it would be softer, pressed it in to place with a small washer and an extension socket. With much effort, I could get enough purchase to tighten down the outer nut.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9424-1.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9425-1.jpg)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9420.jpg)
Exhaust lifter
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9426-1.jpg)
Are you a Mod or Rocker? I am a Rocker box.

As for my cylinder head, it is a long story and I am still scratching my head about my head... I have an earlier, smaller style head and not the big, beautiful DBD head that gulps massive amounts of air and fuel and spits fire. I cannot afford a new one and will use this current head with new valves, guides and springs until I pony up the $1500 to work up a new cylinder head plus a bigger carb to match.

Before I could install the lower motor I needed to finish sorting out the engine plate bolts, washers and nuts.The BSA parts manual is very confusing on this illustration, it took me a long while to measure, sort and figure everything out. Goldies use several different engine plate bolts when using rearsets and I am still missing one which is on order.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9261-Version2.jpg)

Also, I finalized the positions for my clip ons, sorted out the steering dampner and installed the center stand and ensure the rolling chassis is solid and ready to hold my lump. More problem solving, if it was easy, it would be a Honda, if it was more difficult it would be a Triton....

Installing the center stand spring can be an absolute nightmare. I normally attach one end of the spring to the frame and slip the open loop on to the center stand with the hollow cylindrical shaft of a multiple bit screwdriver, but this loop was to too small.  The solution was to grind a flat spot on a garage sale pin punch, slip the open loop on to the center stand stud. I lightly greased the punch and with three attempts it slipped on the center stand stud. I few tests confirmed the stand works as it should.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9469.jpg)

I chose to use non-stock, non-OEM clip-on handlebars for I did not want a fixed control lever position (one style fits all) normally found on Clubman trim. I can stand the heat from the "correctness police" on this issue... It took many micro-adjustments on my Triton to get the clip-ons exactly where I like them for my riding style and expect the same on my Goldie.

My UK made fork tubes narrow several inches below their tops preventing my clip-ons from tightening fully.  Hmmmm, I sat down to sort it out with a pint and I found the answer right in front of my nose. Thin shims made from a beer can! I did this once before on a Honda handle bar pinch assembly and I worked very well. My clip-ons are fully tightened with absolutely no movement now.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9435.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9436.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9437.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9441.jpg)

I had ordered bolts for my handle bar clips last year and put them in storage. Now while installing them I realized they were too long and it is too late to return or exchange them, grrrrr.. I cut them to length and touched up the threads with a die. I cleaned the receiving holes with a tap to remove a bit of powder coat that crept in. The plate to hold the steering dampner knob was installed and works well. It turns out the steering dampner anchor plate I had cadmium plated was for an A10, and not my Goldie. Mine was in a box and I am going to zinc plate (copy cad) and install it.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9444.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9458.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9459.jpg)

With everything on the chassis sorted, adjusted and tightened, I place the lower motor in the frame, added the bolts and engine plates. Starting to look like a bike. I added a fews bits to mock it up, test the fitting and alignments and everything is in order.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/BSAGoldStarroller.jpg)
I also installed the rear fender to ensure my hardware was correct. Both fenders are in rough shape despite polishing the exterior, there are still flaws, scratches, dents, one crack, two extra holes and the front fender has discoloration from PO welds. Both are rusty underneath. As much as I would like to repair them and rechrome, it is not in my budget yet. I may buy new UK made replacements, but most likely will clean the interior of rust and dirt, prime and paint them so they look a bit better, but I am still just polishing a turd.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9452.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9467.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9468.jpg)
The fenders stays were pretty bad, but with Mothers and Maas polishes, WD40 and fine steel wool I was able to clean them up and plan to keep them. Of course I will need to buy new stays for the front to match a Clubman fender.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9319.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9380.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9318.jpg)

It may looks great, but to my eye I see all the things I need to do and the parts I need to finish or buy. Time and money...

I love my new book holder! (former engine stand).
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9466.jpg)

I may start on the gearboxes this evening but the next two weeks are going to be brutal work and travel wise and will have little time to wrench, I'll do what I can and keep you posted. Stay tuned!

Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bikeboy on Jan 14, 2012, 18:17:27
stunning swan, simply stunning.

ian
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bumpthump on Jan 14, 2012, 18:24:48
Finally, a criticism. The beer can you used for your clip on shims is clearly not British. Sloppy work. I will of course, mail you a more appropriate (empty) beer can on request.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Jan 14, 2012, 18:35:39
Finally, a criticism. The beer can you used for your clip on shims is clearly not British. Sloppy work. I will of course, mail you a more appropriate (empty) beer can on request.
HA, as close as I can get here stateside and one of Minnesota's best. I request FULL cans of proper bitter if you please...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: MotorbikeBruno on Jan 14, 2012, 18:55:25
HA, as close as I can get here stateside and one of Minnesota's best. I request FULL cans of proper bitter if you please...

Heck yeah. It is indeed one of our best! haha.  You have an insane amount of patience and skill with that engine work man.  I'm enjoying this thread for sure.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: wfo guy on Jan 14, 2012, 20:13:24
Keep on going. With everything you have done, I'm sure you know where you will end up. A love affair doesn't have to make sense.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: ProSimex on Jan 14, 2012, 20:24:45
Absolutely fantastic.  Any time I check this build and there are no updates I'm pretty dissapointed and sad.  What I want to know is if you're drinking that beer ice cold, or just below room temp as is proper.  If your drinking it cold your bike will never run properly, just the way the universe works.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: Cbaci on Jan 14, 2012, 21:08:17
Lookin good Swan, se ya next wknd. We should get Hoops to brew us a proper brit bitter for your bike's coming out party.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Jan 14, 2012, 21:25:53
Absolutely fantastic.  Any time I check this build and there are no updates I'm pretty dissapointed and sad.  What I want to know is if you're drinking that beer ice cold, or just below room temp as is proper.  If your drinking it cold your bike will never run properly, just the way the universe works.
PromSimex, I use proper glassware for different beer types (the right tool for the job) and drink lagers, hefe's etc cold, pales cool, IPA's DIPA, ESB and bitters at "cellar" temperature and like my milds, browns, porters, stouts and black IPAs a bit warm as they all should be.

Cbaci, good to see you on this sight and look forward to drinking in the woods with you and some of the Ronin crew!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: ProSimex on Jan 14, 2012, 21:30:12
Good man, I figured you knew what you were doing.   Just wanted to make sure.  I consume my beer with the right tools at the proper temp as well.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: Cbaci on Jan 14, 2012, 23:57:20
good to see you on this sight and look forward to drinking in the woods with you and some of the Ronin crew!

I usually haunt Naked Goldwing (http://www.ngwclub.com/) and Not-So-Modern Vespa (http://modernvespa.com/forum/forum19). But since I see back alley bikes (http://www.backalleymotorcycle.com/) is a sponsor here (and of course you're sharing your well documented resto is here) I thought I'd stay for more than just a visit. I wish my taste in Japanese bikes had a good beer match. In the proper glassware for the proper drink category, there's nothing like drinking Shoutoku Junmai Daiginjo-shu (http://www.shoutoku.co.jp/en/company/) from a sake' masu. Of course I lean towards the Belgian monastics for my beer. +1 for your Surly shims!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: leggers on Jan 20, 2012, 15:48:59
As if no one has said this before. This is a wonderful build thread  ;)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bumpthump on Jan 20, 2012, 17:44:37
I am at the point where I actually enjoy that there is no tangible progress. It pushes back the awful day when the bike is finished.............
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Jan 23, 2012, 10:51:26
Thanks Leggers.
I am at the point where I actually enjoy that there is no tangible progress. It pushes back the awful day when the bike is finished.............
BT, half the fun is restoring this, but the other half will be riding her.

I am back from some much needed time off and will start on the gearbox tonight.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Jan 24, 2012, 14:20:14
This would not be any fun if it was easy? I started on my STD and RRAT2 gearboxes thinking I could rebuild both, try them and then choose which I will use.  Wrong...
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9472-Version2-1.jpg)
Standard gearbox

The STD box has two badly worn and scored layshaft bushes and and both ends of the layshaft are scored as well. The bushes need to be replaced and /or the layshaft turned or replaced (more $)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9545-Version2.jpg)
STD layshaft left vs RRAT2 layshaft on right.

My next thought was to use the internal gears from the STD box and fit them to my RRAT2 lay and main shafts. So far so, good, but the 4th gear mainshaft pillon (constant mesh gear) bush is trashed and .030 oversized on the clutch end and needs to be replaced.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9558-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9556-Version2.jpg)

So I'll order a new bush and need to wait before assembly. I must also wait for my reverse camshaft to arrive and think about replacing the kickstart quadrant with a more forward facing type to accommodate the rearsets. As long as I am spending more money, it is time to replace the gearbox sprockets as well.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9557-Version2.jpg)

I did however install two new main shaft bearings and the outer seal with Winona Boiler and Steel's massive press (I really need to buy or build a small press).
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0094.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9562-Version2.jpg)

I also installed the two layshaft Torrington bearings (a gift from Limeyrider, thanks!) They did not have oil holes like the original bearings so after some careful measuring and Dremel work, I created oil holes in the outer bearings and pressed them in place. I used a magnet to deter swarf from getting in to the bearings, but washed and regreased them afterward to ensure they are clean and roll free.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG1070.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG1071.jpg)

That's it for now until new parts arrive and I find/make the time to do more work.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bwald on Jan 24, 2012, 19:08:37
I trust the Goldie won't interfere with Abrasive time tonight...

Looking good.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Jan 24, 2012, 19:30:26
Thanks bwald, will I see you tonight for Surly Abrasive?
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bwald on Jan 25, 2012, 04:05:36
I got to this too late. Unless you meant...the next tonight, in which case, well, probably.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bumpthump on Jan 27, 2012, 01:00:42
Does it look like the gearbox is offering up the biggest clues as to why the bike was eventually laid up?
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Jan 27, 2012, 12:04:19
BT, my Goldie originally came with a ARRT2 gearbox and all is good inside and was not why the bike was parked. I suspect the seized intake tappet and worn camshaft was why the bike failed and was put away.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6493-Version2.jpg)

The ARRT2 gearbox is a weird, one year only mix of gears sent to the US and is not the best combination and as I understand it, the transition from 3rd to 4th is quite a leap. People often say it was an effort to use up stock parts at the factory, but we will never know. I kept a STD box from an A10 RGS replica I was building when I found my Goldie and it is the one that was in rough shape, worn bushes, bearings, layshaft etc. I plan to fit the STD gears in my ARRT2 gearbox to keep original appearance but with a better gear pattern for riding.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: jbrtwork on Jan 27, 2012, 14:50:12
It's a time like this you have to admit, Swan... you are either the smartest or luckiest son-of-a-gun to walk this planet.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bumpthump on Jan 27, 2012, 15:26:12
Your gearbox certainly sounds like a weird set up. As you doubtless know, the "normal" RRT2 gearbox (of which I've had a couple fitted to run of the mill BSAs in my time) had a very tall first gear with the others bunched in close ratios close behind.........really gives the clutch an impossible life in around town. So does your Frakenstein one have conventional gearing in first through third, then a likely collapse in revs when you hit fourth....almost like some horrid overdrive type of thing?
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Jan 27, 2012, 19:34:00
It's a time like this you have to admit, Swan... you are either the smartest or luckiest son-of-a-gun to walk this planet.
"Hard work and luck" defines me.

BT, As valuable and desirable as RRT2 gearboxes are, I have no interest in running one on my bike. I will be riding around town, up and down the beautiful, winding bluffs along the Mississippi River in my area, empty country roads and never on a race track. So for real world riding I am using the STD cluster to start and then tweek as need be. I plan to use a Pearson clutch and there is no need to trash that work of art. You could retire if you sold your original RRT2 boxes today.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/_MG_6344-Version2.jpg)
The ARRT2 box was strange, one year only box used for US 1962 Gold Stars (mine) and 1963 Rocket Gold Stars. I am keeping all my original parts because they are rare and original to my bike.

The "Chart" of BSA of swing arm A and B model gearbox ratios can be found here: http://bsa-a10.hailwood.com/images/gearbox/chart1.jpg
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/chart1-1.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/Bsagearchartedit.jpg)
Abridged version of the chart with the ARRT2 ratios:

As I understand it, 4th gear on the ARRT2 is the same as the RRT2, but getting there is more like a Scrambler ratio and it has a short first gear ratio (2.877). I may install the original ARRT2 gear cluster after getting a baseline with the the STD cluster for comparison. I am very familiar with STD BSA A65 gear ratios but have only ridden an A10 once, so STD is a good place to start.
 (http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/chart1detail.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Jan 31, 2012, 15:24:25
It has been a busy week for me with work and travel but getting a package from the UK always makes my day. My new oil lines and reverse gearbox camshaft arrived today from Autocycle Engineering. Both items are made in Birmingham, very well made and fit perfectly. Some have reported problems with Asian made oil lines kinking and starving the motor of oil. These appear to be solid and will not kink.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9568-Version21.jpg)
The oil lines will route under the gearbox.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9569-Version21.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9570-Version21.jpg)

I will have time this weekend to work on my bike, install the oil tank and lines, tool box etc, stay tuned....
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: cobraace2 on Feb 01, 2012, 10:33:25
WOW this is looking great inspirational for sure
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: jeff4uk on Feb 08, 2012, 04:33:21
Nice workmanship sir,I dont know if you know that here in the uk (Suffolk) there is a man called Andy Ternen who has the most amazing work shop of old brit bikes ,He has a labyrinth of brit bike parts his mechanics are very knowledgeable and are always helpful his webb site is andybuysbikes.com
Dont know if this will be helpful
keep up the good work sir.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: milwaukeephil on Feb 08, 2012, 11:54:49
(http://i15.photobucket.com/albums/a400/rigmort/CIMG1705sm.jpg)

Another way to install that spring without losing an eye.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: Bert Jan on Feb 08, 2012, 19:29:00
kabang! love updates for this one! Last pic is 'the money shot' fo sho!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bwald on Feb 09, 2012, 12:11:26
Swan had the girlfriend and me over for dinner last night...as great as his photos are, they seriously don't do the Goldie justice. I feel bad for anyone else entered for BOTM when this thing is finished.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: pawn on Feb 11, 2012, 20:45:01
i love this thread!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bumpthump on Feb 12, 2012, 13:37:38
The "pennies in the spring" photo made me burst out in laughter. Although the currency was different, me and a mate did the exact same thing a couple of decades ago (hell, it was more like three decades ago). Only worth mentioning because of the currency.........it should have been British 1p coins, but for some reason (and I can't recall why), we had a jar in the flat (apartment sounds way too grand.........it was a flat......Brits know what I mean).......a jar full of farthings. The pretty little coin with wrens on one side. Seeing Swan's spring gave me back a memory that I didn't even know I had! Absolutely brilliant!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bumpthump on Feb 12, 2012, 13:39:55
...........and as for the bike being something pretty special when it's complete, I did say way back that this was going to be one of the best Goldies in the world. My opinion hasn't changed one little bit.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Feb 13, 2012, 11:59:56
Thanks all. The pennies in the spring are not mine, with this project I do not have two pennies to spare. I am back with just a few minor steps forward.

The bushes for my standard 4th gear arrived but one is incorrect. I double checked three parts manuals and the correct part should be 67-3080 a bush with three holes, but I received a bush with 4 holes, so it is going back and I must even longer now to assemble my gear box.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9609-Version2.jpg)
I had a busy couple of weeks but found time to do a few minor things such as place water slide decal and install the tool box, touched up the oil tank (still need to polish), assembled kick starter and Copy Cad plated a few minor bits such as the headlight clip, misc small screws and the end of the gear lever spindle. Details, details, details....
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9591-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9577-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9588-Version2.jpg)

This week is easier and should be able to complete a few more things.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Feb 18, 2012, 22:26:37
A short and sweet update. I polished and installed the oil tank and added the waterslide decal.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9629.jpg)

I wire wheeled the under side of the rear fender and then primed it with etching primer followed by a few coats of aluminum spray paint. It looks better but I will eventually replace it. The front is so ugly I think I am going to order a new one along with correct clubman style sets of stays.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9627.jpg)

That is it until next time...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: Tim on Feb 18, 2012, 23:12:14
Incredible detail.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: crazypj on Feb 19, 2012, 01:19:57
Looking at the charts, it looks like a trials box rather than MX?
 High top to get between sections quicker?
 No idea why anyone would think it was a good idea for the street though?
BSA management got even stranger later on  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Feb 19, 2012, 22:21:00
Wow, just wow... My same front 190mm wheel just sold on e-bay for $1825.00 and the rear wheel for $1030.00 Both were in fair condition, complete, unrestored and had Dunlop alloy rims and bad spokes.

I can buy, title, clean, paint, zinc, paint, reupholster seat, lace new spokes and install new tires and make run well a mid 70's Honda CB for that kind of money for just the front wheel. Stay away from thoroughbred British motorcycles kids...

Also, I was severely outbid on a set of original (incomplete and rusty) Gold Star rearsets on Ebay today. They went for US $253 plus shipping from the UK. Instead I bought a beautiful, UK made, new and complete set from Lyford Classic Services in the UK for US $180 delivered.  Bid smarter, rather than higher.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Feb 19, 2012, 23:04:00
Swivel, only one of the holes in the 4 hole bush will align correctly with the three oil ways on my gear. Both my A10 and ARRT2 gearboxes use a constant mesh gear with three holes for oil to the bush and mainshaft. I cannot remember if my 1966 A65 had three or 4 holes, but either way the bush that I bought will not work. I am calling the UK early tomorrow morning and may order a new gear complete with both bushes since it will be cheaper than buying bushes in the US and paying a machinist to install and bore them correctly. I will post my results. This one bush is holding up my gearbox build, installation and a few other items on my bike. If it was easy, everyone would have a Goldie....

Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Feb 20, 2012, 10:56:30
British bikes:"Everyday is a school day"
At this rate I should be finishing my PhD Dissertation soon...

Alright, after some head scratching and caliper work I have the high gear bushes sorted out. I threaded a hacksaw blade through the gear and CAREFULLY cut a kerf into the old bushes. One came out easily, the other I pried apart with a screw driver.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9632-Version2.jpg)
I am sending back the 4 hole bush for it is too short and the holes do align with the three oilways on the gear.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9636-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9635-Version2.jpg)

The solution is to exchange the 4 hole drilled bush (67-3080 right side) for another undrilled bush (67-3073 left side) and then use the old drilled bush (center) as a template and drill three new holes for the oilways in the new bush. These bushes are rather thin and I am going to have a machinist install them properly so I do not damage them. Then I can finally assemble, install and enjoy a leak free gearbox with standard gear ratios.

Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: ProSimex on Feb 20, 2012, 11:17:29
I get all excited when I see you've updated this.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: 50gary on Feb 20, 2012, 11:56:32
Show your machinist the parts, both bushings and gear.  He can make them and probably quicker and cheaper than waiting and paying for the shipping from UK.  It's a simple part really. 
   Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Feb 20, 2012, 12:16:27
50gary, my gear is still good, I simply need to exchange one bush for the correct one from British Only and drill it.  They cost $27 and look simple, but are a special bronze alloy. Cheaper than paying a machinist to turn one with the correct material, but I will pay to have them installed.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: joeficsit on Feb 20, 2012, 13:13:45
This is an AWESOME thread to watch!

I felt compelled to post that.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: 50gary on Feb 20, 2012, 17:38:13
I made a mistake saying "them" making it sound as if I referenced the gear along with regard to making a new part.  I meant just the three hole bushing, I would take the gear to the machine shop just so it could be measured.  The bronze  alloy is not unusual for this type of bushing.  Best of luck, tell the postman to hurry.
  Cheers, 50gary
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bumpthump on Feb 26, 2012, 17:24:33
In the interests of being utterly pedantic and anal, is the four hole bush 90 degree separation, and the three hole 120 degrees? Is that why only one hole would align? As ever, the thread is a gem....
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Feb 27, 2012, 19:29:36
In the interests of being utterly pedantic and anal, is the four hole bush 90 degree separation, and the three hole 120 degrees? Is that why only one hole would align? As ever, the thread is a gem....
Yup, 0, 90, 180, 270 degrees versus  0, 120 and 240 degrees.

I m back after several days of travel and had two packages waiting for me. The replacement bush and a few other bits along with my, beautiful new rearsets from Lyford in the UK. They are beautiful! I will post images tomorrow.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Feb 29, 2012, 11:22:04
One of my rearsets from Lyford Classic Services http://lyford-bsa.co.uk/. Nice powdercoating, UK made, CEI hardware and they look and feel great. Nice people, good prices, good communication and fast shipping and I am ordering my rear brake pedal, rod, linkage and some cables from them this week.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9670-Version2.jpg)

Also I picked up the long out of print and way overpriced book "BSA Gold Star Super Profile" by former president of the BSA Owners Club in the UK, John Gardner. It is concise, has many good photographs, historical details and is a good reference source. Some of the content is a bit dated (1980's, the dark ages, before internet) but I am happy with it and the fact that I paid under $40 USD for it on Alibris. I have been outbid on E-bay many times on this same book and have seen it go for twice the price.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9671-Version2.jpg)

Going to my machinist today to have my gear bushes pressed in and honed to fit my transmission mainshaft. Once done, I can finally assemble the gearbox. Stay tuned as always....
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bumpthump on Mar 01, 2012, 20:13:13
Rear sets look nice and tidy, with no frills or frippery. The super profile is a book I picked for 50p (75c) in a charity shop sometime around the millennium, and as you say, eBay prices can go a bit mental on stuff like this. It's the double edged sword of being great for getting best prices when you sell, but obviously, you can pay top dollar when you buy.

Did you ever resolve your dilemma with the chronometrics?
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: swan on Mar 02, 2012, 10:10:26
Thanks BT, nice find on the Gardner book for 50 p!

I am considering Dave Woods http://www.chronometricspeedos.co.uk/ to restore my speedo. Memberss on Britbike forum recommended him and he does amazing work.

Just placed another order with Lyford Classic Services again for my rear brake pedal and assembly, cables, bulbs and some other "odds and sods".
Title: Re: 1962 BSA DBD34 Gold Star restoration (Motor in rolling chassis!)
Post by: bumpthump on Mar 02, 2012, 20:00:23
I would agree with the assessment of Dave Woods standard of workmanship. Top quality stuff. I have one friend who did an exchange, and he was blown away by the quality of work, and after arsing around for three days trying to overhaul a unit on his own. was at a complete loss as to how it could be done at such a reasonable price.......us Brits are very used to paying good money for poor service, and when somebody like Woods comes along, we tend to be surprised by it.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Mar 03, 2012, 12:32:50
Bumpthump, thanks for chiming in on Dave Woods, a member on Britbike forum posted some images of his work and it is beautiful.

My gear bush arrived, so I built the my ARRT2 gear box with STD gears. I will write up and link to a separate page with loads of images and information to make it easy for the next restorer.

I drilled the correct three oil holes in the new bush with a uni-bit and had The Engine Store of Winona http://theenginestore.com press and hone the new bushes. They did perfect work, it was done the following day for $27, thanks guys!. The mainshaft fits and rotated beautifully with no more gap or leaks.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9558-Version2-1.jpg)
Before. Mind the gap...
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9780.jpg)
After, with new bushes, no more leaks!

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9882-Version2.jpg)
Gearbox is done!

I also picked up an original OEM 7" Lucas headlight from a cool member on Jockey Journal. It matches my original headlight but without the massive crack right down the middle. The price was right, considering there is the same NOS Lucas light on ebay for $249 with one day to go in the auction.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_9884-Version2.jpg)
Enlightening...

I made a large order from Lyford's and should see new cables, bulbs, ammeter, rear brake assembly and some other bits by the end of the week. It is beginning to look like a motorcycle and I am seeing light at the end of the tunnel. I still need to purchase a chain, chain guard, new 12 volt dyno kit and regulator, carb parts, battery, fuel lines etc and possibly a new front fender and stays. My cylinder head needs new valves and guides, the magneto and speedometer need to be rebuilt. Time and money....

Gonna spend some quality time with the Triton this weekend, cleaning, putting the carbs on and battery back in and am watching the weather for I think I can get the first ride of the year in on Tuesday. I cannot wait.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Hoosier Daddy on Mar 03, 2012, 13:44:39
Enough people have pumpped sunshine up your skirt, you really don't need to hear it again... but WOW you sir, are an artist. Fantastic!
 Seeing the e-bay prices for these items like the headlight is staggering. Makes me cringe that I sold BOTH my A-65's for $1200 back about 20 years ago. A Thunderbolt and a Lightening... each had those 7" Lucas lenses and one I put on I found NOS still in the box. Think I paid $30 for it... Probably worth a fortune today  ::)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: bumpthump on Mar 03, 2012, 19:23:22
Not only stupidly expensive, but back in the day, they were well known for being poorly made with near pitiful levels of quality control, but also nothing ever better than average in terms of fitness for purpose. Yet here we are three or four decades later, and the stuff is damn near worshipped!

There were many terms used to describe Lucas BA ck in the 60s and 70s, and they were all based around the theme of Lucas being the Lords of Darkness.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Mar 04, 2012, 12:39:04
Thanks HD, the concourse builders need medication, Two 190 mm front brake hubs went on e-bay this week for $1825 and $1320 each. I cannot find an OEM Lucas rear brake switch that does not cost and arm and a leg. But with patience and luck I eventually get what I need and the forums are a great source for parts for less than E-bay prices.

Many slag Lucas but I have never had a problem with their products. Like most things, they should be kept clean and maintained, but most people are too lazy to do so. If I wanted a maintenance free, push start bike, I would buy one. Instead I want an old classic with all its charm, quirks and maintenance.

Swivel, I am going with a rebuild mag with a new modern condensor, rewind, proper seals, bearings etc and converting my dyno to a Hawker 12 v system with a modern voltage regulator. There is no room for an alternator in my bike. My bike should start first kick and with all the deer and other animals in my area, I need a 12v system to stay alive. I am going to pay dearly to restore my chronometric speedo, but to my eyes, they are absolutely beautiful and perfect.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: crazypj on Mar 04, 2012, 14:06:44
Personally I've never had issues with Lucas electrics either.
 
You can use late model reflectors and find 1970's cars with sealed beam headlights.
 It is possible to remove the glass with careful grinding around periphery
My father used to do it on a really regular basis for people
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Rustynuts on Mar 04, 2012, 14:42:27
your  right on the money with what you are intending regarding the electrics,Im a late arrival from Scotlabd to your amazing blog! Uour thoughtful , methodical approach to your rebuild in this age of instant gratification is to be highly commended.Ive used one of Sean Hawkers units on my DB32 , and it works well , you may also want to consider one of the AO units , made by Al Osborne, his stuff is used but lots of Velo riders this side of the pond , your not to far off now to getting the bikes wheel son the road  , i'll  be watching with great interest and looking forward to the book publication!!!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Rustynuts on Mar 04, 2012, 14:55:08
sorry for the various typos in my last message , comes with using an ipad and being distracted by the smell of Sunday dinner coming from the kitcken ,once again all the best from a new fan accross the pond.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Mar 11, 2012, 13:20:36
Thanks Rustynuts!

With many thanks to Gordo's sharp eye from Britbike.com forum, I pulled my motor, dissembled the lower end, heated the primary case, removed the bearings and found that I did in fact have the wrong shim installed. I replaced it with a new 66-0661 shim as seen below.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0001-Version2.jpg)
66-0661 on left, ? on right, removed from my motor
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0005-Version2.jpg)
Empty
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0006-Version2.jpg)
With new 66-0661 shim
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0014-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/BSAGSdriveside.jpg)
Part number 8,
BSA 66-0661 shim dimensions:
OD 39.5 mm (1.555")
ID 25.3 mm (.996")
Thicknes .7mm (.027")

With my lower end sorted and my gearbox complete, I placed everything back in to the frame and tightened everything down. The gearbox works beautifully and shifts easily through all the gears.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0023-Version2.jpg)

I started cleaning up my old original 6 spring clutch and am going to install it just for the purposes of mock up and to kick the motor over. I plan to buy a new Pearson clutch soon. Slowly starting to look like a bike.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0037-Version2.jpg)

My order from Lyford is delayed in US customs for they claim the contents were not correctly listed on the outside of the box and on the customs forms. After a dozen e-mails and phone calls Fed Ex still cannot grasp the concept of "new and used motorcycle parts" and want a price and material breakdown of every of each nut, bolt, washer, cable, part, brake pedal etc. I told them to open the box, read the invoice and inspect the contents. Pat from Lyford was kind enough to send my box the morning they went on holiday, but they are not answering their phone or e-mails while away. All three people I spoke to at Fed Ex had never heard of BSA motorcycles, frustrating... Professionally, I had an epic problem this week with some art work coming in to the US as well. Walmart can bring in ships filled with 1000 cargo containers of cheap plastic crap every hour but I cannot get $400 worth of BSA parts through. Grrr, sorry for the rant....

Rode the Triton yesterday and had a blast, spring is here in SE Minnesota.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Shouter on Mar 13, 2012, 01:21:20
Amazing build! My girlfriend lives in Nowthen, just outside of Elk River, sometime when I am in the area I would very much like to see this bike in person!

Sent from my SCH-I400 using Tapatalk
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Maritime on Mar 13, 2012, 08:24:54
Drool!  Nice that someone caught the seal. Could have made for a small drip that would drive you nuts.  Love it as usual and you are lucky to get out for a ride already this year.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: MotorbikeBruno on Mar 14, 2012, 18:25:24
Amazing build! My girlfriend lives in Nowthen, just outside of Elk River, sometime when I am in the area I would very much like to see this bike in person!

Sent from my SCH-I400 using Tapatalk

What he said, but I'm just north of the cities!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: johnu on Mar 14, 2012, 19:13:36
Yes, looking very tasty indeed.  I see you mentioned the Pearson clutch, my dad is doing his own similar conversion using the Suzuki clutch for his Goldie.  Has to be better than the stock unit for sure.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Mar 15, 2012, 10:29:28
Johnu, Phil Pearson is the one who first converted a Suzuki clutch to fit BSA Gold Stars. He makes his own and they are works of art.

Good news, my Customs drama is over and my parts arrived yesterday. Cables (speedo, tach, air, throttle, magneto and clutch), brake pedal and rear brake rod and hardware, ammeter, bulbs, bellmouth for carb and few other misc. bits. I will install these parts this weekend. We are experiencing record breaking temperatures and I have by riding and wrenching the Triton as much as possible

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0039-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0041-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Lickety Split on Mar 15, 2012, 15:42:55
I've been watching this thread since I hooked a '61 DBD34 that's been lounging in a lock-up for about 30 years. I have yet to reel it in, but lately I feel the line going slack, so it will either escape to be caught by someone else, or my creel will soon be bulging with barn-fresh Beezer. I'm in metro MN, so I'm doubly pleased to have you vetting all the area vendors. Many thanks in advance. :D

Meanwhile, you're certainly doing it right, and sharing it here is inspirational to say the least. Keep 'er going.

LS
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Mar 15, 2012, 17:55:24
LS, reel it in or let me know who it is and I'll go after it.

Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: johnu on Mar 16, 2012, 11:42:46
Johnu, Phil Pearson is the one who first converted a Suzuki clutch to fit BSA Gold Stars. He makes his own and they are works of art.

Yes the clutches he converts are indeed works of art but then they should be for the price of them!  Fortunately my dad has the ability to make convert one of the clutches for himself.  He actually bought the donor clutch while he was here in the states visiting me for $25.  Your work on the the resto really is top notch.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Mar 17, 2012, 12:46:38
Swivel, If I wanted a new, push-button, carbon fiber/plastic, mutated insect looking, souless modern sport bike, I would ride one. I have ridden many modern sport bikes including a CBX and a 916, they are fast and fun, but I have no interest in owning one. A 50 year old Gold Star has a higher top end speed, at nearly half the weight, than a Vmax. There would never be any modern Japanese or Italian sport bikes without British race bikes such as Manx Norton and BSA Gold Star, not to mention the original cafe racers who emulated the British racing singles and twins they watched on the racetrack.

Phil Pearson's 40 years experience of working on Gold Stars, as well as being a professional engineer, designer and machinist is good enough for me and thousands of other satisfied customers worldwide. He apprenticed under BSA factory designer Roland Pike and Pearson works from original BSA factory designs and Pike's personal drawings and notes. There is nothing "romantic" about him, he makes high quality parts. He is friendly and enthusiastic on the phone and passionate about getting and keeping old bikes on the road. That is what this forum is all about.

Andy Molnar and his crew also make nice bikes and parts, but most are direct copies of Matchless' and Norton's factory parts specifications of which he acquired the rights.

For the record, I am not a Mahler fan, but rather prefer punk rock, indie, alt-country and electronic music. Nothing "epic" about this build, I am just a guy who is happy to restore a classic bike back to its original glory and am sharing my progress like hundreds of other builders on DTT. This restoration thread has over 50,000 page views on two forums, so others seem to enjoy it. If you don't, there are plenty other threads for you to read.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Greg-NWO on Mar 17, 2012, 12:58:28
50,0001 views....  keep up the great work and thanks for sharing the experience with us!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: haplo_84 on Mar 17, 2012, 13:00:29
I'm Glad you said something, cause i read it yesterday and wanted you to have the first crack at it swan. Modern bikes are great and all and they do run better to a certain extent. But its all about what you like and what you want. I love your build swan and he can get off his high horse and realize not everyone should have the same preferences as him. I'm less picky with bikes than cars, I wonder if it makes him irritated that I have an obsession with inline 6's in my cars. Is that the norm or whats easier to obtain? Not really but its what i prefer.

By the way swan, I think you said exactly what needed to be said with the most etiquette of anyone i have seen on here. I hand it to you for not flying off the handle and handling it like someone with true intelligence.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: ProSimex on Mar 17, 2012, 13:25:17
Well said Swan, that post was really hatefull and lame, I'm glad you handled it like an adult.  I really like this thread and dont see the need for such negativity. 


Keep up the good work, you are an inspiration to us all.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: haplo_84 on Mar 17, 2012, 14:05:53
I really don't see the need for you to come in here and bash on someone when they are obviously building something with a true passion. I do believe swan said somewhere in here that obviously it was never really going to compare to a modern bike in shear performance but that he was building it with a true labor of love. Its not like he is making some gaudy piece of metal that was originally a piece of handcrafted art. Regardless whether it modernized or not it is one of the bike companies that helped keep the racing motorcycle heritage alive after the wars until countries like German, Italy, and Japan could get back on their feet and push the boundaries of motorcycle development. 
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Mar 17, 2012, 14:37:26
Swivel,

If you do not like BSA's or Gold Stars, do not ride one.
If you do not like Phil Pearson, do not buy from him.
If you do not like this restoration thread, do not read it.

You are right about the Yamaha Vmax specs. I did not know what one was until I Goggled it and misread the hp as max speed.

Art and taste are subjective and to my eyes most any motorcycle made past 1976 is "souless". Sure modern bikes are faster, more efficient, reliable etc., but I like the look, design, mechanics and performance of old bikes. I have no "delusions, rapture or dreams" about this bike, it is not a modern bike and is just a restoration. I look forward to riding it and am sharing the build process with others who want to come along for the ride.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: dewjantim on Mar 17, 2012, 14:43:49
Swivel....... I will agree with you on the top speeds of the Gold Star VS V-Max. It just "feels" like one is doing 150 on a Gold Star while the earth is shaking (along with your teeth) as the speedo sweeps past the ton. The Gold Star earned it's name in 1937 when Wal Handley came out of retirement to race the alcohol fueled Empire Star at Brooklands and earned a Gold Star for lapping the circuit at 100 MPH. BSA was coming out with a higher spec version of the Empire Star so it was named "Gold Star" being able to do over the ton from the factory.  You stated that this bike was 20 years obsolete when it left the factory and that if it was as good as claimed that it would still be made. When production was stopped in 1963 the Gold Star was still competitive ...... and.... still winning races for years afterward. The reason production was halted was not because sales were bad or the Gold Star was outdated. The real reason was that production costs were much to high due to the labor intensive nature of setting up a race bike for the street.     I wonder if you have ever ridden or owned a Gold Star or anything like it ? Having owned a CBX, and ridden both a 916, and several Vmax I can honestly say that those bikes do have soul...... but it is different than riding a British single, especially one which you resurrected on your own. There is a certain indiscernible feeling attributed to riding these thumping pieces of machinery which gives one a nostalgic sensation of times past. Oh yeah, I know you will say that is just the sentiment of an old fart trying to relive the past........ but...... get that same old outdated British single on Deals Gap, Rt32 in Ky, or "The Snake" in Tennessee  and it will make a mockery of the CBX or the Vmax (probably not  the 916). As for the HD Sporty, even though still being produced, is not a better sporting bike. My 883 would do 110 MPH (indicated), same as the Gold Star, but I am afraid it would come up short in the handling department. Not bad....... a 1930's designed single cylinder 500,which you claim was outdated technology when new, being as fast and better handling than a modern motorcycle almost twice it's engine size with an engine redesigned in the early 2000's. Why not try one of those "dated" British engineered singles for yourself and see if I am correct. If you can't find a Gold Star ......... go to your nearest Royal Enfield dealer and get a test ride. Not quite the same bike in terms of speed or style, but it will suffice........
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: dewjantim on Mar 17, 2012, 15:01:44
Hahahahahaha............ yeah, I bet. ;) ;) ;)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Tim on Mar 17, 2012, 15:17:12
Take it outside gents :)  No need to use this thread to throw the glove down.

Honestly I don't think it would matter what make or model of bike Swan was devoting this much time and effort into not only restoring but documenting the process on.  There would still be a great deal of appreciation and admiration for the process.  I'd enjoy reading this every bit as much if it were a moped being restored.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: haplo_84 on Mar 17, 2012, 15:29:27
sorry Tim, i don't post much these days but felt the need to defend his work.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: dewjantim on Mar 17, 2012, 15:48:16
dewjantim,Pick your road and bikes and put your money on the table sometime,then.How many top racers and WSB racers have complimented you on your fast riding of late?I don't nickel and dime around,it would have to be 10K to start.
Well...... last week I was at Roberts' ranch and passed Rossi on Kenny's short track which is in the south forty. Thought I was pretty hot until KR cruised by me and kicked the shit out of my left boot. He yelled.... "Get the fuck outta' my way asshole" as he slid by and I wobbled around like a kid learning to ride a push bike. Then that little  smurf Rossi flew by and spit on me..... screaming, "You fuckin' novice" in Italian. So..... to answer your question..... no, my riding skills have not been complemented on by any major road racers. My road? Rt 32 in eastern Ky....... time, tomorrow at 12:00 noon. Bet: how about 15000 USD to start. Meet up at the Rt 7 intersection just outside West Liberty (well it used to be there before the tornado anyway). And..... if I am not there, start without me and I will catch up.  To be fair about it...... you can use my RE and I will use one of my Ducs. Gauntlet thrown.......... and challenge accepted.  By the way....... why don't you put a little info in your profile, like where you race at, kind of bike you race, where you live, or even your age. Just claiming to have big balls doesn't impress me......... or anyone else for that matter. Sorry, if I hijacked your thread Swan. I admire your work and passion. Gold Stars are one of my favorites and I am jealous......... Swivel, see ya' tomorrow........ and please bring cash.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: ProSimex on Mar 17, 2012, 16:56:31
oh snap

Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: crazypj on Mar 17, 2012, 21:48:42
Swivel,

If you do not like BSA's or Gold Stars, do not ride one.
If you do not like Phil Pearson, do not buy from him.
If you do not like this restoration thread, do not read it.


I was going to type out a diatribe but decided it wasn't worth the effort.
 
 Swivel is just looking for an argument, I have no idea why? (maybe something to do with the amount of money he has accumulated?)
Sounds like a guy I used to work with,
If you had a black cat, he had a blacker one  ::)
  If you don't rise to it, he'll just go somewhere else
 He never did reply about his bikes/building experience when I asked a few months ago
The other thing, Top Racers don't  compliment amateur's, unless they are being sarcastic  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: 03rangerxlt on Mar 19, 2012, 04:31:02
Why did this cat Swivel have to come crap in this thread.  I can't even fathom why he is a member of this forum.  His attitude towards this build seems contrary to the what the average member here exhibits towards any kind of project posted around these parts.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: bumpthump on Mar 19, 2012, 09:57:22
Anyways....now that we've learned (yet again) that there's loads of folks out there who know the price (and speed) of everything, and the value of nothing, lets return the thread to Swan.......
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Mar 19, 2012, 10:28:14
...and now back to our regularly scheduled programming....

I went through my Amal 389/004 carburettor and ordered replacement parts directly from Amal UK.  My plan is to use the existing cylinder head and carb until next winter when I can afford a larger DBD cylinder and Amal MKII carb to really let the motor breathe and spit. I am also going to talk to my machine shop about replacing the valves and guides on CB head with some new ones made from modern materials.

There will be more light at the end of the tunnel when my tax return arrives next week so I can buy the last of the needed parts including the clutch assembly, new dynamo kit, regulator, switches and wiring harness and have my speedometer restored and magneto rewound. This bike will see the light of day soon.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: 03rangerxlt on Mar 19, 2012, 13:14:33
can't wait! more pics soon please!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Hoosier Daddy on Mar 25, 2012, 16:01:21
GO SWAN!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: sifty on Mar 27, 2012, 17:09:17
Fantastic write up - I was sharing the emotion hearing the reading out of 'D.B.D.3.4'...
Thanks for the great pics of your journey, much appreciated.   :)

And for the record, my first road bike was a GSXR, I am too young to have ever seen BSA in their heydey, and I would still give my left one for a Goldie. You are living the dream of many, cheers...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Mar 28, 2012, 10:46:41
Thanks sifty, HD, 03rangerxlt and everyone else, glad to know people are still reading this. My bike karma nearly struck again for I was the second person who responded to a 1953 Triumph 650 basket case on Craigslist for $500. Would have loved to grab it at that price and restore it after the Goldie. I cannot complain for I am the luckiest person and have a Gold Star.


Minor update-my carb parts arrived yesterday from Amal in the UK. My original carb was incomplete, rough and dirty so I had it vapor blasted and basically am replacing everything but the body, jet block and Webco float cover. Again, it is so nice to work with clean used and new parts.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0091-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5050.jpg)

I am patiently awaiting my tax returns which should be sent any day now so I can buy the clutch, electrical upgrades, and the rest of the missing bits. Stay tuned...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: jbrtwork on Mar 28, 2012, 11:38:02
Wonder if he whistles while he works?  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Frito Bandito on Mar 28, 2012, 12:28:15
Swan, I can't tell you how much I've enjoyed this thread (with the very minor exception of that obnoxious 'swivel' fella)!! I'm currently negotiating for a 1957 BSA 441 Alloy Clipper that a friend has in his barn (next to his BSA A5). When I get it (I'm pretty confident I can talk him into letting me have it), I'll post pics. Thanks again for keeping us up to date on your progress!!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: makotosun on Mar 28, 2012, 13:58:31
This has got to be one of the best reads on the internet for bike restorations. Even if you are a fan of a different Marque, Swan, you are showing how to do one of these writeups the right way!

Absolutely amazing detail, documentation and patience!

I just wish I was close enough to come take a gander in person.

_
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Shouter on Mar 29, 2012, 08:38:32
If you dont mind me asking, what city do you live in? My girlfriend is in the elk river area and I am there quite often, I would love to see this bike in person sometime.

Sent from my SCH-I400 using Tapatalk
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Mar 29, 2012, 11:01:40
I am in Winona, MN. I guess that makes me a Winona rider.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: scroggins5000 on Mar 29, 2012, 12:13:15
I am in Winona, MN. I guess that makes me a Winona rider.

http://instantrimshot.com/
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: MotorbikeBruno on Mar 29, 2012, 14:29:25
Well Played Scroggins...haha  ;D

Eventually we should really get a MN/WI group to meet at some place that has great food.  Seems there are a few of us MN guys on here and the Western WI guys are close enough too.

  *Now back to Swan's regularly scheduled program *
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Mar 30, 2012, 10:34:19
Another slight detour, my new ride, she's a '64... http://www.dotheton.com/forum/index.php?topic=35538.0
(http://i170.photobucket.com/albums/u272/66triton/1964%20Schwinn%20Hornet/IMAG0202.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: dewjantim on Mar 30, 2012, 10:55:45
Sweet bike...... I had a blue stingray when I was in junior high. Saved my pennies from the 1st grade to buy it. It had a cheater slick and three speed trans which would slip out of gear at the worst moment......... resulting in busted nut syndrome.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: jbrtwork on Mar 30, 2012, 12:37:23
Very cool, Swan. Now you can get a paper route to subsidize that Goldie.  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: jbrtwork on Mar 30, 2012, 12:39:40
My ride, back in '66 was a gold AMF Roadmaster... you know, AMF... the company that damn-near killed Harley Davidson.
Title: Re: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: Shouter on Mar 30, 2012, 16:39:17
I am in Winona, MN. I guess that makes me a Winona rider.
Funny, her brother lives in winona, thats a nice town for sure!

Sent from my SCH-I400 using Tapatalk
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Apr 02, 2012, 18:59:23
Very cool, Swan. Now you can get a paper route to subsidize that Goldie.  ;D
Thank is how I filled the tank on my first bike, a Honda Trail 90, when I was a kid.

Quick update, the carb is done and my tax return is here so I am calling England tomorrow to order the clutch, wiring harness and a few other goodies. Also going to pack up the magneto for restoration.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0109-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0110-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0112-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0113-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0114-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0116-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0117-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0118-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0119-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0121-Version2.jpg)
English tickler
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0124-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0125-Version2.jpg)
Here is Burlen Amal's new hard anodized slide
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0128.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0130-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0131-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0134-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0136-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0122-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0140-Version2.jpg)
I kept the non-stock Webco carb bowl extension that came with the bike.

Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: crazypj on Apr 02, 2012, 19:52:32
I actually like AMAL carbs.
 You can see where Mikuni 'smoothbores' and Kei-Hin CR came from when you look at the bore of the 'crude old things'  ;)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: jbrtwork on Apr 02, 2012, 21:25:37
Those aren't very different from the SUs on my old MGB.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Apr 02, 2012, 21:59:16
Monoblocs seem to be hated be most, but I actually like them too. I ran twin monoblocs on my BSA Lightning and once I sorted them out, they were great. Like most things, it is easy once you know how to do it. Many people simply do not take the time to learn to tune and adjust their carbs and prefer "set and forget" function of modern carbs and fuel injection systems. For me, the fewer the parts, fewer the problems.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: crazypj on Apr 02, 2012, 22:57:25
The main thing that lets them flow so well is the removable jet block and thin wall throttle slide.
On Lightening with left and right float chambers, did you have the lower balance pipe to main jets?
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Apr 03, 2012, 00:27:41
Yup, I ran a balance tube and they had left and right matched bodies.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Gearbox is done)
Post by: swan on Apr 04, 2012, 17:00:37
I ordered my new clutch yesterday and should see it next week.  Also, I managed to find an original OEM Smiths speedometer dial with the exact matching numbers as my old one. When it arrives next week, I am going to bite the bullet and send it out to Nisonger for restoration. Joe V is getting my mag next week for restoration as well.

I could not find a replacement quick detach QD Gold Star wiring harness from the normal US vendors, so I asked Phil Pearson in the UK and he did not know. George Prew told me he did carry them but does not anymore because the current ones are “rubbish”. Both taped and cloth braided non quick detach versions are easily available. I read somewhere older Land Rovers utilized the same Lucas QD plug (???) Also, I read on Tiger Spares' (http://triumphpartsusa.com/about.html)  website (but could not confirm) an earlier Triumph Pre-unit QD harness would work on a GS. "We offer Early Replica Parts ranging from QD Wiring Harnesses for 1949 TR5 '60-'62 Pre-unit TR6 and T120. This harness is also found on the BSA Gold Star, Rocket Gold Star and many other competition machines of the period."


I thought my bike had an incomplete wiring harness, so I went back and studied my breakdown photos and realized I did have a full harness to begin with, but did not know where I put it. I dug through my BSA parts boxes and could not find it, but today a friend needed a Honda CB750 part and when I searched my Honda spares I found my missing section of GS harness. Yes! It is dirty and dusty but not terribly bad or chewed up. I think I can salvage it. If not, I will order the correct color wires and bullet connectors from British Wiring and make a new one using the old as a template. Or as suggested by rick e (thanks!) I could order a non-quick detach harness and splice it with the male and female 5 pin QD plugs from my old harness. The original Lucas 41SA switch is frozen solid and will be replaced.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0167-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0168-Version2.jpg)
I am going to bead blast and re-zinc the metal parts of the plugs.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0171-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: Hoosier Daddy on Apr 05, 2012, 06:49:24
Anyone who has owned an Amal with a "tickler" can appreciate this...  ;)
 
 
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: teazer on Apr 05, 2012, 11:31:07
Oh yes.  That's for sure.  I had chopped monoblocks on a T100 alloy motor, GP on my Goldie and Concentrics on a T120 race bike.  In fact I copied the Z needle profile onto a CB750 needle for alky conversion on a CB77. GP and TT were beautiful carbs.  Never owned an RN but the GP was super smooth bore.  Nothing in the way.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: andycafe on Apr 09, 2012, 07:13:17
WOW Nice!
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: swan on Apr 11, 2012, 14:09:54
Thanks Andycafe!

Look what the FedEx guy just dragged in....
My new Phil Pearson clutch, oil slide plate and needle bearing timing plate.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0191-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0198-Version21.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0199-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0202-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0195-Version2.jpg)

Timing plate with needle bearing:
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0192-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0194-Version2.jpg)

Sold my original clutch set up for $200 yesterday on E-bay which takes some of the sting out of this. This complete clutch weighs 5.4 pounds and my new hardened DID 428 primary chain arrived yesterday. Looks like I need to make the time this weekend to polish my primary cover and the lower end will be complete!
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: crazypj on Apr 12, 2012, 01:33:31
That's too damn pretty, your going to HAVE to run an open primary  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: teazer on Apr 12, 2012, 12:37:18
That is way too pretty to hide inside a cover.  Did you say 428 chain? My that's small.  Our Honda 160's use a 428 rear chain and it doesn't last long with all of 20hp.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: crazypj on Apr 12, 2012, 13:56:31
Face cam on engine sprocket should prevent the worst shock loadings?
Strange how small bikes can beat the hell out of final drive, I found same thing with 175 'slopers'
Must be down to shock loadings, small front sprockets and not very good cush drive?
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: teazer on Apr 12, 2012, 15:16:13
Our 160s are 175 slopers and you are right about the cush drive which allows sprockets to wobble.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: andycafe on Apr 13, 2012, 09:07:56
Just noticed in your sig 400f cafe? did I miss this or was this done before you joined? care to share a couple of pics of the beast anyhow?
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: swan on Apr 13, 2012, 10:22:25
Andy, Sold these three CB400F's that I rebuilt:
(http://i170.photobucket.com/albums/u272/66triton/CB400f/IMG_1195.jpg)
(http://i170.photobucket.com/albums/u272/66triton/CB400f/_MG_0146-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/CB400f/IMG_5907.jpg)

Great bikes and a blast to ride.

I have one more CB400f in pieces; titled, frame and engine painted, new bearings, seals, gaskets, tires spokes etc just need to find/make the time to finish and sell it. I have been prepping the tank and side covers and would like to finish them by next week.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: andycafe on Apr 14, 2012, 03:38:47
Nice thanks for the pic's, I have seen pic's of the first 1 on the net before, V nice! you would be very familiar with the 400F after doing 3 and 1 on the way. Just a personal thing or just cause you the have been easy to get your hands on ? cheers Andy.
Title: Re: 1962 BSA DBD34 Gold Star restoration (making progress)
Post by: swan on Apr 15, 2012, 13:31:29
Andy, I cannot pass up $50-100 CB400f parts bikes when I find them.

I made some time this weekend to install the clutch and timing plate.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5146.jpg)
Original clutch and primary
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0253-Version2.jpg)
New clutch and primary

I did this in several stages and I started by installing the clutch and cush drive without the back primary cover so it is easier to align them with a straight edge, as suggested by Dave Kath on the Britbike.com forum.

I made a crude, but effective, tool to tighten the cush drive nut from a 2" washer, large nut and some 1/4" square stock. Four pieces of square stock were welded to the back of the washer to correspond with the four slots on the cush drive nut. I can now use a socket and a torque wrench to tighten the cush to the correct tolerance. The factory service and Haynes manuals suggest tightening the cush with a drift and hammer! I did not want to pound on my new crankshaft end. SRM offers a nice nut driven cush drive nut, but I chose to re-use the original.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0214-Version2.jpg)
Homemade service tool

Cush drive (without washer, replacement still on order)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0261-Version2.jpg)

Aligning clutch basket (chainwheel) with drive sprocket.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0263-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0262-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0259-Version2.jpg)
Shimming

I used three different straight edges and checked alignment with the gearbox pushed forward, in the middle and pulled all the back. The cush sprocket is .010" narrower (.2825") than the clutch basket sprocket (.2925") so I needed to account for the .005" difference on each side of the drive sprocket while shimming. I asked Pearson to throw in some shims with my clutch and I ended up shimming the drive sprocket out .027" and checked alignment again throughout the swing of the gearbox. All good.

Next, I fit and cut the primary chain to 70 links and left 1/2" chain play.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0225-Version2.jpg)
The closed end of the clip faces the direction of the chain travel.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0247-Version2.jpg)

With the shimming done, I installed the back of the primary cover and did it all over again.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0233-Version2.jpg)
felt washer
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0234-Version2.jpg)
Sliding oil seal plate
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0235-Version2.jpg)
bolts
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0236-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0237-Version2.jpg)
adapter and woodroof key
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0238-Version2.jpg)
clutch basket
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0241-Version2.jpg)
clutch nut and plates
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0242-Version2.jpg)
lifter, needle bearing plate, hardened washer and ball bearing
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0246-Version2.jpg)
installed the lift plate and tightened the springs all the way down

Next, I fitted a 1/4" ball bearing and the original clutch push rod through the gearbox mainshaft. Obviously it is too long, so I cut it and left  5/16" of the rod protruding on the timing side (9 5/8" overall length). I heated the end to cherry and quenched it oil to harden it and keep it from mushrooming. Many suggest (including SRM) to quench in water, I have read the arguments on the Britbike forum and elsewhere chose to quench in oil. The clutch adjuster was replaced, tightened and I adjusted the cable. The clutch works beautifully and does everything it should and nothing it should not.

This is a dry run and not the final installation. I am still pondering machining down my transmission sprocket and rear wheel sprocket to fit a modern drive chain so I will need to remove the clutch again to do so. Once the drive chain is installed, I will safety wire the inner primary cover bolts, torque the cush and clutch nuts to spec, use a bit of loctite and oil the clutch plates and chain. And I still need to make the time to polish the primary cover.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0284-Version2.jpg)
ball bearing
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0283.jpg)
original clutch push rod

The new timing plate was easily installed
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0275-Version2.jpg)
I added the oil release ball to the timing cover and and installed that too.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0279-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0280-Version2.jpg)

It is beginning to look like a motorcycle!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0269-Version2.jpg)

I also painted the inside of the ugly ass front fender, polished the stays and installed them. The exterior still looks like crap and I really want a new clubman fender and stays but first I need to restore the speedo, rebuild the magdyno, new wiring harness, battery, rear chain and guard and install new valves and guides. Speedo will go out for restoration this week and am waiting for new bearings for the mag and dynamo so they can be serviced as well. Getting closer!
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: ProSimex on Apr 15, 2012, 14:48:18
*fap fap fap*



Jokes aside, that is one damn beautiful bike.  Nice work.
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: two wheels of hell on Apr 15, 2012, 15:18:21
It's a fine line between sickness and genius. Swan you walk that line. Amazing.
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: swan on Apr 15, 2012, 18:45:17
Thanks guys! The fine line between hobby and obsession is passion. Two Wheels of Hell, we need updates and images on your Triton project!
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: crazypj on Apr 15, 2012, 22:50:33
That's a helluva nice pic  8)
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: andycafe on Apr 16, 2012, 05:32:59
Nice! GREAT work on the pictures to, we sometimes get caught up in the moment of doing, that when we are done we remember " Ahh thats right pic's " so again Nice!
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: swan on Apr 16, 2012, 18:23:30
Well, my original front fender lasted less than 36 hours on the bike... It was too ugly with the weld discolorations so I broke down and bought a new, made in the UK Clubman fender (mudguard), stays and hardware. I sell my original one once the new one arrives to offset the cost.

original fender/ mudguard
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0291-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0294-Version2.jpg)

Frustrating day trying to order new wiring harness from Tricor: their line is engaged or goes straight to voicemail. Also, Hawker is not offering the 12 volt dynamo kit on his website nor answering my e-mails. I do not like working hard to give someone my money. Sorry for the first-world whine, but I am cranky today...

Still trying to sort out my cylinder head and valve dilemma but some good news, my machinist will turn my drive train sprockets down so I can use a modern 520 chain. Dropping them off tomorrow.
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: Tim on Apr 16, 2012, 18:25:22
When you're ready to sell the fender let me know - I might be able to make use of it :)
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: swan on Apr 16, 2012, 18:40:13
Tim, you are first in line!
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: Tim on Apr 16, 2012, 19:11:18
Hope you won't be offended if it makes its way onto an XS650 bobber :D  If you'd rather it go onto a proper BSA restoration I'd understand of course.
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: swan on Apr 17, 2012, 07:00:41
Hope you won't be offended if it makes its way onto an XS650 bobber :D  If you'd rather it go onto a proper BSA restoration I'd understand of course.
Tim it is yours to do what you like. But if you are looking for a better fender I highly recommend using an alloy fender from Royal Enfield USA. They are super lightweight, undrilled and work with 19"wheels on nearly any motorcycle. I painted one black and installed it on my Triton with Converta style y brackets and had a friend polish one to a mirror finish for his CB750 cafe. They are $69 USD: http://nfieldgear.com/enfield-store/aftermarket-parts-accessories/body/alloy-mudguards.html
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: swan on Apr 17, 2012, 13:52:38
All right, I am in a much better mood this morning. I was able to order a quick detach wiring harness from Tricor (http://www.tri-corengland.com)  via e-mail and Paypal (thank you Andy!) and will post images and a review once it arrives. For now, here is a dramatic recreation (not the real thing, it is for a Triumph Trophy...)
(http://i170.photobucket.com/albums/u272/66triton/Triumphtrophyqdharness.jpg)

New magdyno bearings from Simply Bearings UK (http://simplybearings.co.uk) arrived yesterday afternoon and I removed the transmission (gearbox) and rear drum sprockets, bought a new 520 0-ring chain and dropped the sprockets off at the Engine Store of Winona to be lathe tuned to the correct width. I'll post images and specs once they are done on Friday.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0296-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0302-Version2.jpg)
Before

Good references for chains:
http://www.britbike.com/forums/ubbthreads.php?ubb=showflat&Number=261491&page=all
http://www.gizmology.net/sprockets.htm
http://victorylibrary.com/brit/chain-c.htm

That is it for now!
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: 03rangerxlt on Apr 18, 2012, 18:36:29
i absolutley love this thread!
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: swan on Apr 19, 2012, 12:59:39
Thanks 03rangerxlt!

Minor update, The Engine Store could not turn my sprockets with their equipment so I took them to River Valley Tool and Machine and they will have them done next week.

Another step towards completion: my NOS Smiths chronometric speedometer dial just arrived! Not a replica, but the real deal original from Smiths. Now I can send my speedometer in to Nisonger for a rebuild.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/chronometricNOS.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5473-Version2.jpg)
My original speedo
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: DreadRock on Apr 19, 2012, 15:27:19
Thats so cool that you can still find NOS parts for your bike swan ! cant wait to see that speedo all done and new !
Title: Re: 1962 BSA DBD34 Gold Star restoration (clutch and primary are done)
Post by: swan on Apr 22, 2012, 15:15:27
Thanks DreadRock!
Chain update:   River Valley Tool and Machine (http://rivervalleytoolandmachine.com/) finished turning my sprockets and I installed a 520 O-ring chain. $50 for machining and $65 for a Parts Unlimited chain. I opted not to buy the fancy DID x-ring chain, mostly because I do not like gold anodized metal which would look wrong on a period restoration, Dave K and Gordo from the Britbike.com forum were very helpful with this process, thanks guys! After doing the research, I believe it is worth the time and expense to upgrade to a modern chain. Here is what I did:
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0302-Version2-1.jpg)
Before
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0308-Version2.jpg)
After
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0321-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0306-Version2.jpg)
Used and new thinned sprocket

The sprockets were turned to .227" thickness and material removed from the outboard side. My machinist reported the transmission sprocket was extremely hard to cut (Emgo, made in Taiwan) and the rear sprocket was easier (Made in the UK). He matched the angle of the slight bevel at the top of the outboard teeth to the angle on the inboard side. The chain is riveted so I ground off one side of a pin, used my normal chain break tool, cut the chain to 98 links and used a clip type link to hold it together. The alignment is perfect and I had no problems with clearance at the gearbox or anywhere else.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0331-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0333-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0345.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0366-Version2.jpg)

I reinstalled the primary and clutch, adjusted the primary chain, tightened the gearbox and then adjusted the rear chain so there is the correct amount play. One step closer to a running bike. It was a beautiful weekend and I was outside riding and wrenching the Triton, hunting morel mushrooms but did not make the time to polish the outer primary cover. Soon...

Chain links:
http://www.britbike.com/forums/ubbthreads.php?ubb=showflat&Number=261491&page=all
http://www.gizmology.net/sprockets.htm
http://victorylibrary.com/brit/chain-c.htm
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: andycafe on Apr 23, 2012, 05:01:19
awesome!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: MotorbikeBruno on Apr 23, 2012, 12:50:52
I love every update  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: swan on Apr 24, 2012, 13:03:57
A micro update: My new main switch and Miller style horn and dip switch arrived from the Classic Bike Shop LTD in the UK, bought through ebay seller bsa111. The horn button broke off when I pressed it for there is only a small spot weld holding it in place.  I contacted the seller and they are shipping a replacement. Hopefully the replacement last longer than one push. Another good seller, thank you Kerrie !
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0421-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: swan on Apr 25, 2012, 13:26:21
I know I will catch flak for this, but I went with new OEM valves, guides and springs instead of modern manufacturers' valves and guides. My reasoning is this is only a temporary cylinder head and I was having trouble finding a local or regional machinist willing to do this, (they wanted my to be find the blanks, parts numbers etc) and shipping it out to be done was expensive. So, I went with a quick, easy and less expensive solution by using OEM parts and I dropped my cylinder head off at The Engine Store of Winona today to have the guides installed, seats cut and valves ground in. Next year, I want to have a new DBD cylinder head, modern valve train and an Amal MKII carb on my Goldie. ($2000, yikes)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0424-Version2.jpg)
News valves and guides, ancient cosmoline.

For now I am waiting for my wiring harness, rebuilt speedo and front fender to arrive, still need to rebuild the mag, buy a chainguard, sidestand and fuel lines . Also, I still need to decide if I am going with a 6 or 12 volt dynamo and then buy the correct battery, bulbs and horn. Getting closer to finished bike....
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: crazypj on Apr 25, 2012, 13:38:00
If your not going racing, the originals will probably be a better bet.
2K is a lot to shell out in one go, particularly as you have a head that looks like new
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: Worst cb650 ever on Apr 25, 2012, 13:38:37
I know I will catch flak for this, but I went with new OEM valves, guides and springs instead of modern manufacturers' valves and guides.

In my mostly uninformed opinion, what is wrong with new OEM parts?  They lasted for many many years on the bike originally, and they help keep a rare bike stock.  Seems perfectly logical to me especially if you're going to put on a hi-po head and carb in the future.  If you ever sell it, you could put the stock head back on and get extra value from it being full of NOS parts. 

For your own sanity, I would go with 12 volt electrics.  I've always stuck with 12 volts on British cars and have done better for doing so.  Does choosing 12 volts affect the originality and value of the bike any?

I've really enjoyed following this thread - thank you for taking the time to share the build with us.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: swan on Apr 25, 2012, 13:54:39
The BSA racing geeks suggest RD titanium springs, Kibblewhite valves, guides and other high end and expensive parts. Crazy PJ, you are right I am not going to race it but I plan to sell the head to pay for part of the big, beautiful and modern cast DBD head from Pearson or ABSAF next year. My head is smaller and offer less power than a proper DBD, but I will get by with this for now. 2K is a lot of money and I can buy, build and restore a used Honda CB for that kind of money....

The dynamo (generator) part of this bike's magdyno was original 6 volt. There are 12 volt conversion kits which allow for a higher watt bulbs in the tail and headlight. With all the deer and animals in my area, I need all the light I can get at night.

Glad people are still reading and enjoying this thread after 46 pages of my babble.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: crazypj on Apr 25, 2012, 14:02:06
Ah, I see.
I though you had the DBD head when you posted pictures of the fin repairs.
I would go 12V, less voltage losses through wiring (percentage wise, so more efficient)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: swan on Apr 25, 2012, 15:16:37
It turns out my 1962 Gold Star DBD34 came with an earlier and smaller DB head and Amal 389/004 carb. I am going to run it in this setup and see how she goes. I pick it Friday from my machine shop and can then finish the motor assembly. Here is consensus on my on the Britbike forum. http://www.britbike.com/forums/ubbthreads.php?ubb=showflat&Number=410414&page=1
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6775-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6772-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: crazypj on Apr 25, 2012, 16:58:42
I remember reading you had something of a Bitsa (It's BSA = Bits Stuck Anywhere, not, bloody sore arse)  ;D
 Thanks for the link, some very good advice there.
I would plug the holes , angle drill new ones at 65mm (plus re-face intake flange) then raise port roof and fit 1/2"~3/4" spacer
 I really don't know too much about DBD, way out of my price range.
I do have a couple of early 50's (plunger) A10's though

 BTW, I have a Pontiac 400.
You can get Comp Cams 'beehive springs with 1.700" fitted length
Around 135lbs seat pressure (I'll have to look up max lift pressure)
I personally think they are the greatest non-electrical engine improvement in the last 40+ yrs
 
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: Garage Rat on Apr 27, 2012, 09:57:37
I'm seeing lots about those springs all over Power Block TV.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: bumpthump on Apr 27, 2012, 15:06:36
I'm actually quite glad that the existing cylinder head is going to get a season's airing. You're about to experience two wonderful things.............you'll feel, smell and hear and touch how this bike ran when she was in her prime....(sans modification if you will), and then you'll get to feel the improvement that the DBD head brings to the proceedings. When you think about it, not too many people get to experience both of those things. Usually, a motheared bike is subjected to all manner of changes, and the person doing the work seldom gets to indulge in such an undiluted form of time travel.

I am madly envious of you and your Goldie..........but I'm not in the slightest bit jealous......if that makes sense. I am just enjoying the journey so much!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: swan on Apr 29, 2012, 15:58:57
Thanks BT! Crazypj, I went with stock springs.

Minor updates: Good news and bad news, four steps forward and one back... Step forward, my new proper front Clubman fender and stays arrived and are installed.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0444-Version2.jpg)
Much better

Step backward: my machinist installed the new exhaust valve guide but the new inlet valve guide is too small (it is standard diameter ) so I need to find or have made an oversized inlet guide (65-1595). The old guide is .008" larger in diameter than the NOS guide. My machinist suggested knurling it and using Loctite, but I said "no" and will find another solution. Looks like Phil Pearson has them on his website and I will give him a ring in the morning. If he does not, then??? Sources or ideas anyone? Have one turned for me? Where? If this was easy, everyone would be doing it.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0463-Version2.jpg)


Another step forward, broken down, cleaned and inspected the dynamo on a rainy Saturday. I'll put it back together and bench test it.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0453-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0459-Version2.jpg)

Set valve clearances and timed my welder's Honda CB750 while he welded up the standard slot on my extra kick start quadrant. We turned it on the lathe and I ran out of time and still need to mill a new slot 60 degrees clockwise so that the kick start arm is aligned in the one o'clock position and is out of the way of my rearsets. Will try to get in the shop tomorrow to finish the quadrant.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0435-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0333.jpg)
My Honda tuning worked well, so well that two squad cars chased him down on his way back to the shop after test driving it...oops...
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMAG0335.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: crazypj on Apr 29, 2012, 19:40:34
Making guides from phosphor bronze is no big deal, jut depends on max OD needed
 It's real simple when you already have one to take measurements from.
 Looks like you have access to a lathe so it should be real simple, you'll only need a reamer for finishing after fitting, then just get seat re-cut
 It's pretty cheap for stock 13" length,
 You can use better material than originals, high silicon bronze, manganese bronze, aluminium bronze, etc (or some of the latest bronze bearing alloys which are even tougher)
I've not used Beryllium bronze yet but intend to next time
 I've made BSA/Triumph guides in the past

Bronze information

http://www.metaltek.com/alloy-guide/non-ferrous/bearing-bronze/ (http://www.metaltek.com/alloy-guide/non-ferrous/bearing-bronze/)

http://www.farmerscopper.com/aluminum-bronze-954-c954-c95400.html (http://www.farmerscopper.com/aluminum-bronze-954-c954-c95400.html)

Prices

http://www.onlinemetals.com/merchant.cfm?pid=10535&step=4&showunits=inches&id=761&top_cat=0 (http://www.onlinemetals.com/merchant.cfm?pid=10535&step=4&showunits=inches&id=761&top_cat=0)

http://www.speedymetals.com/showproduct.aspx?productid=946

Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: swan on Apr 30, 2012, 10:32:55
Crazy PJ thanks again. I know just enough about a lathe to be dangerous, though I really want to restore an old one and learn how to use it.

Problem solved. Phil Pearson is going to spin up an +.008" oversized valve guide (65-1595) out of phosphorus bronze valve guide material for me. He did mention a DBD valve is larger on the OD and could also be turned down to the size I need.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: swan on May 08, 2012, 12:26:14
Sorry for dropping off but lots of work and travel lately and the next two weeks will be brutal at work so I have little to no time to work on my bike. Good news, I am renting a workspace near my house so I will no longer be working in a 6' by 12' cramped work space or have a motorcycle in my living room and parts on my kitchen table! June 1 move in!

Tricor sent my QD quick detach harness (RS123) but I thought I was going to get a complete wiring harness but it is only the quick detach plug and some wiring to the main switch. Hmmmm, looks like I will need to order the correct colored wires and male and female Lucas style connector and make a new harness myself.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0530-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0532-Version2.jpg)

The new valve guide should be here soon I can finish the motor. That is it for now...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: jonnyTHUNDERmaker on May 08, 2012, 12:40:48
Glad to see the progress I am pretty sure your build is an inspiration to EVERYONE on this site :)

HAHAHA I love that you snap a picture of your buddy and his run in with the law.  ;D Did he get a ticket?
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: swan on May 08, 2012, 13:02:47
Thanks jonnyThundermaker. Unfortunately, he did a ticket for no helmet (a requirement while riding with a permit) but did manage to charm his way out of not having a license plate (applied for), no proof of insurance and riding on the sidewalk/ riverwalk (there was no sign). He was lucky...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: swan on May 10, 2012, 18:20:21
The only bright spot during a very stressful and brutal work week was the arrival of my rebuilt speedometer.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0573-Version2.jpg)

It is absolutely beautiful! Nisonger did an excellent job, had a fast turnaround and guarantee their work. The restoration cost more than twice what I was originally quoted, but I gave them the go ahead to do it because for me this is an extremely important detail on my bike. I wanted it done right so it looks and functions properly. Chronometrics in my eyes are the most beautiful looking instrument I have ever seen on a motorcycle.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0571-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5473-Version2.jpg)

I also managed to get a little shop time last night to mill the new slot in my kickstart quadrant so the kickstarter is better aligned with my rearsets.

Back to work for me, no rest for the wicked....
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: andycafe on May 10, 2012, 20:04:58
That looks amazing! they really did a grat job! I would have loved them to give you a pic of the internals to compare against that pile of rust you had, I'm sure it's cool!   
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on May 11, 2012, 12:57:12
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0577-Version2.jpg)
Thank you Phil Pearson. New inlet valve guide going to my machinist this morning so I can finish the motor.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: scroggins5000 on May 11, 2012, 13:09:52
Wow, that speedo looks better than NOS. I wonder how many parts they were able to reuse.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Worst cb650 ever on May 11, 2012, 13:20:37
Yea, that speedo looks better than a Rolex!  I think the ridiculously high quality of the photographs has a lot to do with that though :)

Do you know what the valve guide is made of?  It doesn't look like a bronze alloy, but maybe that's the light/alloy?
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: crazypj on May 11, 2012, 14:36:36
The original is a bronze alloy, but, probably been sitting around for 40~50 yrs  ;)
The new one looks like it may be aluminumbronze?
 Do you have a professional light set up for macro photography?

 
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: scroggins5000 on May 11, 2012, 18:50:41
It looks like two white umbrellas pointed at a white backdrop.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: marsupialwoe on May 12, 2012, 00:40:08
So what's the line at 30mph mean?
Title: Re: 1962 BSA DBD34 Gold Star restoration (Clutch, primary and rear drive are done)
Post by: bwald on May 12, 2012, 01:10:44
Thanks jonnyThundermaker. Unfortunately, he did a ticket for no helmet (a requirement while riding with a permit) but did manage to charm his way out of not having a license plate (applied for), no proof of insurance and riding on the sidewalk/ riverwalk (there was no sign). He was lucky...

Now, if only he could pay off his bar tab.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: crazypj on May 12, 2012, 11:01:54
So what's the line at 30mph mean?

 There is a 30mph speed limit in Britain in built up area's (street lights/lamp posts are 100yds apart or less)
It just makes it easier to know when your going over the limit  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on May 12, 2012, 11:02:15
Ha, thanks all. Flash panels for the photographs.

Phil told me it was "modern" valve guide material and I do not know the alloy, but trust him to use the best.

The 30 mph line was to remind the rider of the newly imposed national speed limit in Britain, which of course they ignored. Also it indicates when the 6 volt dynamo system brings the head lamp up to full brightness.

Bwald,"Now, if only he could pay off his bar tab." I was wondering why I have not seen him at the bar lately...

My girlfriend flew in and surprised me last night so I will not be working on my bike this weekend for all the right reasons...



Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Greg-NWO on May 12, 2012, 11:36:20
Well at least you'll still get to go riding ;)

Looks great, the chrono restoration looks amazing.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: andycafe on May 12, 2012, 23:48:47
Well at least you'll still get to go riding ;)

photos ? LOL..................
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Nephelim on May 15, 2012, 18:56:44
This is a fantastic thread though I'm sorry to say I haven't read all 49 pages yet! Did it turn out to be the close ratio gear box? If it is guard it with your life. I had one on a 58 Triton back in the UK and bought the bike with out me or the seller knowing that. Later on I was offered 900GBP for the gear box alone- this was in about 2000/2001.

Just read page 9- sorry to hear you don't have the RRT2 after all.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Jewbacca on May 15, 2012, 19:36:19
That valve guide looks like it might be manganese bronze, also known as bearing bronze. It has a very light yellow color, but shines silver"ish" in pictures. It's hard as a wh*re's heart and wears unbelievably well. That speedo looks absolutely gorgeous too.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on May 16, 2012, 11:29:34
Thanks all. Andycafe, you do not get to see those photos.....

New valves, guides and springs are in. I can button up the motor this weekend!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0655-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0657-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: andycafe on May 17, 2012, 03:38:54
Thanks all. Andycafe, you do not get to see those photos.....

Haha well done, now back to your build......................
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: bumpthump on May 17, 2012, 18:25:06
The chrono looks fantastic. On the trip meter digits, is there a variation in colour from one digit to the next? If so, it looks absolutely brilliant. It's like a really fine piece of patina has been captured within the instrument. Very cool.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Marc on May 18, 2012, 11:12:00
I just read trough the complete project, really great job here! This is a perfect restoration, you should be real proud off this!!!

Keep up the goodwork!!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: andrew6v on May 30, 2012, 12:08:47
I can't wait to see a video of this thing firing up. I imagine you can't either haha
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on Jun 03, 2012, 10:45:23
Thanks all. Sorry dropping out for so long, but I have been extremely busy with work, play and life and have nothing major to update on the Goldie.  Yesterday I did however move in to a new workspace next to my house. I was working in a 8' x 6' room in my apartment with parts on my kitchen table and am now sharing 1200 sq ft of workspace with three friends (the Winona Riders). Clean, safe, great light, kitchen, bathroom, lots of storage, etc.  I can now drive my bikes inside next to my tools and work on them, rather than hauling tools up and down my stairs to work on the Triton outside my apartment. The Goldie is still going to stay inside my house until I am ready to start her up.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triton%20Cafe%20Racer/WRmovein.jpg)
(http://i170.photobucket.com/albums/u272/66triton/Winona%20Riders/WRcompositecopy.jpg)

Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: ProSimex on Jun 03, 2012, 11:32:39
awesome
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: jonnyTHUNDERmaker on Jun 03, 2012, 14:02:12
Excellent 8)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: andycafe on Jun 03, 2012, 17:06:49
Nice  :D
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: wfo guy on Jun 10, 2012, 22:28:17
I saw 2 of these restored at the Wichita Ks. vintage motorcycle club show today.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: 03rangerxlt on Jun 25, 2012, 22:50:47
any progress on this????  I miss the updates!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on Jun 26, 2012, 10:44:13
Sorry no updates. No time, no money....

My girlfriend is in town for a few more weeks so no time to work on my Goldie. My new workspace is awesome, the Triton is purring and I cannot wait to get back to work on the Goldie. I have decided to build my CB400F and sell it to pay some bills and finish the Goldie. Frame is painted, engine cases painted and heat treated, many new parts, bearings, seals, gaskets, tires, spokes, rims etc so it should go together quickly. I am burning a vacation day tomorrow so I can hole up in the shop and start putting it together.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: ProSimex on Jun 28, 2012, 15:36:01
Sell the GF and make with the updates,...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Hoosier Daddy on Jun 28, 2012, 21:35:14
She does know about the other women in your life.... right?
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: MotorbikeBruno on Jun 30, 2012, 12:54:23
Sell the GF and make with the updates,...


Hahaha.  I'm just glad this build is in my state so I can see it someday! 
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: asdfqwer426 on Jul 16, 2012, 13:51:43
awesome restoration. I'll be keeping an eye on this build, as well as keeping an eye out for a triton when i'm driving around town in Winona. I have on occasion seen one or two other guys on cafe's in Winona, but its not often. have you got a link to a thread, or pictures of your triton? I'd love to check that out.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: bwald on Jul 16, 2012, 16:32:47
asdf, is that your scrambler in your profile photo? I've never seen that around town. Here's a couple shots of Jon's Triton that I took a couple of months ago when he was doing some field repairs in my driveway: http://www.flickr.com/photos/bwald07/sets/72157629557267972/

Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on Jul 16, 2012, 17:05:27
Thanks guys, GF is here until Aug 1 so NO progress on the Goldie, sorry. I have however eeked a little to time start building a 1975 CB400F cafe I have had in boxes for two years. I want to flip this next month so I can finish dumping money into the BSA and get her out on the road. Did I mention I bought a nice 1975 Kawasaki KZ400 S last night for $120? Winter project.

asdfqwer426, We should ride sometime and/or meet up at Ed's No Name Bar for a pint and bike talk with myself and the other Winona Riders. What do you ride?
My Triton:
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triton%20Cafe%20Racer/IMG_0772.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: asdfqwer426 on Jul 17, 2012, 12:42:13
asdf, is that your scrambler in your profile photo? I've never seen that around town. Here's a couple shots of Jon's Triton that I took a couple of months ago when he was doing some field repairs in my driveway: http://www.flickr.com/photos/bwald07/sets/72157629557267972/

yeah, although i just got the scrambler pipes on last week. i only put it together 4 months ago, so it hasn't been driving around town all that long.

its a 75 honda cb500t (basically just a stroked out 450) but it has a lot of 450 parts, tank, pipes. sometime in the next couple weeks I should be getting my front drum brake on in place of my disk brake.

I would definitely be up for a pint at eds and meeting you guys and your bikes. just shoot me an idea of when you'd want to.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: bwald on Jul 17, 2012, 14:10:40
Ah, I assumed it was a CL (tiny profile photo, sort of hard to tell). There's about a half dozen of us with vintage, custom bikes (the "Winona Riders") and it's not uncommon to find at least one of us at Ed's. It probably doesn't hurt that two of us tend bar there as well. We do have a private shop we just started downtown last month, so admittedly we're not spending quite as much time at the bar now. Either Andrew (another rider) or myself work there from Thursdays through Sunday nights and are always more than happy to talk bikes, as long as it's not too busy. I'll be in around 7:30 tonight for homebrew club, but I have no idea what Swan's schedule looks like today.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: asdfqwer426 on Jul 17, 2012, 15:32:18
ah, that might explain the custom honda i've seen parked in front of eds quite often. 2 cylinder I think, definitely not stock rear end.

regretfully i work tonight 6-1, deliver for dominos. but tomorrow night I'm off at nine, i'll swing by then and look for some of you guys.

good eye on the CL. my first bike i got 4 years ago was a cl350 I restored stock, so I started and spend most of my time over on hondatwins. just now starting to branch out to other sites. I look forward to meeting you guys and checking out all the different bikes. if you're curious, a link to my build.
http://www.hondatwins.net/forum/viewtopic.php?f=5&t=16546
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on Jul 17, 2012, 16:45:29
 Bwald and Andrew do not work on Wednesdays and I will not be out on Wednesday so perhaps another night...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: bwald on Jul 17, 2012, 17:29:15
That was probably Andrew's Rebel that he recently sold. White seat? I'm really loving those pipes, man. Anyway, to avoid hijacking Jon's thread, I'll move this to PM.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: asdfqwer426 on Jul 17, 2012, 17:32:43
That was probably Andrew's Rebel that he recently sold. White seat? I'm really loving those pipes, man. Anyway, to avoid hijacking Jon's thread, I'll move this to PM.

sounds like the one, i thought it was a rebel but i dont know newer bikes that well.

I was thinking the same thing about the hijacking.

keep up the great work swan, hopefully I'll be able to see the BSA in person someday soon.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: 03rangerxlt on Oct 04, 2012, 10:25:56
I really miss this project :(
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Hoosier Daddy on Oct 04, 2012, 12:48:19
GF visits have a way of slowing down a build thread. ;)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Mydlyfkryzis on Oct 04, 2012, 13:18:58
Just marry her, and the build will get even slower ;)

Seems like people I meet with multiple bikes, always are divorced or not married. Seems like motorcycles and marriage are not quite compatible...LOL

Hopefully, MY wife hasn't ask me to chose her or the motorcycle, cause I would really miss her... :D
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Kanticoy on Oct 04, 2012, 13:37:42
Not all...my wife doesn't care as long as they aren't in her house (that has happened).



Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on Oct 04, 2012, 15:07:28
Sorry all, no time, no money...  Tomorrow marks two years I have had this bike and I am frustratingly close to finishing, but I simply have not had the time or the final $1500 I need to finish her right.  My CB400f runs, is nearly complete and will go up for auction as soon as I can in order to finish paying for the final expenses for my Goldie. GF is out of state and does not care what I do, understands my passion for bikes and that they were with me before she came along, but she does not like a bike in my living room. Lately, I wake up, stare my Goldie and leave the house before 7 am, come home for lunch sometimes, stare at my Goldie, get home after 11 pm stare at my Goldie.... Barely had time to ride the Triton with work, prepping car, house and garden for winter and 60-100 hour work weeks lately. Soon...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Maritime on Oct 04, 2012, 16:03:49
Geesh that's the lamest excuse ever...................Just kidding ;D we will all wait for the finish because this build is one of the cleanest restorations I have  ever seen documented, just don't go and burn yourself out completely before you get the chance to finish it and go for a ride on it.  Oh and how much do you want to get for the 400F because I want one and if I have funds when you go to sell I will buy it knowing it is likely put together better than I could do myself.

Cheers,

Maritime
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on Oct 04, 2012, 16:57:35
It is a tough time of year to sell bikes so I expect less than I would in the spring. I would like to see $3500-4000 when it is complete, synched, shook down and running perfect It is essentially new with only one real flaw-the front fender, It is a bit beat up and I am not in the mood to spend money on a replacement. I may e-bay the CB400F but dread the fees, hassle etc of selling a bike on e-bay.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Maritime on Oct 05, 2012, 11:41:35
Well post up in for sale, I may no thave hte dough when you finish, but if I do I would be interested, or know someone who might be.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Green199 on Oct 05, 2012, 13:57:38
I cannot believe I have only just found this thread.

Just spent the last few hours reading through it! Excellent job and attention to details...gonna be a real looker!

...and those Phil Pearson parts....too pretty.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on Oct 07, 2012, 14:54:04
Thanks Maritime, I will let you know. Thanks Green199, it has been a long trip. I hate to cover up the Pearson goodies but think of the peace of mind a new crank and clutch will offer when I really give her the whip.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: bumpthump on Oct 11, 2012, 12:41:00
It's funny.....I am much older these days, so you'd reckon I'd be really impatient to see this bike finished....but I'm not. We all know it's going to happen, and it'll be worth the wait.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: two wheels of hell on Oct 11, 2012, 13:17:00
I agree 100% with bumpthump. I will greatly miss this thread when the bike is finished. We all want our bikes to be finished. I am hoping to start work on mine again in the next week. I have no funds to complete. I don't really have the time. but I look outside and see the cold setting in and it's time to work on it again. Let's face it over the course of the next 5 months it will get done. Probably when snow is still on the ground or it's pissing rain. Stupid to panic and rush now anyway.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Mydlyfkryzis on Oct 11, 2012, 18:56:01
... I have no funds to complete. ...

the Ancient Hawaiian Ailment ... LaKaMoni ...

I am in the same place....

There is something very primal about the old BSA singles, I really like them, and I am enjoying this build coming together....It is funny how we look forward to the build finishing, and at the same time, will miss the whole build process when it is done....
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: rundown on Nov 03, 2012, 12:59:23
I can't believe I just found this yesterday; read until nearly mid-night and then up this AM to finish, and no finish.  Someone, please buy the Honda so Swan can finish this amazing build.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on Nov 05, 2012, 11:08:33
Thanks rundown, mydlyfkryzis and the rest of you. Trust me, I am more anxious than anyone to see this bike finished, but it must be done right with no corners cut. Time and money...

The CB400F is done, I am shaking her down and she runs extremely well. I am still tweeking the carbs to make the idle circuit a bit better (pods are notoriously difficult to tune on these small inline fours). It has been cold riding and frost on the windows every morning. I want to sell her ASAP but may need to wait until spring to sell her so I can get a much better price.

Anyways, I plan to bring the Goldie over to the Winona Riders' workshop soon so I can slowly do what I can (wiring, compression and leakdown tests, etc) As always, stay tuned....
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: davidc on Nov 19, 2012, 05:23:12
Swan,
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: davidc on Nov 19, 2012, 05:24:14
Swan, I've read that the GS must have a timed breather - My ZB32 (1950) engine does not have a timed breather or a tacho drive or a slotted nut on the mag pinion. It looks like it never had any of this, or.. a PO has removed the original timing cover and all the breather gubbins that go with it.
Or....
It never had one and the breather pipe on the bottom of the timing housing is all that's needed.
I don't seem to have any breather issues- but I've only finished the bike a few tankfuls of petrol ago.
Do I need to look at a timed breather and all the mods mentioned or is that for a later model?
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: swan on Jan 20, 2013, 00:30:12
Davidc, sorry for the lengthly delay in my response but the short answer is to hit up the Britbike.com forum for they know more about earlier Goldies than I do.

I want to finish this bike more than anything, the days are getting longer and spring will be here in a few months. Once I file my tax return and get my refund I shall have the money to complete this bike.

Hmmmmmm.... I spent the morning reading Britbike.com forum member Magnetoman's lengthy discourse on magnetos and did my own research on what my options are for rebuild, electronic ignition and/or new replacement. The afternoon was spent working on the Goldie's magdyno and a Lucas K2FC magneto for my Triton when I go to a pre-unit motor. The good news is both magnetos are functionally normally. This frozen hunk of anodized alloy, 40 year old dried grease and insect infected magdyno is now working.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5426-Version2-1.jpg)

It was vapor blasted, cleaned, hardware cadmium plated, inspected and re-assembled and both the magneto and dynamo portions work properly.  But for how long? It produces a nice even and consistent spark. The weakness in these devices is the condenser /capacitor which tends to fail once the unit heats up. I rigged up a qualitative bench test and ran the magdyno for 20 minutes. The spark remained consistent the through the entire test.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3268.jpg)

This is where the hmmmm... comes in. The cheap and impatient portion of my mind which wants to ride this bike ASAP says put it in and start riding (and save $400-500 on a rebuild). The rational and logical side of my mind says it will fail and I need to at minimum have it professional tested and preferably rebuilt with a new condenser. If I don't replace the condenser there is strong chance it will fail after riding it for awhile and then my bike will be down for several weeks right at the beginning of riding season (false economy). The challenge is finding the right person to restore it correctly to factory specifications. To start, there is small motor shop in town with a motorcycle friendly old timer working there. I will ask him if he has test equipment and at minimum remagnetize my magnetos. There are many old magneto tractor and tractor collectors in my area so if he cannot do it, he will know someone who can.

My neighbor and machinist Skip is an old motorcycle mechanic and all around great guy lent me a Lucas NC1 single competition magneto. It appears to be the same girl as my magdyno's magneto but in a different dress and different ignition plate. He stopped in tonight to pick up my Honda CB750 cylinder head he is machining for me and laughed. "You want to spend how much to rebuild a working magneto? Ride it!" Thanks Skip.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3280.jpg)

Hmmmmm.. more variables to consider. I can now get my bike running but still need a chain guard, side stand, horn, battery and fuel line ($700 +). Seeing spark tonight means there is light at the end of this long, long dark tunnel. My local pub has a firken of fresh hopped pale ale on cask tonight. Gonna walk down, grab a pint and suss this out. Stay tuned...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: two wheels of hell on Jan 20, 2013, 02:24:49
You want to spend how much on a rebuilding a working Mag? I have to say Skip is the voice of reason here. Cross that bridge if it needs to be crossed. Just my 2 cents and has no cash value.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Hoosier Daddy on Jan 20, 2013, 05:21:41
Quote
I rigged up a qualitative bench test and ran the magdyno for 20 minutes. The
spark remained consistent the through the entire test.

I think you answered your own question.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: unclerob on Jan 20, 2013, 08:11:44
Hi Swan, just wondered if you knew about 'easycaps'? If not have a look here...
http://www.brightsparkmagnetos.com/index.htm
Great work btw, cheers, Rob
Title: Re: 1962 BSA DBD34 Gold Star restoration (Speedometer is restored)
Post by: Worst cb650 ever on Jan 20, 2013, 12:26:45
Those "easycaps" guys look to be using high quality modern solid state surface mount capacitors in their replacement parts.  Nice!

As far as replacing the condenser, a question that should be asked is the type of capacitor (condenser) that was originally fitted.  There are two main types of capacitors (and about a million sub types), one filled with liquid (electrolyte) and one not.  The electrolytic capacitors can fail over time as the electrolyte drys out / leaks out / breaks down.  If you're familiar with the capacitor plague (http://en.wikipedia.org/wiki/Capacitor_plague (http://en.wikipedia.org/wiki/Capacitor_plague)), you'll understand the limitations of electrolytic capacitors.  If it is a dry capacitor, then failure is somewhat more limited, mostly due to insulator breakdown because of age.  Still possible and probably increasingly likely in an old bike, but less likely than with an electrolytic capacitor.

It's hard to test capacitors while they are installed in a circuit, and I imagine getting multimeter probes into the heart of darkness would be about impossible, right? 

Unless the unit is about impossible to remove from the finished bike I'd run it until (if ever) the magdyno failed, and then worry about this then.  Other than peace of mind and the annoyance of having to walk home or call for a pickup on the odd chance the unit should fail, I don't see a huge return on overhauling the unit. 
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: swan on Jan 20, 2013, 13:20:53

I think you answered your own question.

HD, Yes and no.... The main problem with older Lucas magnetos is the failure of the condenser, particularly after they become hot. I plan to retest while warming the unit up to 120 F, running it longer and see if it still functions well.

Unclerob, welcome aboard DTT and thanks for chiming in. I am familiar with easycaps and they are one of many options I am considering. On my mag I would need to remove the existing  condenser by performing a "condensectomy".  Another option would be to run my original set up, buy a second armature, fit it with an easycap and have it ready if/when my original condenser fails.

Worst cb650 ever, magnetos and condensers are still mysterious alchemy to me. It is my understanding it is heat and age which breaks down the original material (wax paper) found n the OEM Lucas condensers.  It is buried under wound copper and sealant in the armature so there is no easy way to access it for testing. Magnetoman on the Britbike.com forum (A university physics professor obsessed with magneto theory and function) has a lengthy and informative discourse on magnetos and condenser design, material and failure. I can't seem to grab the link but it is under BritBike Forum » Forums » Projects started by BritBike Forum Members » Members Bike Projects » Restoring a Rotating Armature Magneto.

One of the many things I like about restoring old motorcycles is learning new things and problem solving. BSA and Lucas are great classrooms.
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: Worst cb650 ever on Jan 20, 2013, 14:01:49
Worst cb650 ever, magnetos and condensers are still mysterious alchemy to me. It is my understanding it is heat and age which breaks down the original material (wax paper) found n the OEM Lucas condensers.  It is buried under wound copper and sealant in the armature so there is no easy way to access it for testing. Magnetoman on the Britbike.com forum (A university physics professor obsessed with magneto theory and function) has a lengthy and informative discourse on magnetos and condenser design, material and failure. I can't seem to grab the link but it is under BritBike Forum » Forums » Projects started by BritBike Forum Members » Members Bike Projects » Restoring a Rotating Armature Magneto.

A capacitor / condenser is in its most basic form two metal plates separated by an insulator; when a battery or other power source is connected to the plates it causes a buildup of electrons on one plate and a lack of electrons on the other plate.  The closer the two plates are to each other (while still being insulated from each other) the higher the rated capacitance (measured in Farads)

Problems happen when the insulator breaks down - the electrons can then flow between the two plates and equalize the charge, which ruins the capacitor's ability to store a charge.  Wax paper seems like it would be pretty vulnerable to this breakdown, but then again, your unit works, at least at room temperature. 

The capacitor acts like a kind of electron "bucket"; it can store a charge and release that charge to fill in a dip in supplied power (for example, smoothing out the flow of power from an unreliable power source).  It can also absorb a charge to prevent sparking (such as in how it is used in a points type ignition system).  It is also used along with a diode or network of diodes to smooth out the conversion of AC power to DC power. 

I could go on and on about this until everyone died of boredom, but if you have any questions about capacitor or other electronic theory, let me know.  I was an EE in a past life and still do a lot of practical and theoretical electronics work. 
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: crazypj on Jan 20, 2013, 18:13:46
Great link for the caps, I'll eventually be doing my 1952 A10, they have a lot of interesing stuff
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: Rich Ard on Jan 20, 2013, 18:36:05
Fantastic work swan, and great for the rest of us to be able to follow along. Thanks kindly!
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: davidc on Jan 21, 2013, 06:45:56
Swan, IF the magneto is working at the present, why don't you buy a condensor/points mod kit off ebay for $15 and keep it in your tool kit for if and when it breaks down.
Ride the bike in original magneto form until then.
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: swan on Jan 21, 2013, 10:24:24
Thanks all. Quick update, I heated my magnetos last night to 130 degrees F for 30 minutes and bench tested them for 20 minutes and they ran fine, with fat sparks at their plugs and a tiny spark at the ignition points. Hmmmmm.... What to do? The next step is to have it tested locally if I can and have it remagnetized. Both mags seem to function normally, but a test will tell me if they wire produce spark in a compressed cylinder.

Davidc, the Easyspark is not something installed on the side of the road. The magneto needs to be completely disassembled, old condenser by passed or removed, wires soldered etc.

Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: davidc on Jan 21, 2013, 10:33:43
Hello Swan, you are right if the condenser shorts and fails- then it's not a road side repair, but if it fails open, then you can connect onto the wire at the points.
But - given the high standard of your restoration to date - I would go with the original magneto.
I bought an over hauled unit from the net 3 years ago- and it still works fine- I don't really drive it that hard- but I have had a couple of 120mile days all over the hills- so a lot of on and off the throttle.
A magneto rarely fails without some warning- so if you are on a trip- it will probably give a few hints before stranding you.
It's not too big a job to fit a new one -once  you're near your tools and puller
Good luck with the first start-up 
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: Bert Jan on Jan 21, 2013, 13:33:23
i've been lurking this topic since you got it in that truck.. and all i want to say is you're putting such an enormous effort into her, that it would be kind of stupid to tie ends and go riding. I know the process of building a bike has some points where you think it'll never get finished, but it will. Hang on! It will be done and you'll be happy with it and even happier if you fix all problems the right way ;)
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: teazer on Jan 22, 2013, 02:10:55
I loved the K2F on my T100 and hated the mag-dyno on my DB32 GS.  it kept vibrating loose with that silly strap retention arrangement
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: crazypj on Jan 22, 2013, 12:53:19
I loved the K2F on my T100 and hated the mag-dyno on my DB32 GS.  it kept vibrating loose with that silly strap retention arrangement

 I found a lot of them wear the platform they sit on and need a shim made so it can be fully tightened down (can you still buy the shims?
Of course, I haven't done one for at least 25 yrs although I do remember it was a 350 Ariel which has chain drive so you don't need to worry about gear mesh  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: teazer on Jan 22, 2013, 13:09:06
Good point.  I had forgotten about shims to get the correct gear tooth depth of engagement.  I'd be surprised if they were not still available and it's always possible to machine the seating face flat.

The big problems I recall on K2F were broken commutators (Slip ring), demagnetization and timing on the cams. Face cam on a single is easy to time, but on a K2F I spent hours fine grinding the ring cam to get both sides to fire at exactly the same time.  It used to be reasonably easy to get them magnetized but I doubt there are as many people with magetizers or Gowlers any more.

In a way it's a shame that the magdyno is operational.  If it was DOA it wouldn't be hard to convert to an ALTON 12v system and slip an electronic trigger inside the mag and hide a coil somewhere.
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: joea on Jan 28, 2013, 03:46:05
 if the straps are tight they stay in place with no fretting, you usually find worn parts when you find loose straps,and you can make up some shims with s/s if needed..... hard to not run a mag/dnyo if you want lights as they actually work fine if in good condition, but if you need killer lights for night riding they are not too bright! if you install a new modern capacitor and a good rewound armature it should last another fifty years. there are no commutators in a magneto (so no growlers needed ) and slip rings do not break by themselves they usually are grooved because people install brushes that are too hard of a material which then cause them to wear into the slip ring and the armatures ground point. even though most magnets(alnico) are not 100 percent saturated they still work for most machines providing a good spark, it is normally the old original foil and wax capacitors or secondary windings that fail. there are still plenty of magneto magnetizers around since many mags are still in use in general aviation plus the guys working on brit bikes . i agree with teazer on the cam ring vs the cam plate...sometimes difficult to get symmetrical timing with the cam ring even after using all the tricks in the book!  ..bad thing about most but not all electronic igntions is you need a fully charged battery to work. i have a self generating electronic mag/dyno on my absaf engine that does not need a battery but can not remember the name at the moment.......
joe   
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: joea on Jan 28, 2013, 11:56:44
on the condensor swan i have a capacitor tester and i heat the cap as i test it and all original type lucas even nos fail when they become hot. it is a good idea to replace the armature and the capacitor as a set for a few reasons....best capaictor is a kizer capacitor the same fellow who produces the podtronics,doug wood and i have not had a failure yet some of the small caps are ok for a short while but then fail...if you want i have them for both mag/dyno and n1 which would be the correct race mag for the g/s ..
 hope to see you on the road this year,stop in when you come up to the cities..
joe
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: teazer on Jan 28, 2013, 12:17:12
That's what happens when you make a reply short, details get mixed up. Growler and commutator for the Dynamo part of the magdyno.  Slip rings are the appropriate term for the K2F and they break when people strip them and are not careful or they forget those pesky screws - what do they call them - Grounding screws? Slip rings on a K2F do tend to end up with grooves in them as the brushes leave the brass strip and dig into the phenolic resin or bakalite ring.   

The problem I found on my late model DB32GS IIRC (it was in 73 or 74...) was that the magdyno base and the platform had fretted in the past and were no longer dead flat or smooth so it tended to move a little. You are righ Joe that the strap has to be tight. What a thirties (twenties ?) way of retaining parts.

On My T100 I removed the dynamo and fitted an alternator inside a set of alternator primary cases. I also fitted a one piece crank and later model clutch but who's counting. :-)

I should see if I can dig up any pics of those old bikes.
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: Hoosier Daddy on Jan 28, 2013, 13:18:19
Quote
I doubt there are as many people with magetizers or Gowlers any more.

Ahhh the memories this place stirs up.... Back when I went to school we were tought how with a working unit on the bench, but rarely utilized one out in the field. Rebuilt plenty of Starters or Alternatorsv in my day... Then within the next decade, you didn't rebuild anymore, just replaced them.  ::)
 
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: crazypj on Jan 28, 2013, 14:38:56
Mexicans still know how to recondition stuff, most auto shops 'reman' says 'Made in Mexico'  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: joea on Jan 28, 2013, 20:45:13
yea people try to remove the armature before removing the safety(grounding) screws or brushes and break the slip ring....i repair them by machining the broken side off and leaving a step and then installing a round piece of micarta cut with a hole saw and held on by pressed fit and epoxy. new ones retail for 65 plus dollars so i repair them when i have time and parts.......if was not for people like most of us nothing would be repaired anymore in the throw away society we live in today.
   
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: swan on Jan 28, 2013, 21:18:40
More light at the end of the tunnel... Just filed my taxes and my refund will cover the remain expenses to finish restoring this beast, including the magneto restoration. Hurry up spring! Now, I need to get the bike out of my living room (I know, I know...), down a flight of stairs and over to my shop soon.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0269-Version2.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: Ringo on Jan 28, 2013, 21:39:13
That turned out very nice.  Looks as nice in the living room as it would out on the streets!
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: 03rangerxlt on Jan 28, 2013, 22:13:29
yay! i have been depressed without updates!  ;)
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: MotorbikeBruno on Jan 29, 2013, 00:53:24
yay! i have been depressed without updates!  ;)

me too  ;)
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: jeff4uk on Jan 29, 2013, 04:45:15
Swan mate ,You started this Dec 17 2010 !!!!!!! thats wow, the bike is as new if not better, when spring comes ride this mother man ride and enjoy every bloody min;it you have (and dont start another one for at least a year) Ride,ride,ride,ride,ride,ride,ride and then RIDE, life is to short
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: joea on Jan 29, 2013, 14:47:33
swan.....if you can send just the armature i can install a new kizer cap(two .1mfd caps for m01) for you or i'll sell you them so you can do it yourself....
 joe
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: Peter1 on Jan 31, 2013, 10:48:39
Excellent dialogue - love it.
I am purchasing a 58 DBD 34. It has stamped on the top of the gearbox SC T and I wonder if you know what this is?
Sorry to be a nuisance. Peter1
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: swan on Jan 31, 2013, 11:37:26
Peter 1, thank you. We need pictures of your Goldie! Start a thread on this forum or on Britbike.com.  The SC T is a scrambles gearbox. Search on Brikebike for lots of information on your 58 DBD34 and gearbox.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/chart1-1.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: teazer on Jan 31, 2013, 21:15:08
Swan,  That scan is a little hard to read, would you care to spell out what RR and T2 and SC or TRI mean so that OPs reading this can get some idea of the awesome nature of the Goldie :-)
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: crazypj on Jan 31, 2013, 22:03:55
  Teazer, you know RRT2 is a close ratio set for 'racing'
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: teazer on Jan 31, 2013, 22:10:19
I know that but it's not my thread.  I can't remember what box was in my Db32GS but I think it was STD but with a triumph clutch.  So long ago, and so few brain cells survived to tell the story.
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: crazypj on Jan 31, 2013, 22:12:38
Yeah, it won't mean anything to anyone not riding or restoring a BSA though.
 Don't think my A10 would survive close ratio ('52 plunger Golden Flash)
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: teazer on Feb 01, 2013, 23:23:39
Watched a bolt up flash blow a rod through the cases on the A74 many decades ago.  Big cloud of smoke and debris everywhere - just before the clutch on my T100 came loose and sheared the key.
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: crazypj on Feb 01, 2013, 23:47:09
Hi Swan, sorry for the temporary 'threadjack'
Yep, they do that, when they don't lift cylinder off case (thin flange round barrel)
 By 'bolt up' I guess you mean the semi-unit construction that Harley 'invented' a few years ago? (instead of conventional BSA separate box like the DBD34)
One advantage though, it runs a duplex primary chain as things stay lined


Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: swan on Feb 07, 2013, 22:11:35
Teazer, here is the BSA gearbox chart: http://bsa-a10.hailwood.com/images/gearbox/chart1.jpg

I packed up and shipped out my magdyno to be rewound with a new condenser, remagnetized, tested etc. I had been e-mailing with Joe V's Cycle and Doug Wood and both come well recommended, but I went with Joe a. because he is two hours away and has the skills, experience and equipment do it right. Additionally he rides a Gold Star and is building a Triton, so he has good taste in bikes (like me...).

My tax returns are in and I now have the money to complete the project and have a little left over so I am considering a vintage 10" Atlas lathe or a Schwinn Black Phantom as my next restoration project. Looking at the Schwinn in the morning, the price is too good to pass up.

I spent several hours last weekend going through each plate in my parts book and noting every part I need to complete my bike. Ordering a chain guard, misc. hardware, side stand, fuel lines and horn tonight and tomorrow.

After much internal debate, I decided to stay with the original 6 volt system as a baseline, with original dynamo, regulator and a new 6v battery and 6v horn. I can easily upgrade to 12 v in the future if I really think it is necessary. I am ordering a new braided wiring harness and extra connectors and will modify it to fit my original Lucas QD plug.

Thanks all for bearing with me and this project for such a long time. The days are getting longer, the sun is still up when I leave work, spring will be here soon and I will finally be able to ride this bike. Stay tuned...
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: edhaeuser on Feb 07, 2013, 22:26:34
Good to hear you have the cash to finish it up.  Even though I was at the Winona Riders shop last week, I have yet to see the Goldie.  Does it really exist? :-)  See you around.

Ed
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: swan on Feb 07, 2013, 22:45:18
Yup, I am "that guy" with a motorcycle in his living room. I am television free for two years now, but spend a lot of time staring at my bike...
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: dcmspikes on Feb 08, 2013, 11:52:46
thats ok im "that guy"  with a bike in the living room and one that isnt runnig int he front window of the kitchen.    atleast yours is amazing.    cant wait to see it finished.
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: swan on Feb 14, 2013, 23:57:19
Thanks, dcmspikes. Quick update, the final parts are starting to arrive and despite feeling ill with sinus and respiratory crud, I dragged my sick ass over to the shop to do some work.

First, my harness and connectors arrived from British Wiring. First time buying from them and they are great! Good communication, fast shipping and I now have a nice cloth wound harness with tail light section and dynamo wires included. I know my 1962 BSA GS should have a plastic wrapped harness, but I like the look of the older cloth bound harness. I'll take the heat from the "correct part police".
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3428_zpsbd8057ee.jpg)

Using my old harness as a guide, I converted a standard BSA harness to the Quick Detach style using my QD set up from Tricor UK.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0532-Version2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3401_zps0b675df2.jpg)

There are some minor differences between the two harnesses and I think I finally have it sorted. Once I test it on the bike, I will post a complete diagram. I could not find a Gold Star wiring diagram, but I found a Rocket Gold Star diagram that was close to my original loom.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/RocketGoldStar_zps6419c472.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3408_zps454738c3.jpg)

I had a difficult time considering a $150 replica Lucas Altette horn, but found a very nice 6v Italian made replica from Domiracer for $56. I looks really nice and weighs over 2 pounds. Have not tested it yet because I still need to find a 6 volt battery.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3402_zps8663329b.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3404_zps669eeac6.jpg)

I have a nice pile of misc hardware and am waiting on my sidestand and chainguard from Burton Bike Bits in the UK. I have a busy week coming up and will be offline for a while. I need to get the bike out of my house and over to the shop to fit the final parts, add fluids, await my restored magdyno and get ready to fire her up.

Soon...
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: MotorbikeBruno on Feb 15, 2013, 11:26:40
I love the pictures in this thread. So clean.  This bike is going to be beautiful when done.
Title: Re: 1962 BSA DBD34 Gold Star restoration (We have ignition...)
Post by: swan on Feb 17, 2013, 13:35:51
Good news, my bike is out of my house and finally at the Winona Riders' workshop! Three friends and I took the bike out of my apartment, across my snow covered rooftop garden, carried it down a flight of stairs and I rolled it down the street to our workshop. The seat, mud guards, tank, cylinder head, clocks and head light were removed to make it lighter and to protect those items from damage. It was much easier than I feared and I rewarded the guys with a growler of kind beer and pizza. I spent that evening putting all the pieces back on and cleaning her up.

Despite still feeling ill, I spend more than 10 hours at the shop yesterday. My new chainguard and side stand arrived from Burton Bike Bits. The triple chromed, UK made chainguard was USD $175 and side stand was USD $158 with delivery. Expensive, but very nice components.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3439-Version2_zps8e1adb3d.jpg)

I assembled my cylinder head and rocker boxes, measured the gap between the head and cylinder in 12 different places. My new cylinder gasket is just over .033" and the largest gap was just over .032" so I am within recommended tolerance (gasket is 001 to .002" larger than the gap).
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3455-Version2_zpse8f2cfc2.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3466-Version2_zpsd187d0bb.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3468-Version2_zps26b9c2f8.jpg)

I fitted the head, cylinder studs, rocker boxes and pushrods on to the cylinder. It took me quite a while to get this correct and I must say I am not a fan of the inverted cylinder bolts on this motor. It was very tedious, time consuming and difficult to reach even with the magdyno off the motor. Time for me to bend up a wrench which all Goldie owners are familiar with. Everything is buttoned down to spec but I still need to set the valve clearances before turning over the motor.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3463-Version2_zpsc903fa96.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3474-Version2_zpseea94d09.jpg)

I also roughed in the wiring harness, headlight switch panel, wired and tested the horn (sounds cool!). My battery will be here in a few days so I can finish the electrical.  The exhaust pipe and silencer were installed and the other finals parts will be here this week (misc hardware, compression release cable and gas line kit). I am so happy and we are on the home stretch and time to end this obnoxiously long build thread, hurry up spring!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3484-Version2_zps72d7f7dc.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: MotorbikeBruno on Feb 17, 2013, 15:05:57
Wow. Just wow. Love this thing.  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: ProSimex on Feb 17, 2013, 15:32:17
huzzah!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: stroker crazy on Feb 17, 2013, 19:48:17
So close!

Crazy
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Hoosier Daddy on Feb 18, 2013, 08:45:54
She is looking stellar... Congrats!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Worst cb650 ever on Feb 18, 2013, 11:05:05
Wow, yea, that is one beautiful bike!  The old pictures and drawings of them don't do it justice.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Maritime on Feb 18, 2013, 13:44:48
Yay, you'll be ready for spring for sure!  Beautiful bike.  Will it be BOTM March or April?
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Feb 20, 2013, 11:06:29
Thanks guys! A few more pieces of the puzzle have arrived: new battery, fuel line, drip tray and hardware for my side stand and chain guard.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3518-Version2_zpsd4dec28a.jpg)

Spent a couple hours last night installing the side stand, misc hardware, battery, making fuel lines and tweeking the wiring harness.

Of course the side stand lug on my frame was slightly bent, so it took time and force to fit the new stand. It now looks and works well.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3520-Version2_zps424384fb.jpg)

I used the two small petcock connectors from my original fuel lines and two new connectors to make two new ones. The crimping tool is simple to use and works great. I am going to make new lines for my Triton. No more hose clamps. The new black hose had white lettering screened on to it, but it was easily removed with a rag and some carb cleaner.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3521-Version2_zps63ee5980.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3522-Version2_zps0d776bf7.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3526-Version2_zps325d7b56.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3527_zps94bba46a.jpg)

I also soldered and heat shrink wrapped more electrical connections, charged and installed the battery and realized I neglected to order a tail light bulb. The original bulb came out of its base upon removal and it took a while to get the base out and clean out 40 + years of dirt.

If all goes well, I will have a day off tomorrow and will spend it in the shop. Cannot wait!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: two wheels of hell on Feb 20, 2013, 12:11:16
Light-bulb! I am adding a crimping tool to my tools. For some reason I never thought it was so easy to make. Thanks for the details. Looks like you are close to firing this old girl up.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Feb 21, 2013, 23:24:39
Crimping is easy...

Another quick update; I am feeling better, spent a few hours in the shop and finished the electrical. Initially I wired the new switch incorrectly and had to do a lot of troubleshooting  to realize I needed to move each wire one position over on the switch. Once that was done, it was fairly simple and everything works perfectly. I do need to order a bulb and holder for the speedometer. Part number anyone?
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3548_zps6d0ae8db.jpg)

I will create and post a wiring diagram soon detailing how I converted a stock harness to a QD quick detach harness.

With the money I saved on the horn from Domiracer, I splurged and bought a UK made Halcyon mirror (based on the original Stadium brand). It is stainless steel, solid and so much nicer than the Emgos I use on my other bikes.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3545_zpsbda74b28.jpg)

That's it. I have most tomorrow free (after snow removal) and all of Saturday to work on my bike. Need to install the chain guard, finalize all the control cables, add fluids and do compression test. Come on spring!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: ProSimex on Feb 23, 2013, 10:17:39
oooo I like that
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Feb 25, 2013, 13:13:19
 I am so close, but the plot thickens... I assembled the motor, cylinder head and rocker box and began to adjust the valve/ pushrod clearances only to realize the inlet valve was not seating all the way.

After much head scratching and posting on Britbike.com, we determined my pushrods were too long and/or my vavle stem height was too high due to valve seat being cut too deep.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3621_zpsbf6f23ed.jpg)
Looking down inlet port with light shining in spark plug hole. The sliver of light shows the valve not seating all the way.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3616_zps6190dfcd.jpg)
Inlet valve and seat (top) is set too deeply into the head, thus raising the valve stem height too high to close via the push rod.

I met with Skip Green, my neighbor and machinist last night. He is nearing retirement after a lifetime of working as a motorcycle mechanic, VW mechanic, machine tool salesman for Winona Van Norman and other machine companies,  a world traveller, vintage radio and electronic equipment genius and a man of many more talents. Not to mention has owned two Goldies along with any other bike I mention. He is setting up his shop so he can do high end machine work on vintage motorcycles in his retirement. http://apparatusmc.com

We pulled the cylinder head and he examined everything and we discussed several possible solutions including shortening the push rods, shortening the valve stems, adding shims and/or additional gaskets to rocker cover etc. But rather than treating the symptoms, I wanted to address the cause, which we both agree is that the intake valve seat is too deep. So he is going to replace and properly re-cut the valve seat. Here is the old one and obviously someone has been in here before:
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3689-Version2_zpsd239b282.jpg)

We measured the old intake valve stem height  and it is 1.668",  .034" less than new valve stem height. This I believe is why the new valve is not closing all the way.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3700-Version2_zps2a0d3361.jpg)

Someone removed quite a bit from the old valve stem:
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3685-Version2_zps85ac2718.jpg)
old left, new right
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3686-Version2_zps81e6153c.jpg)
crude grinding
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3694-Version2_zps16b0c798.jpg)
Intake valves, new left, old right

The exhaust valve seat looks much better, but he is going to cut it to properly match the new valve. The exhaust rocker however shows wear. I need to regrind or replace it or have it stellited and reground.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3692-Version2_zps64f2734e.jpg)


This is 100% my fault for failing to measure valve stem height heights or re-cutting (rather than lapping) the valve seats to the new valves. I was anxious to get the motor done but am glad I am taking the time to have a new valve seat installed and cut now while there is still snow on the ground. This is what happens when you overlook something or cut corners. Live, learn and move on.

Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Rich Ard on Feb 25, 2013, 13:32:04
Five seconds now or five minutes later, right? Glad you caught it.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: 03rangerxlt on Feb 25, 2013, 16:03:49
I am loving the updates in this thread!  I know you had good reasons to not be working on the bikes, but I'm excited to see it going again!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: haplo_84 on Feb 25, 2013, 18:33:19
lucky have a guy like that around.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: crazypj on Feb 25, 2013, 18:43:57
The dumb shit some people do to 'save money' or offload junk.
Oh well, looks like you got real lucky with a neighbor who does precision engine work though  8)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Garage Rat on Feb 26, 2013, 10:13:05
In San Diego, I can get you the address of the shop if you like.

(http://sphotos-g.ak.fbcdn.net/hphotos-ak-ash3/538356_10152577239575361_1066888007_n.jpg)

(http://sphotos-a.ak.fbcdn.net/hphotos-ak-prn1/17512_10152577234665361_362558821_n.jpg)

(http://sphotos-b.ak.fbcdn.net/hphotos-ak-ash4/307370_10152577228600361_278403809_n.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Feb 26, 2013, 20:51:26
The dumb shit some people do to 'save money' or offload junk.
Oh well, looks like you got real lucky with a neighbor who does precision engine work though  8)

I am beyond lucky. Skip is a great guy and I just shut up, listen and learn. He has all the right machines and tools to do it perfect, not just "good enough".

Garage Rat, nice bikes!

Just got an e-mail from Joe A (Joe V's Cycle) telling me my magdyno is done! I will be in Minneapolis tomorrow and may swing by his shop to pick it up and drool over his shop equipment, Triton build and Goldie. I am waiting on a compression release cable and that is it for parts. My head should be done in a week or so and I can start thinking about starting this beast. Come on spring!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Feb 28, 2013, 10:40:11
Picked up my freshly restored magdyno yesterday from Joe A. He did great work and installed new bearings, insulators, new condenser, rewound armature, tested and more. He is a nice guy and has a beautiful workspace and a garage full of bikes in a quiet residential area . I did not get to see his BSA's but did look over his Triton project on the bench, very nice. As a former airline mechanic, his shop is clean, well organized and everything looks well used but very well cared for. I highly recommend him. http://joesvcycle.net
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3725_zps36a3f4c9.jpg) (http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5426-Version2.jpg)

Skip my machinist repaired my rocker arm. He built some type of rocking pivot to hold it in his mill so the cut would keep the exact radius and seat correctly on the valve stem. He also mocked up a valve seat in plastic to test the valve stem height. We are going to install the head with weak valve springs to dial in the correct valve stem height then he will cut a new seat with his beautiful Neway valve seat cutters.

I have a busy work and travel schedule in the next two weeks but will eek out any and all spare time to keep moving forward on my Goldie.

Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: MotorbikeBruno on Feb 28, 2013, 10:57:44
Awesome!  I've always wanted to meet Joe A.   I've sent a few guys his way before, as I clean carburetors for people and they wanted more work done I didn't feel comfortable with.  That magdyno looks perfect! 
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: 03rangerxlt on Mar 02, 2013, 20:21:30
Love it!  That Magdyno looks nice!
Title: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: AbbyRider on Mar 06, 2013, 12:02:23
BSA's are my favourite bikes from that era. Nice to see you doing a proper job of it.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Mar 08, 2013, 12:32:34
Thanks all! Another quick update, both valve seats are installed, the valve stem heights are correct, the tappet/push rod gap is .006" and the valves seat correctly!

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3737_zps48009fd3.jpg)
new intake and exhaust valve seats
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3733-Version2_zps55c71e11.jpg)
nice matching grind on valves

I tested the vale stem heights and tappet adjustments with weak valve springs.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3731-Version2_zpscb8f3da6.jpg)

Next I fitted new valve springs, installed the cylinder head and rocker cover, tightened everything down and carefully adjusted the  eccentric rocker pins to obtain the correct tappet clearances.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3740-Version2_zps45e1fc09.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3743-Version2_zps19ceb7c7.jpg)

The motor is done, so now I am moving on to fitting, shimming and timing my restored magdyno. Getting  closer, but I have a crazy work week and can only sneak in a few hours this week. Sun is shining, snow is melting, spring is coming and this young man's thoughts turn to fancy motorcycles.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Hoosier Daddy on Mar 09, 2013, 06:30:41
Congrats! Glad you crossed that hurdle.
One of these days I want to go back and copy every one of your stunning pictures and make a slideshow from begining to ultimate ending.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: stroker crazy on Mar 09, 2013, 06:58:10
Swan has set a standard for workmanship and documentation that we can attempt to emulate, but few will approach.

Crazy
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Mar 16, 2013, 23:42:42
Thanks SC and HD, you guys are no slackers.


I am so close..... had a killer week at work so did not spend any time working on my bike until last night. The last of the parts have arrived and I chased the treads on the magdyno armature with a die and fit a new pinion nut. It did the trick. Spent several hours last night and this morning timing the ignition. I used a degree wheel on the primary side, held with rare earth magnets and it worked beautifully. I used a dial indicator gauge to find absolute Top Dead Center (TDC) and then set the points to just about open at 37 degrees Before TDC. Triple checked my settings and they are good.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3869_zpsf46a3660.jpg)

I plumbed in the rocker oil feed with OEM herringbone oil line and after searching through every box in the shop and my house for the missing metal oil feed pipe, I gave up and bought a length of 3/16" brake pipe, cut the flanges off and bent it to fit. It too works well. I flushed the oil bag one last time in the parts washer and it was spotless. Filled it with oil and kicked her over several dozen times to get the oil flowing.

I bought and paid for a compression release cable on E-bay from a yet unnamed large Brit Bike parts supplier more than a month ago. I got an e-mail from the seller saying they were out of stock of the item. What the hell? If a seller lists an item on an E-bay auction with images, you should be able to send the item. They offered to send one once the get stock again, I asked for a refund several days ago and have yet to get my money back. I am 0-3 from this vendor. Instead I bought a cable from British Only and had it in two days and it works well. As long as I am on a first-world problem rant, I went to another vendor with whom I had a problem a couple of years ago. I bought some hardware, a battery carrier and a magneto strap. The screws on the magneto strap do not fit my mag and I cannot identify what tread standard they are, The powdercoat has drips and flaws too. It is going back. Don't get me started on the new Photobucket site either....
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3898_zps2351ca17.jpg)

On a positive note, I did however find a light bulb holder for my chronometric speedometer from Domiracer. Cheap and works great.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3890_zps23e9372a.jpg)

I checked and tightened all the bike's nut, bolts and screws and thought it is time to start it. When I added fuel to the carb it started leaking from the bottom, so I pulled it to discover the problem and a major set back. The threads on the jet block are stripped beyond repair so I cannot tighten the main jet holder enough to stop gas from leaking. Of course the stripped jet block is a rare size and not available from anyone, so I will post a WTB on all the forums and scour e-bay to try to find one so I can start my bike. If anyone has or knows of a source for an Amal 389 jet block with a 1.156" diameter bore please let me know. Please....
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3880_zps638f1af6.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3883_zps6712cc2c.jpg)(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3885_zps9e2b43c1.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3889_zps9d333f27.jpg)

This is why I am in a surly mood, I am so close to starting this beast and must wait. The snow is melting, the days are getting longer and warmer and I am itching to finally ride my Goldie. I guess this means I finally have to polish my primary cover this week.  Time to walk away, go down the street for some dirty rock and roll and a pint. Stay tuned...
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3893_zps7231c1fe.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: ProSimex on Mar 17, 2013, 01:14:21
oh man what a bummer
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: edhaeuser on Mar 17, 2013, 02:54:21
Hang in there, its not quite riding weather yet..
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: jeff4uk on Mar 17, 2013, 05:16:38
Swan nice job , can you get the jet block drilled and helicoiled to get the jet in ? Or Alli welded then redrilled to size and taped ? Just a thought.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Hoosier Daddy on Mar 17, 2013, 06:28:08
You know I am just getting back into BSA's so my part resources are minimal at best...
But what about here?
http://www.groveclassicmotorcycles.co.uk/carburettor-22-c.asp (http://www.groveclassicmotorcycles.co.uk/carburettor-22-c.asp)
4 pages of carb parts listed, might be worth a call.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: crazypj on Mar 17, 2013, 15:10:16
I would just bore jet block and make an insert rather than Helicoil.
You have a buddy with all the equipment so it shouldn't take long
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Mar 18, 2013, 13:24:38
Thanks all for the replies, links, suggestions and encouragement. It is snowing today but I am anxious to start my bike. I did meet with Skip my machinist, but he was not very optimistic because the block is pot metal and a weird 19TPI thread standard (not BSW, BSF, BA or BP) so I would have to find the appropriate tap.

The good news is I found a good quality used and correct sized jet block from Jockey journal member theAppleknocker. It is on the way and I threw in a little extra cash to buy him a beer. Onwards...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Mar 21, 2013, 11:23:03
A quick little update while I wait for my carb jet block to arrive. I ordered several bags of BSC/CEI hardware from Nooky's Nuts in the UK. Good people to deal with, quick shipping, good price and nice hardware. Four large bags of several hundred assorted bolts, nuts, washers and spring washers will serve as my "hardware store" and spares in my bike's tool kit for roadside repairs. With British Standard Whitworth hardware, you cannot simply walk in to a Ace hardware store and buy it, you need to order it. So to preemptively avoid any down time this spring and summer, I stocked up. I also bought a pair of shock absorber spanners, one of which works well on my primary side crankshaft nut.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3901_zps27def26d.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3911_zps8ff3c0d7.jpg)

My bike came without a head steady running from the frame to the cylinder head. I mistakenly ordered a DBD one which was too small so I fabricated, primed, painted and installed a new longer one. The hardware I ordered with the DBD steady did not fit either so I hit up my new store of hardware and found the correct three bolts, washers and hardware. I am getting older and wiser...

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3941_zps69f673ab.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3943-Version2_zps3d253fb7.jpg)

I just received the updated version of the "Gold Star Buyer's Guide" by Charles Falco in the mail yesterday. Had I had this book at the beginning of the project, it  would have answered many of my questions and avoided headaches and confusion. It is clear, concise, well written, researched and illustrated and is a must have if you are considering buying a Goldie.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3908_zps3f94ec25.jpg)

I have a very busy weekend at work, but I am going to try to find some free time to fix my carb and start this beast. If I cannot, I will have some time off next week to get her going.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Tim on Mar 26, 2013, 22:31:03
Going to have to create a new Bike of the Millennium contest to suit this one.  Just absolutely epic not only in the detail paid to the restoration work, but the incredible resource you've created by documenting every step so carefully.

Just don't ever let your Photobucket account go stale - or maybe we'll have to get your pics uploaded to the server here and I'll update all the links somehow :)  Need this preserved for generations to follow.

Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Mar 27, 2013, 01:19:40
Thank you Tim. I am so glad this thread is on DTT because my entire build thread with all the comments from veteran Gold Star builders, restorers and riders on britbike.com was erased two days ago by a software glitch along with many other invaluable posts from others.  I can copy and repost my words and images from this site, but what is lost is the sage advice and wisdom from other veteran BB members who know infinitely more than I do about Goldies. As I have said all along, my documentation will help the next person avoid the pitfalls, problems and mistakes of my build. We all dream of a barn find of a rare, desirable and valuable bike, and it still does not seem real to me.

I simply have been too busy with work and wrenching to sit down and restore the BB thread at the moment, for it will take hours and hours to rebuild it from internet archives, but it will never be the same as it was.

Anyways, I have been quadruple checking my valve tolerances, clearances, valve opening and closing timing, mag timing, etc and am ready to fire my bike up, but am still having carb issues. The aftermarket Webco extension carb cover that came with my bike was held in place by allen screws, which always vexed me but I failed to investigate their thread standards. Well today I cleaned the carb again and tightened the allen bolts on the cover only to have them all spin. F#$k, DPO used the wrong thread standard. Pissing gas everywhere so I could not start the bike. I have a back up 389/004 carb body but after 3 hours of searching  I could not find its original Amal cover. I will be in Minneapolis and Rochester tomorrow so I will buzz over to Mitch Klempf's and buy a cover for the carb and try and start the bike tomorrow night. I am so close, trying to be patient, but have been so overworked lately I have little patience and am itching to ride. The good news is I have several days off this weekend, including a rare Sunday, to get the Goldie going, clean the Triton and get my restored CB400f and my other CB400f ready to sell. Spring is almost here. Soon...
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Maritime on Mar 27, 2013, 14:37:46
Sorry to hear about the lost BB thread. bummer to be so close and have the carb issue. Good luck on the weekend. I hope you can get the parts and get this girl ridable.

Cheers
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Apr 01, 2013, 13:11:52
Thanks Maritime.

I have been moving forward anxiously wanting to start my bike for the first time, but nothing is easy.  I spent many, many hours quadruple checking the tolerences, settings and timing of the camshafts, pushrods, valve train, magneto etc. My valves were checked with a degree wheel and Skip my machinist brought over his leakdown tester. The motor passed his test but there is a slight leak past the rings, but this may be OK since the motor has not been run nor have the rings and cylinder been bedded in. I will test again after it has been run in.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4016-Version2_zps9c2f4f5d.jpg)
Skip, the man with all the cool tools.

The original carb was giving me grief but I had another 389/004 body which I picked up from E-bay last year for cheap to swap and I picked up a standard cover and screws from Mitch Klempf on my way back from Minneapolis a couple of days ago. Somewhere in a box I have a vapor blasted standard cover, but cannot find after 3 hours of searching. The new carb body is out of round and the throttle slide binds up when I tighten the main jet holder tight enough to stop gas from leaking out the bottom. I met with Skip again and we worked on it and checked the jet block for roundness in his lathe. We rigged up an external gas tank and long fuel line and again gas pissed out of the carb. We suspect the float and valve are not set right and gas is flooding the bowl and flowing out the jet holes in the front of the carb. The float was left in my parts washer for 30 minutes and it still floated with no liquid inside. We switched fuel valves but it still pissed gas. Worn fuel valve seat? Monoblocs' float height can only be changed by adding shims or washer beneath the valve holder. We added a drop of solder to the float tang and filed it flat to lower the float height. I eventually drilled and tapped the original carb body to accept 10-32 screws and rebuilt the original carb with the new cover.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_40431_zps03f2f400.jpg)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4031-Version2_zps10c2d994.jpg)

With this set up the slide functioned better, but still dripped gas from the main jet holder washer when loose enough to raise and lower the throttle slide. After many, many attempts, adjustments, rechecking valve openings and closings, magneto timing, etc we still could not get her to fire up. We have ignition, compression, but cannot get the right fuel/air mixture from a leaky carb.

I am stubborn and cheap, but after spending more than two days of my life fighting a 50 year old pot metal carb, spilling and smelling gas and getting nowhere, I threw in the towel and ordered a new and complete Amal 389 from Amal UK this morning. At least a have a pile of spares for it. It reminds of George Washington's fabled axe which is original except the handle broke so it was replaced and the head cracked and it too was replaced. I guess I finally will have to polish the primary cover while I wait for my new carb to arrive.


The good news is the rain is melting all the snow and washing the sand and salt from the streets. I spent a full day last week cleaning, tweeking, changing fluids and tuning my Triton. I was going to buy new tires for her, but that money went to a the new GS carb. All she needs is a sunny day and some warmer weather and I am ready to go. 

Title: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: gpfaster on Apr 01, 2013, 13:41:59
There is a gentleman in Ontario (Canada) that's resleeves worn/out of round amals, I can get his contact info from my dad if you think that carb is worth repairing..
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: crazypj on Apr 01, 2013, 13:49:33
Around 10% or more leakdown is pretty normal on a 'brand new' motor that hasn't been run.
Check after 3~500 miles, you'll probably have less than 5% when everything is bedded in
It won't be zero unless you use total seal rings
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Apr 01, 2013, 14:23:14
Thanks guys. I am familiar with Lund Machining and their carb re-sleeve process, but the main problem is with jet block to slide tolerence. When I tighten the main jet holder tight enough to stop fuel from leaking, it pulls the jet block out of alignment. Trust, I tried everything and buying a new $90 jet block, $20 valve seat  and a $100 re-sleeve for a 50 year old carb body is past the point of return. It was cheaper to buy the new carb.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: edhaeuser on Apr 01, 2013, 14:56:04
Well, that new carb will sure be nice!  Had I been keeping up with your thread a little better,  I could have let you dig through my box of old Amal stuff.  I can't wait to see you out on the road!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Apr 01, 2013, 15:31:25
Thanks for the offer Ed, but I am done with the old carb and thought you were in Holland. I did contact Wes but all he had were concentrics.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: edhaeuser on Apr 01, 2013, 18:14:45
You are right, I am away at work, but I could have had my wife grab the box for you.  At least now you know you will have a good carb :-)
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Apr 09, 2013, 11:37:19
Pure torture, my new carb just arrived from the UK and I must work until 5 pm… I hope to finally start my bike tonight!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Rich Ard on Apr 09, 2013, 11:45:32
Pure torture, my new carb just arrived from the UK and I must work until 5 pm… I hope to finally start my bike tonight!

Doing the GMT math right now...okay, I know when to check back. Best luck!
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Apr 10, 2013, 00:40:57
SHE LIVES!!!!!! Image and story tomorrow.....
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Sonreir on Apr 10, 2013, 00:46:17
Tomorrow?!  WTF is that all about?!  We demand images and story right now!  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Rich Ard on Apr 10, 2013, 00:48:54
rabble rabble rabble
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Apr 10, 2013, 00:51:10
Sorry guys, time to grab a pint! I will say she sounds ferocious.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: crazypj on Apr 10, 2013, 11:21:20
It's 'tomorrow', wheres the vid, story and pics?  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: swan on Apr 10, 2013, 11:28:00
Sorry to leave you all hanging.....The new Amal 389 monobloc carb arrived yesterday and my first impression is it is well made and looks good, but I will need to put some miles on it before I can recommend it fully. Some people have had problems straight of the box, so I inspected mine carefully before mounting and putting fuel it. It is much heavier (2.5 lbs) than the original monobloc carb and the finish, casting and machining look better too.
(http://i170.photobucket.com/albums/u272/66triton/IMG_4144-Version2_zps6df07c0c.jpg)
(http://i170.photobucket.com/albums/u272/66triton/IMG_4150-Version2_zps0338b199.jpg)

It came with a Stay Up float and viton tipped brass fuel valve. Some people have had problems with the distance piece on the float arm hitting the cover and causes the float to stick. You can see that mine has clearance and will not touch the cover when tightened, allowing the float to move freely.
(http://i170.photobucket.com/albums/u272/66triton/IMG_4154-Version2_zps3efc3036.jpg)
(http://i170.photobucket.com/albums/u272/66triton/IMG_4155-Version2_zpsc68c951e.jpg)
(http://i170.photobucket.com/albums/u272/66triton/IMG_4158-Version2_zpsee045279.jpg)

My air slide cable fit right in but the throttle valve cable had too large of a adaptor on the end so I needed to remove it. Other people have also had cable adaptor problems with the new Amals, but this is minor.

I bolted the carb on, added fuel and there were no leaks or drips. I retarded the ignition a bit, closed the air slide, slightly cracked the throttle, kicked until top dead center, closed the compression release and kicked her over. On the third kick she ROARED to life. Man oh man, she sounds ferocious and is really frickin' loud. I stopped the motor after 20 seconds because my idle was set too high and I needed to shorten the sleeve on my cable to allow for more movement of the cable.

After kicking this bike over dozens of times with Skip last week, the kickstart ratchet and quadrant started to bind and slip and made the bike hard to kickstart last night. I took the gearbox cover off last night and found the problem. The ratchet is worn badly, so I swapped it with my other used one. It is better, but still shows some wear so I ordered a new one today.
(http://i170.photobucket.com/albums/u272/66triton/IMG_4162-Version2_zpsa6e068ea.jpg)
(http://i170.photobucket.com/albums/u272/66triton/IMG_4163-Version2_zpsbdea377d.jpg)

With a newer kickstart ratchet it kicked over easily and smoothly so I started the bike a couple more times. Wow, this is the first time I have ever heard a Gold Star and sounds unlike any other bike. It is LOUD, ROARS and the TWITTER upon deceleration sounds great! I do not know if it is the assembly lube or simply clean parts, but she smelled so good after running. I know most of my neighbors and generally try to be considerate with late night  noise and bike tunings, but I have a feeling all my neighbors are going to know who I am very soon. I cannot wait to ride this beast and hear her in the bluffs of our area.

No video yet, I want to tweek and tune some more and my plan all along was to make a really nice video after she has been shaken down for 500 miles and I can really let her scream. I have ridden my Triton and CB400F a few times this week, but now we are experiencing "ice pellets" for the next three days, so I will not ride for a while.  Gives me time to put new tires and tune a friend's 1972 BSA Lightning and work on my next CB400F.  My GF will be here soon for a week so there will be little time in the shop, but will post a few more images soon.
Title: Re: 1962 BSA DBD34 Gold Star restoration (Nearly done...)
Post by: Rich Ard on Apr 10, 2013, 11:33:04
Well sorry to give you heat, man - I expect you were busy staring at your bike with a face-splitting grin. Congratulations!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: crazypj on Apr 10, 2013, 13:39:24
COOL  8) 8)
Thanks for update
I didn't even know you could get new 389 monobloc carbs.
I quite liked AMAL because until the Concentric they were all 'smoothbore'
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Greg-NWO on Apr 10, 2013, 13:58:43
Hooray!! Just in time for spring too :)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Chucklhead05 on Apr 10, 2013, 14:17:19
swan, congrats on the restoration! This was definitely a labour of love and well worth it!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Worst cb650 ever on Apr 10, 2013, 15:08:05
Very nice Swan, when you're done you need to make this into that coffee table book  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: biggiesmalls on Apr 10, 2013, 18:59:21
I love these old BSA bikes. Just sitting here drooling at the old posts...
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: rjz5400 on Apr 11, 2013, 09:37:04
That comment is right, you SHOULD make this into a high dollar large format book. you know how I know, because I would buy it.


Great work, I have been reading since Day one it is the only thing I look at on the Interweb some mornings......



Thanks.

Also waiting for video but will wait patiently as always.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: ProSimex on Apr 12, 2013, 10:58:01
Thank god its finally done!  Ok right well

You have a problem.

You have set the standard for build photography, every item on a white background, well lit, and perfect.  How the hell are you going to make videos of this thing that nice?
I swear, if we get some kinda crappy cell phone camera walk around in dim light with tons of wind noise we are going to have problems.

But I am so damn happy for you that after all this time ITS ALIVE!!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: MotorbikeBruno on Apr 12, 2013, 11:12:50
Thank god its finally done!  Ok right well

You have a problem.

You have set the standard for build photography, every item on a white background, well lit, and perfect.  How the hell are you going to make videos of this thing that nice?
I swear, if we get some kinda crappy cell phone camera walk around in dim light with tons of wind noise we are going to have problems.

But I am so damn happy for you that after all this time ITS ALIVE!!


^^^ This.  hahaha
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Maritime on Apr 12, 2013, 11:57:06
Ha, you do need to put this in an edited, full colour print coffee table book. I would totally have one in my house to pick up and read anytime I feel the need for inspiration on a project, and not just a MC one, your level off detail can be applied to get results on any worth while project.  Congrats on the fire up and now comes a season of riding around on her and being mobbed at every stop by any bike guy or girl for sure.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: jbrtwork on Apr 12, 2013, 12:32:11
Congratulations, Swan! As of late, the word epic has been hijacked by a bunch of beardless twits, but I can think of nothing that describes this build, your attention to detail and documentation better. I've followed it since page 22 and anxiously awaited each amazing installment. Although not young, I'm regretfully too young to have witnessed the era when auto races smelled like castor oil or the "roar and twitter" of the Goldstar could be heard along a stretch of country road. I long to hear that sound in a forthcoming video.

An epic feat, Swan. In the words of my old Alabama grandma, "You done yourself proud!"
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Hoosier Daddy on Apr 13, 2013, 09:25:00
 (http://i520.photobucket.com/albums/w325/juancarlos722/applause.gif)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: KeithIn AZ on Apr 14, 2013, 04:00:13
So I started through your BSA thread, knowing an old neighbor of mine from where I grew up in California imported BSA's. Lo, and behold! I saw his name on the Dating Certificate you posted way back on page 1. I knew him as Mr. Alzina. He gave me a bunch of BSA notebooks. I don't think they had anything in them. I wore them out using them in junior high school. I vaguely recall he was the sole importer for awhile and then lost the rights.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Apr 14, 2013, 14:40:31
Thanks all! A book ? Maybe... I will make a nice video (no ratty ill-light cell phone video) when I have ridden and shook her down for 500 miles and then can start to explore higher RPM's. I have access to a decent video camera and a Go-Pro camera, but please be patient for it is snowing here today. At some point in the near future I will make a website documenting this bike build, organized in a logical progression with loads of images and what to and not to do when build a Gold Star.

Keith, Hap Alzina is a LEGEND in the BSA and Indian motorcycle community and was the biggest distributer in the western US. My and countless other bikes went through his business. http://www.motorcyclemuseum.org/halloffame/detail.aspx?RacerID=9

Finished my friend Wes's 1972 BSA Lightning yesterday, it runs and sounds great and he is really happy with his new bike. GF is here til next weekend, so no shop time for me.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: axelcrypt on Apr 16, 2013, 18:52:11
Damn snow!  Can't wait for the vid!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Apr 18, 2013, 12:33:52
Had a spare hour while my GF was out with a friend the other day, so I went over to the shop for a sip and stare and ended up starting her up again. Wow, what a beast. I cannot wait to take her out for the first time. Hopefully the rain will stop and I can get out next week sometime.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: MotorbikeBruno on Apr 18, 2013, 16:20:50
Had a spare hour while my GF was out with a friend the other day, so I went over to the shop for a sip and stare and ended up starting her up again. Wow, what a beast. I cannot wait to take her out for the first time. Hopefully the SNOW will stop and I can get out next week sometime.

Fixed it for you ^
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: MotoBob on Apr 18, 2013, 19:28:03
Hey swan, beautiful bike! I read through this whole thread last night while it was slow at work. Not to be redundant, but Bravo, really spectacular work. I'm up at Dennis Kirk in Rush City, has the snow ever put a damper on things this year! Do you ever get to any shows or anything closer to the cities?
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Hoosier Daddy on Apr 18, 2013, 20:33:23

Finished my friend Wes's 1972 BSA Lightning yesterday, it runs and sounds great and he is really happy with his new bike. GF is here til next weekend, so no shop time for me.
You do know I will be looking towards you for input when it comes time for my Spitfire this summer... right?  ;)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Apr 19, 2013, 12:38:50
MotorbikeBruno, you are right, it snowed again last night.

MotoBob, thanks. 63 pages, yikes, insomnia? I order many parts and tires from Dennis Kirk for my Hondas. I have never been to a bike show and have no desire to do so, I would rather ride.

HD, I know the A65 motor well, built and rode a 1966 BSA Lightning which I never should have sold. Let me know if you need help, part sources etc.
(http://i170.photobucket.com/albums/u272/66triton/1966%20BSA%20Lightning/_MG_3743.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20BSA%20Lightning/_MG_3743.jpg.html)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: MotorbikeBruno on Apr 19, 2013, 16:43:35
MotorbikeBruno, you are right, it snowed again last night.

MotoBob, thanks. 63 pages, yikes, insomnia? I order many parts and tires from Dennis kirk for my Hondas. I have never been to a bike show and have desire to do so, I would rather ride.

HD, I know the A65 motor well, built and rode a 1966 BSA Lightning which I never should have sold. Let me know if you need help, part sources etc.
(http://i170.photobucket.com/albums/u272/66triton/1966%20BSA%20Lightning/_MG_3743.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20BSA%20Lightning/_MG_3743.jpg.html)

This is one of those times that I hated being right. Ugh.  I'll have to ride down sometime and say hi this year.  I heard there's some nice roads on the way down.  (I'm in Circle Pines MN)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: MotoBob on Apr 19, 2013, 19:16:27
MotoBob, thanks. 63 pages, yikes, insomnia? I order many parts and tires from Dennis kirk for my Hondas. I have never been to a bike show and have desire to do so, I would rather ride.

I tend to agree with you, but it's a great way to network and get ideas, ask questions. Much like an internet forum but in real life! A close friend of mine recently bought a lightning similar to yours but in need of some attention.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Apr 20, 2013, 15:37:17
Just rode the Gold Star for the very FIRST TIME! Wow, wow, wow. Loud and powerful and hard to keep under 4000 rpm. Rear brake and clutch need adjusting, but sounded and rode great! Cannot wait for next week's nice weather and start shaking her down. Happiness!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: MotorbikeBruno on Apr 20, 2013, 15:55:14
Just rode the Gold Star for the very FIRST TIME! Wow, wow, wow. Loud and powerful and hard to keep under 4000 rpm. Rear brake and clutch need adjusting, but sounded and rode great! Cannot wait for next week's nice weather and start shaking her down. Happiness!


Congrats!! Woohoo!!!!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: edhaeuser on Apr 20, 2013, 16:43:19
I figured you might get that beast out for a ride today.  Still cold out, but warm enough for a quick ride.

Congrats.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: 03rangerxlt on Apr 20, 2013, 20:10:29
Congrats man! I'm actually feeling excited about your bike!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Worst cb650 ever on Apr 20, 2013, 21:50:59
Yes!  Congratulations, I bet you are still smiling!  :)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Apr 21, 2013, 11:32:22
Thanks all. Still smiling but it is still snowing... GF leaves today and I will be in the shop all week tweeking the Goldie and working on CB400F #5. The weather will be much warmer by the end of the week and I plan to ride the Goldie again.  I guess this means I finally need to sand an polish my primary cover.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Worst cb650 ever on Apr 21, 2013, 18:18:18
I hear that about the snow.  I took the first real ride on my project 360 yesterday amid snow flurries and froze my ass off and froze a big smile on my face too!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: edhaeuser on Apr 23, 2013, 00:03:01
Hey Jon,  Thanks for letting me get up close and personal with the Gold Star today!  A beautiful lass she is! 
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Apr 26, 2013, 22:46:40
Thanks Ed. I am still sorting out the idiosyncrasies of the starting ritual, but she is starting much easier. Slight tickle, no choke, hit TDC then go just past it with compression release lever, let the lever go, no throttle, kick hard and then VAROOOOMMM...

The weather went from a threat of snow (again) to 73 degrees, sunny and beautiful today. I did 15 more shakedown miles and all is good. She will start in one kick once warm (with an audience). Still need to polish primary cover, sort out a drip from the gearbox and primary cover. But wow, she runs, idles and rides beautifully and sounds great. Tomorrow is going to be nicer and I plan to wrench and ride most of the day. I am in love with this machine!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: DreadRock on Apr 27, 2013, 09:45:50
Very glad to hear she's up and running sir that is one hell of a Beautiful Machine !
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Apr 28, 2013, 15:17:21
Thanks DR. Everyone wants a video of this bike running and I keep telling you all to be patient because I will put together a nice video after she is all shook down and running at top speed. I stopped by my machinist Skip's shop and our friend Wes sent me this video from his phone. This is just a teaser but at least you can see and hear it running.

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/th_IMG_0750_zpsa8ba2a93.jpg) (http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0750_zpsa8ba2a93.mp4)
The weather was gorgeous yesterday and I put 30 more break in miles on my Goldie. It is not if, but when am I going to get a speeding ticket on this thing. She pulls like a mule and cruises at 55 mph at 3000 rpm. I want to do 500 break in miles before I can start to get past half throttle and all that power above 4000 rpm. Now that I have the starting ritual sorted she starts in 1 or 2 kicks and with 1 kick once warm (even with an audience). Sounds great, runs smooth and I still cannot believe I own this bike.

I finally sanded and polished my primary cover and reinstalled it with a new gasket and a slight smear of Yamabond sealer. I put ATF in the primary cases and the leak has stopped. The red color of the ATF will indicate the source of any future drips. RF Wahtley's article http://www.gabma.us/docs/primary_cases.pdf prompted me to buy some thin o-rings for the fill and clutch covers on my primary cover. The o-rings stop leaks and weeps as well as hold the caps in place. Thanks!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4349-Version2_zps793b095b.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4349-Version2_zps793b095b.jpg.html)

I still have a leak from the gearbox and plan to sort it out tonight if I can.

Spring is here and I plan to ride as much as possible to break her in quickly. I hope the sun is shining where you are too.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: kopcicle on Apr 28, 2013, 15:24:10
Quote
she starts in 1 or 2 kicks and with 1 kick once warm (even with an audience)

even with an audience ... I don't believe it  ;)

~kop
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: jbrtwork on Apr 28, 2013, 15:39:38
Such a tease!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Apr 29, 2013, 17:44:46
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4368-Version2_zps8b503a3a.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4368-Version2_zps8b503a3a.jpg.html)

80 break-in miles and she is running very well. Primary no longer leaks but the gear box and/ or tach cable connection is still leaking.  This is common problem and there is an o-ring in there that causes a leak. I will try to get to it tonight after another ride.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Mydlyfkryzis on Apr 29, 2013, 18:15:43
Geez, that's a sexy looking bike.

You will totally ruin the mystique if you fix the oil leak. Rumor and whispering says it will no longer be British if there are no oil leaks....DON'T RUIN IT!!!

J/K

However, you do stretch credulity talking about easy starts and no oil leaks on a BSA.    You really are making difficult to believe the whole project is not some sort of hoax.   

I still love the bike....I hope it doesn't break anything at all, except tradition. Have great luck with it...

Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Worst cb650 ever on Apr 29, 2013, 22:22:11
I was going to ask when he's going to stop riding it long enough to fix the leak  ;)  I'd have trouble getting off that bike myself!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: jeff4uk on Apr 30, 2013, 05:01:00
Nice job mate,Oily rag bikes are the best a true brit bike.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: ProSimex on Apr 30, 2013, 11:49:19
*trouser explosion*
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on May 01, 2013, 11:04:54
Ha, thanks guys! I had another beautiful ride last night in the 80 degree weather. It is going to snow tomorrow, ah Minnesota.....

I sorted out the gearbox leak by installing two new gaskets with a thin and even smear of semi-hardening Yamabond sealant. Also I believe the Haynes manual was wrong (what a surprise) in its recommendation of 570 cc of oil in the gear box. I refilled with 400 cc as recommended by the BSA owners manual and BMS's "Gold Star Book". I overfilled the first time and that may have contributed to my earlier leaks. I rode 25 miles last night and there are no drips or leaks of oil beneath the bike this morning.

I am really get a feel for this bike and it is an absolute pleasure to ride. 125 miles so far and no major problems and she starts in 1 or 2 kicks and 1 kick once warm. Smooth, great handling, cornering and is mechanically quiet with that beautiful and distinctive exhaust note. I am smiling just thinking about her and looking forward to more riding this weekend.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Maritime on May 01, 2013, 11:08:21
Wow, your break in is almost done and then you can really ride!  SOOOOO glad you are not just putting her on a pedistal and looking at her, ride her till stuff wears out or breaks, fix her ride, rinse repeat.

Awsome
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: AgentX on May 01, 2013, 11:54:48
nothing to say but omfg...
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: hartley353 on May 04, 2013, 10:24:03
From the backseats I have watched this build from the start. The goldstar has always been close to my heart,and to watch her rise gracefully from her barn rest has been a total pleasure. No machine has had a better master,and the love, time,skill,and labour given to her by yourself, will be repayed many times over as you ride her. Well done.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on May 04, 2013, 17:40:49
From the backseats I have watched this build from the start. The goldstar has always been close to my heart,and to watch her rise gracefully from her barn rest has been a total pleasure. No machine has had a better master,and the love, time,skill,and labour given to her by yourself, will be repayed many times over as you ride her. Well done.
Thank you very much for your kind words and watching all this time. Finding a rare, old bike in a barn and restoring it is a dream we all share

It was 80 degrees and spring a few days ago, then we got several inches of snow and rain. Warmed up a bit today and the sun came out so I went out riding and am going out again. She is purring and I am putting more break in miles on her.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/MayMNGoldStar_zps25995d54.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/MayMNGoldStar_zps25995d54.jpg.html)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: bumpthump on May 08, 2013, 17:22:51
I am smiling in a way I seldom do these days. It takes many of us many years to work out what really matters in a motorcycle, and for those of us who lean towards the lithe and the spartan, it can take even longer to settle aas you plough your way through varying degrees of the modern motorcycle knowing full well "that ain't it"............and here we have Swan, with not only  the luck to fast track to an iconic motorcycle , but also the balls to see it through. He knows full well that the bike reeks of integrity, and that;s no mean achievement. I salute you.
There are hundreds of motorcyckes that quicken my heartbeat, but probably only a handful that slow my heartbeat,,,,,,,,,,,and this is one of them. It;s a bike I will never tire of looking at.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on May 09, 2013, 12:48:48
Thank you very much bumpthump. Hard work and luck defines me. I never tire of looking at this bike but it makes my heart race rather than slow down.

Had an absolutely beautiful ride last night before a rain storm rolled in. Went up the twisties in the bluffs to the long, straight and empty roads of the prairies. This is the most comfortable and best handling bike I have built and the sound, oh the sound..... I am still breaking her in but hit 5000 rpms and 80+ mph briefly and she has plenty of throttle left to go. This weekend is going to be nice so I will ride as much as possible. No problems yet but I am going to adjust the throttle cable length and adjust the front brakes. I plan to change the oil again at 500 miles, recheck the valve clearances, timing etc and then start to ride her harder and faster and do the same at 1000 miles when I can consider her broken in and the real fun begins.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/BSAspeedo_zps85309c34.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/BSAspeedo_zps85309c34.jpg.html)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on May 19, 2013, 14:34:01
500 Miles!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/BSAGS500miles_zps7f7160ee.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/BSAGS500miles_zps7f7160ee.jpg.html)

So far, so good. I began but simply starting the bike a few times, then short rides with cool down periods, followed by progressively longer rides, never over or under reving the motor and kept the throttle varied so the motor will be properly broken in. Now I can riding her harder with higher rpm's and for longer periods until I hit 1000 miles and consider her broken in.

Yesterday, I changed the primary, gearbox and motor oils and there were no surprises, chunks of metal, etc. Checked the timing and valve clearances-all good. My primary chain stretched out and was loose, so I  removed 1 1/2 links, moved the gearbox forward and added 1 1/2 links to the drive chain. I checked and tightened all the bolts on the bike and found I lost the brake pedal stud somewhere, so I ordered replacement hardware. Still trying to get more out of the front 190 mm drum brake, but it is better than it was.

There is a slight oil leak in the primary behind the clutch dripping and spraying the chain, center stand and rear wheel. I have a Phil Pearson seal holder and believe it is set up properly, but after some research another BB forum member had similar problems until drilling a small pressure relief hole in the inspection cap. I will do this tonight and test it out. I know it is not leaking gearbox oil because the leaking oil is red ATF.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0234-Version2.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0234-Version2.jpg.html)

Summer is finally here, I had several beautiful rides yesterday in the bluffs and it felt so good to start going past 4500 rpm's and feeling her really pull. And the sound, simply beautiful. My poor Triton is going to get some attention tonight, I have not ridden her in weeks.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: axelcrypt on May 21, 2013, 12:23:58
I will make a nice video (no ratty ill-light cell phone video) when I have ridden and shook her down for 500 miles and then can start to explore higher RPM's. I have access to a decent video camera and a Go-Pro camera, but please be patient...


Nudge nudge.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on May 23, 2013, 00:52:56
Axelcrypt, please be patient, rain and my job get in the way of my fun.

My bike is up for Bike of the Month and please vote if you enjoyed this l-o-n-g build thread. I still cannot believe this is really my bike and it still feels like a dream we all share; finding a rare bike in a barn, restoring it and riding the hell out of it. My bike is fast, smooth, handles well and sounds simply amazing. Here are few before and after images:


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/rtside.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/rtside.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4563_zps27ecb4a0.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4563_zps27ecb4a0.jpg.html)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5069.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5069.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4591_zps3ba5c770.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4591_zps3ba5c770.jpg.html)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/brokenclocks.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/brokenclocks.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4551_zps3037abf8.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4551_zps3037abf8.jpg.html)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5146.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5146.jpg.html)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0253-Version2.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0253-Version2.jpg.html)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5238-Version2.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_5238-Version2.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_6782-Version2.jpg)[/URL]


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7877.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_7877.jpg.html)


(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4581_zps9949e9eb.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_4581_zps9949e9eb.jpg.html)

(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/BSAJDS02_zps25512ebb.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/BSAJDS02_zps25512ebb.jpg.html)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Texasstar on May 25, 2013, 09:31:54
Hey Swan it's Zeke. I am one of the nominations for bike of the month. I was wondering what kind of clip on handle bars you have? It was really cool how you got your engine unseized. My dad and I tried a lot of the techniques you used to unseize your engine. My dad found the burning technique,but our piston were set at the top so we couldn't  set them on fire. If we did we could do what tWistedwheelz said. Get a lounge chair a few juice boxes and have a gear head campfire. Oh! We're the cb200 in the nominations. Wish you luck.    - Zeke
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: tweakin on May 25, 2013, 11:54:32
Simply beautiful.  What a transformation.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: McBrenner on May 25, 2013, 13:05:49
This is something to be proud of. Beautiful build, great attention to detail. Awesome job.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: bumpthump on May 26, 2013, 11:31:21
Pleasing  ;D


It is an absolute joy to behold. Well done!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Jun 18, 2013, 10:45:08
Thanks again everyone, she is running well. Duke at the Bike Shed did a nice article my bike and a shout out to DTT. Thank you!
 http://thebikeshed.cc/2013/06/18/jon-swans-bsa/
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: pawn on Jun 20, 2013, 10:01:04
PERFECT.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Texasstar on Jun 23, 2013, 00:25:50
Swan,
Zeke and I got to see a 62 Gold Star today at Baxters in Marne Iowa...your Goldie is still more beautiful.
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Jun 24, 2013, 16:50:01
Thanks TS and Zeke, there are many, many cool bikes include Vincents in Baxter's back room.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20build/DSCN2193_zpsc7e221c5.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20build/DSCN2193_zpsc7e221c5.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20build/DSCN2189_zps1f39abd8.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20build/DSCN2189_zps1f39abd8.jpg.html)

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20build/DSCN2185_zpsedfb393f.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20build/DSCN2185_zpsedfb393f.jpg.html)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Texasstar on Jun 25, 2013, 16:20:12
Thanks TS and Zeke, there are many, many cool bikes include Vincents in Baxter's back room.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20build/DSCN2193_zpsc7e221c5.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20build/DSCN2193_zpsc7e221c5.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20build/DSCN2189_zps1f39abd8.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20build/DSCN2189_zps1f39abd8.jpg.html)

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20build/DSCN2185_zpsedfb393f.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20build/DSCN2185_zpsedfb393f.jpg.html)
Swan do you want to se a video of Zeke in Baxters? It is hilarious!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Aug 02, 2013, 09:47:35
I am not a bike show kind of guy, but I went to my first one in June because it was literally out my front door. Winona's city wide celebration called Steamboat Days includes an all day car and bike show with 100's of vehicles all along the downtown streets.  I entered my BSA Gold Star in the show, sat around all day drinking beer, talking with friends, meeting new people and talking old bikes. Yesterday, out of the blue, I received a call from a well known Brit Bike enthusiast in town saying he had a trophy for me at his shop. I thought, hmm do I need a Triumph Trophy project, but it turns out it is a show trophy because my bike won best motorcycle in the show. I was very surprised!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/trophy_zps44ec0689.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/trophy_zps44ec0689.jpg.html)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Hoosier Daddy on Aug 02, 2013, 10:17:15
... and this surprises you how?
Congrats on the trophy! You might want show up at more shows, sure to have a nice collection in no time. ;)
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: Texasstar on Aug 02, 2013, 19:38:26
I am not a bike show kind of guy, but I went to my first one in June because it was literally out my front door. Winona's city wide celebration called Steamboat Days includes an all day car and bike show with 100's of vehicles all along the downtown streets.  I entered my BSA Gold Star in the show, sat around all day drinking beer, talking with friends, meeting new people and talking old bikes. Yesterday, out of the blue, I received a call from a well known Brit Bike enthusiast in town saying he had a trophy for me at his shop. I thought, hmm do I need a Triumph Trophy project, but it turns out it is a show trophy because my bike won best motorcycle in the show. I was very surprised!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/trophy_zps44ec0689.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/trophy_zps44ec0689.jpg.html)
LOL! We sent your link to the Vintage Bike Magazine!
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: bikeboy on Aug 04, 2013, 00:38:11
I was very surprised!

Doesn't surprise me at all fella ;-)

Superb work, and thoroughly deserved. Won't be the last either I should think.

ian
Title: Re: 1962 BSA DBD34 Gold Star restoration (SHE'S ALIVE!!!!.)
Post by: swan on Aug 13, 2013, 15:50:26
Thanks all.

After an extremely busy period of work and now with my girlfriend out of town for two weeks, I have finally reached 1000 miles on the Goldie. I completed all the the factory maintenance (changed engine, gearbox, primary oils, air pressure, spokes, re-torqued all bolts, etc) and cleaned her up well.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/1000_zps65b149cf.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/1000_zps65b149cf.jpg.html)

Recently, my battery was starting to run flat and I observed the ammeter in the negative even while the bike was running (see above),  so I charged the battery over night, load tested it and it passed. The dynamo (generator) was tested on the running bike as per BSA service sheets and Lucas instructions and it too passed. I started to test the regulator as per service sheet and it failed on the A wire (brown/white) running from the regulator the ammeter. There was a poor connection in the female end of the brown/white wire leading to the ammeter in the quick detach connection so I cut the wire, drilled out the old solder and re-soldered it. It now has continuity, allowing the regulator and battery to function as they should. Tested the charging system again and it is working beautifully. I did however discover my Lucas 312 style bulb is 12 volt instead of 6 volt and may explain why my head light is so dim (my mistake). New 6 volt bulbs on order today. I may or may not go to 12 volt system in the future, but I will ponder that this winter.

There is still a nagging oil leak from either the back of the primary or gearbox I am trying to resolve along with weeping petcocks. (insert British bike joke here) New seals on order too.

So with 1000 break in miles completed, I went out last night and did a beautiful 100 mile ride along the Mississippi River up the Wisconsin side through the bluffs and back down the Minnesota side on the highway. Speeds were, ahem..., 65 mph and/or above... for long periods of time. She ran great at higher speeds and rpms. The sound echoing of the trees and bluffs at speed is magical. The bike is now broken in and look forward to full use of the throttle and many, many more miles to be ridden.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/Tremp_zpsd94ae7fe.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/Tremp_zpsd94ae7fe.jpg.html)

Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: EL Sammo on Aug 26, 2013, 05:50:39
Fantastic job of the restoration and build thread! Enjoy your bike.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: swan on Sep 04, 2013, 22:30:00
Thanks El Sammo!
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/1500miles_zps6fb194f7.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/1500miles_zps6fb194f7.jpg.html)
1500 miles... She is running strong and I am riding at much higher speeds. I broke a clutch cable at dusk the other night, so I jumped on my friend Andrew's 77 CB750 to buzz back to the shop and make a quick repair. Note to self; order cable making supplies from Flanders.com and start making my own cables. I also broke a connection to the taillight so the running light was not working, but it was easy to find the fault and a quick fix. These things are going to happen and they do not bother me because I built and know the bike so well, little problems are easy to diagnose and repair. All part of the charm of a vintage British bike.

My new 6 volt headlight bulb works soooo much better than a dim 12 volt bulb on my 6 volt system! I see no need to change over to 12 volt system and and have been doing a lot more night riding now that I can actually see ahead of me in the dark.

The weather is beautiful but the days are getting shorter so I am riding as much as I can before the snow falls and I hope you all are too.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/1185083_10200317779453812_1231376735_n_zpsf636b74b.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/1185083_10200317779453812_1231376735_n_zpsf636b74b.jpg.html)
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: crazypj on Sep 05, 2013, 02:38:01
Did you get a 6v Halogen?
 I know they were available at one time, I used them in my CD175 in the early 70's  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: swan on Sep 05, 2013, 10:48:47
Regular 6 volt lamp. I was running a 12 volt lamp in a 6 volt system and it was very, very dim. Now I can actually see and drive at night.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Hoosier Daddy on Sep 05, 2013, 16:34:37
Regular 6 volt lamp. I was running a 12 volt lamp in a 6 volt system and it was very, very dim. Now I can actually see and drive at night.

I've been half lit myself on more than one occasion
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: swan on Sep 06, 2013, 12:04:31

I've been half lit myself on more than one occasion
Where's the "like" button?
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: ProSimex on Sep 23, 2013, 00:36:03
nothing wrong with 6V, was pleasently suprised by the light thrown out by the lamp on my 59xlh
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: ExTwitterer on Oct 24, 2013, 00:51:59
Swan, I hope you read this.
You have brought back to life for me what was a distant but very happy memory, and for that I can't thank you enough. I came across this forum by chance while searching for pictures of - you guessed it - a BSA DBD34 Clubmans Gold Star.
From my username you'll deduce quite rightly that I used to own a wonderful noise making machine like your masterpiece.
I am a retired machine builder - apprenticed for five years in the UK from 1960 to 1965, but worked in the machine tool industry in Canada from 1980 until I retired two years ago. So I can fully appreciate the enormous amount of work, and the huge amount of care that you bestowed so well on your DBD34.
I owned my 1961 DBD34 from 1964 to 65. It was my ride-to-work bike, my only transport, as I couldn't afford a car on an apprentices's meagre pay.
I have lots of stories about the Goldie, about the joy, and about the heartbreak - about the 'mishaps', and about the rebuilds.
But I have no pictures of 'her' because I also didn't have camera!
The way you portray the rebirth of your Gold Star is amazing, and could only be told that way by someone who loves their work, and by someone who is also very, very good at what they do.
I would love to be able to tell you of a rebuild that I have done lately, but I can't. I only joined this great forum to let you (and all the other classic rebuilders) how much I admire what you are all doing. That you guys can find these old bikes, and rebuild them to the extremely high standards that the original maker didn't have a hope in hell of attaining is wonderful - and inspiring too.
Swan, your Gold Star is more than beautiful, it has a heart - not Reg Pearson's beautiful crank as a heart, but yours. Even if you part with that bike, it will still be yours, the same way that my Goldie is still mine - if it still exists somewhere!!
But that's another story.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: swan on Nov 24, 2013, 15:26:37
Extwitter, thank you very, very much for your kind words and memories, it means a lot to hear this from someone who once owned one of these amazing machines.

After a lengthy search and appeals to my old friends, I did not have a single picture of my first bike as an adult, a 1966 Triumph Bonneville. Sold it like a fool and went to Europe.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: hardcoreharryjr on Dec 08, 2013, 23:57:50
Just found this thread, pretty impressive. How's that video looking? First snow of the year in philly today so my bike is packed away.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: swan on Dec 16, 2013, 22:24:54
Thanks man!

The Goldie just made the cover of the 2014 Do The Ton Calendar. Just bought mine and you can get yours here: http://www.rustrevival.bigcartel.com/product/2014-do-the-ton-bike-of-the-month-calendar
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/tremp_zps8c72e53c.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/tremp_zps8c72e53c.jpg.html)
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: crazypj on Dec 19, 2013, 04:57:31
I do like that picture  8)
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Gold Star on Dec 30, 2013, 16:26:32
Hi Swan,

Just found your thread last evening and spend half of the night reading it. Nice work you've done, congratulations!!
I'm starting the rebuilt of my third Goldie, a BB34 in a plunger frame. I'll try to put some pictures on the thread if someone's interested in.
Here is a picture of my current 1955 CB32GS. It is an original and rare "road racing" model of wich only 4 were imported in France (where I live)in 1955.
Mine has a known racing history and took part (and sometimes won) major races here. It has been "upgraded" by a previous owner with Lyta tank, Dow tls front brake plate and home made seat...but I still have all the original parts. Hope to hear from you and your beauty soon. Reading you was a lot of fun as it brought back memories of my first rebuilt...quite an adventure too!!
So long.
Dorian.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Gold Star on Dec 30, 2013, 16:30:59
On more picture on the move on The Imola race track...
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Hoosier Daddy on Dec 30, 2013, 20:20:19
Quote
...if someone's interested in

Oh Pal-eeeze!
(http://tickerforum.org/smilies/pray.gif)
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Gold Star on Dec 31, 2013, 07:02:37
Ok Hoosier Daddy...here are some more pictures of how my bike looked like when it took part to it's first "Bol d'Or" 24hrs race in 1955.
The two last pictures are from the first Goldie I've built. It is a non original DB32. I've built it from parts over 10 years cause I could'nt afford a complete bike (they've always been expensive!!). It had a B31 frame but with all the correct Goldie stuff (Gp carb, racing mag, RRT2 box, 8¨finned front brake, Lyta tank...).
I had to sell it + a DB500 incomplete basket case to raise the monney to buy the racer I know own. I've always loved the 350. BSA developed the Goldie in 350cc and then upgraded it to 500cc and then, with power rainsing, came the problems (cranckshaft, clutch...). The 350 is a funny reving bike who's chassis and brakes realy do the job. It is in fact homogeneous on every point.
All for now!
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Hoosier Daddy on Dec 31, 2013, 10:47:26
So Jealous! You need to start your own thread full of details!
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Gold Star on Dec 31, 2013, 11:23:21
;-) More to come...next year!
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: swan on Dec 31, 2013, 18:38:49
Gold Star, beautiful bikes and thank you for sharing. As suggested by HD, please start some threads for your bikes.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Gold Star on Jan 02, 2014, 11:33:42
My A7...tested by a friend just after he changed the famous crankshaft plain main bearing!!
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Gold Star on Jan 02, 2014, 11:47:34
And here's my little gem that I should working on first to finish it, before starting with the plunger Goldie.
This is a Monet Goyon MC5s 1928 french "super sport" 500cc ohv. It has a swiss MAG engine (Motosacoche) and is really rare. Only 6 are known to have survived and 150 to 200 are supposed to have been built over the 1 year 1/2 of production. 8¨brakes are original wich was realy uncommun in those days. I hope to finish the rebuilt this year, depending on time&money...same old story!!
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Erskine on Jan 02, 2014, 19:48:21
Gold Star, beautiful bikes and thank you for sharing. As suggested by HD, please start some threads for your bikes.

+1
Please start your own threads. Look forward to reading them.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: johnu on Apr 10, 2014, 12:16:36
Hey Swan, as always the bike is awesome and glad to see that you are getting some miles in!  Funnily enough last time out on my Goldie the nipple came off the end of the clutch cable but I rode her home with out the cable ;) 

How do you like riding with the clipons?  I have them on mine and thought I was going to love them but I really can't stand them!  Think I will try to find a set of straight bars instead.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: KenBB on Sep 03, 2014, 19:26:08
I always love seeing a proper restoration.  Very nice work here.

This build is being featured in our directory here: http://www.bikebuilds.net/bsa-1962-dbd34-gold-star-build-by-swan (http://www.bikebuilds.net/bsa-1962-dbd34-gold-star-build-by-swan)

At this point, we're only displaying a reduced-size photo (similar to what you'd find in Google Images).  We'd like to ask for your permission to publish the original full-size image with your build listing.

If anyone would like to have a build of their own listed, just send me a message with a link to the build thread and we'll take care of the rest.

Ken
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Magicflemo on Nov 12, 2015, 23:19:17
Hi all,
I am new to this forum but have participated in other BSA sites.
I need some advice regarding the new Quick Detach style set up from Tricor UK.
Does anyone know how to assemble correctly and in particular putting the rubber boot on the metal socket?
Help would by greatly appreciated.
Kim
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: swan on Nov 15, 2015, 13:40:02
magicflemo, The male and female ends of the quick detach socket have an outward indentation and must align in order for it to match up correctly. (see third photo) Once they match up, the rubber part covers the connection.
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3401_zps0b675df2.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3401_zps0b675df2.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3428_zpsbd8057ee.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3428_zpsbd8057ee.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3408_zps454738c3.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_3408_zps454738c3.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0532-Version2.jpg) (http://s170.photobucket.com/user/66triton/media/1962%20BSA%20DBD34%20Gold%20Star%20project/IMG_0532-Version2.jpg.html)
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Magicflemo on Nov 15, 2015, 20:07:26
The rubber cover is hard, thick rubber and must fit over metal "female" socket. As the hole is smaller than the flanged end of the female socket cover - how do you fit the rubber?
Kim
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: crazypj on Nov 16, 2015, 03:49:50
Much swearing and cursing if I remember right  ;D
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Mydlyfkryzis on Nov 17, 2015, 19:54:58
Much swearing and cursing if I remember right  ;D

I think you forgot "some bleeding" too.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Worst cb650 ever on Nov 17, 2015, 23:26:21
I found a very nice Gold Star (and friends) at the Solvang Motorcycle Museum in California (near Santa Barbara), and though of this thread...

(http://i.imgur.com/nfVQFY8l.jpg)
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: Magicflemo on Nov 18, 2015, 00:26:14
still cant fit rubber - does boiling water etc help or is there another trick?
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: swan on Nov 18, 2015, 00:44:58
Wintergreen oil is the best way to soft old, hard rubber: http://forums.sohc4.net/index.php/topic,29707.0.html
http://www.dotheton.com/forum/index.php?topic=2692.msg21373#msg21373
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: SpottheDogg on Mar 16, 2016, 17:00:37
Wintergreen oil is the best way to soft old, hard rubber: http://forums.sohc4.net/index.php/topic,29707.0.html
http://www.dotheton.com/forum/index.php?topic=2692.msg21373#msg21373

I've used a 50/50 mix of wintergreen oil and toluene
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: johnu on Mar 17, 2016, 13:14:12
Hey Swan how do you like that Pearson clutch?  I have one in my Goldie and it doesn't seem that great :( Seems like it could be more of a cable issue though.  Also do you have the clipons with the perches welded to the clipon or something different?  I'm going to try to persevere with the clipons but just hate that I can't rotate the levers down.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: swan on Mar 17, 2016, 18:18:13
I love my Pearson clutch, nearly 6000 miles, no issues. Make sure you have a tiny bit of play in the cable before the clutch starts to activate.

I opted not to use original clip ons with welded perches because I like to fine tune the control lever positions to best suit my comfort and riding style.

I have had a few rides so far this season (March, Minnesota) and she is running great. I stored the battery and carb inside my house for the winter and she started on the second kick.
Title: Re: 1962 BSA DBD34 Gold Star restoration (1000 miles and more)
Post by: johnu on Mar 17, 2016, 19:43:22
Good to hear that you are out riding already, year round here in Cali of course ;)  I sent a message to Pearson today about the clutch.  I think I'm going to install a new cable as it feels like it stretches before it actually moves the clutch arm but maybe I am just imagining that.  I hear you on those original clipons, I like my levers down pretty low so I will go down the same route as you.  Could you post up a pic sometime of your clipons looikng from the front, also one of the clutch actuating arm and where the cable adjuster  goes through the casing?

Thanks,
John.