880 Norton Sprint Special - "real - time" build, lots of photos

[grandpaul]

Had to sketch the harness out, along with all the electrical components, and identify which wires would be best suited to which devices. I decided to go with NEGATIVE ground (modern method) on the electrics, which allows an easier means of wiring in a kill button for the Sparx ignition. One problem with that is the use of red wires for grounding Positive-ground British systems, and black wires for grounding Negative-ground Japanese systems. The only conflict occurs with the Sparx ignition red wire which is positive (to the coil & keyswitch); all other red wires will be negative (grounding wires).

This harness had the keyswitch wires chopped off, so I'll need to re-terminate them; that will allow me to use different connectors depending on what other wires will be mated with them, some of which are already terminated. The single cluster switch (clutch side) will have horn, headlight hi/lo, and I'll use the turn signal switch as a kill switch; this wires are a mix of female spade terminations and chopped wires, still to be sorted (have to get out the multimeter and figure out what's what).

The hard part of the wiring is done

 

[grandpaul]

Figuring out switch console wiring color codes without opening the switch, and a 3-position, 5-terminal toggle switch pinout is always fun. It's taking a couple of color cross-overs to make it all work (well documented with an AutoCAD drawing) and several male/female connectors to be able to remove each individual component without disturbing the rest of the harness.

Although some of the connections aren't finished (need a keyswitch still), and some wires are temporarily zip-tied in place, it's getting much cleaner. I'll cover the nest up with a nice thin rubber boot when it's finished (sorry for the blurry photo)...

That headlight is literally a Monster headlight; I like it. Had to go to simple clamp-on brackets because the Monster bracket put the headlight in the way of the master cylinder hose connection AND the clutch cable routing, no matter how I arranged the intermediate bracket. I didn't want to go to a 4" x 2" piece of angle aluminum, it would look horrible.

 

[Tune-A-Fish]

In at 1000 views... Lookin good, knew you had time to get one going... is the shop all squared away now??

 

[grandpaul]

At present, it looks as if a tornado ripped through the shop and kept going. I tend to make a huge mess when I get on a roll. Tomorrow is cleanup day (Saturday).

I've got a few new tools, and getting much better with the wire welder. Also I've really been utilizing the belt grinder that my knifemaker friend gave me; that thing is amazing how what looks like a giant belt sander can eat through steel like shredding cheddar cheese.

On the work list is-
-880 Norton custom build
-Triton custom build next
-Norton parts bike rolling project a bit at a time
-Client's Bonneville & Commando tune-up / fix-up / sell-off (Bonnie is on e-bay at the moment)
-Client's Triton project partial dismantle, re-work, then complete & sell
-My 880 engine build (non-priority)
-My ZRX carb tuning and prep for regular use again
-Screw with the 5-speed conversion on my Triton, it just isn't right
-about 6 tune-up / make-runs for bikes that have been sitting over a year (includes my race bike which I need back up to speed by October for the Texas Mile)
-My '68 Bonneville restoration
-My '65 Bonneville restoration
The list just gets longer and longer, I also have a Triumph trike and a Triumph Street Tracker that I need to get busy with one of these days (not to mention another dozen bikes to refresh and ride after several years of sitting)

 

[DohcBikes]

At present, it looks as if a tornado ripped through the shop and kept going. I tend to make a huge mess when I get on a roll. Tomorrow is cleanup day (Saturday).

I've got a few new tools, and getting much better with the wire welder. Also I've really been utilizing the belt grinder that my knifemaker friend gave me; that thing is amazing how what looks like a giant belt sander can eat through steel like shredding cheddar cheese.

On the work list is-
-880 Norton custom build
-Triton custom build next
-Norton parts bike rolling project a bit at a time
-Client's Bonneville & Commando tune-up / fix-up / sell-off (Bonnie is on e-bay at the moment)
-Client's Triton project partial dismantle, re-work, then complete & sell
-My 880 engine build (non-priority)
-My ZRX carb tuning and prep for regular use again
-Screw with the 5-speed conversion on my Triton, it just isn't right
-about 6 tune-up / make-runs for bikes that have been sitting over a year (includes my race bike which I need back up to speed by October for the Texas Mile)
-My '68 Bonneville restoration
-My '65 Bonneville restoration
The list just gets longer and longer, I also have a Triumph trike and a Triumph Street Tracker that I need to get busy with one of these days (not to mention another dozen bikes to refresh and ride after several years of sitting)

Boy thats a lot of projects. Hopefully your employees can handle all of that!

 

[grandpaul]

Boy thats a lot of projects. Hopefully your employees can handle all of that!

Hee hee. Good one.

I'm a one-man show here.

 

[grandpaul]

Preliminary wiring diagram; still need to change several color codes, and alter a connection here or there to properly relate to where physical connectors actually are...

 

[Tune-A-Fish]

At present, it looks as if a tornado ripped through the shop and kept going. I tend to make a huge mess when I get on a roll. Tomorrow is cleanup day (Saturday).

I've got a few new tools, and getting much better with the wire welder. Also I've really been utilizing the belt grinder that my knifemaker friend gave me; that thing is amazing how what looks like a giant belt sander can eat through steel like shredding cheddar cheese.

On the work list is-
-880 Norton custom build
-Triton custom build next
-Norton parts bike rolling project a bit at a time
-Client's Bonneville & Commando tune-up / fix-up / sell-off (Bonnie is on e-bay at the moment)
-Client's Triton project partial dismantle, re-work, then complete & sell
-My 880 engine build (non-priority)
-My ZRX carb tuning and prep for regular use again
-Screw with the 5-speed conversion on my Triton, it just isn't right
-about 6 tune-up / make-runs for bikes that have been sitting over a year (includes my race bike which I need back up to speed by October for the Texas Mile)
-My '68 Bonneville restoration
-My '65 Bonneville restoration
The list just gets longer and longer, I also have a Triumph trike and a Triumph Street Tracker that I need to get busy with one of these days (not to mention another dozen bikes to refresh and ride after several years of sitting)

If you can find an AHP200 inverter (TIG/Stick) welder, the thing is a dang good welder for the money and easy setup. the belt sander is the best thing since sliced bread, if I had room I would have a snow ski sander... freaking belt is 12' long and never wears out if used correctly

You sure have a lot to stay focused on, I am on the home stretch with the CBR6, all the parts are gathered to finish the BSA, XL185 is ready for frame paint and reassembly 350 is in a basket waiting to decide on motor work, KZ1000 parts are getting close, still looking for side covers NOS or real good used, NOT pulling the tarp off anymore until I finish at least two of these : :

 

[grandpaul]

Spent a couple of hours at Joe Gregory's M/C & Salvage, found some more neat stuff (off-topic). Got a brand new, in-the-box Indian keyswitch for $35 (not pictured). Anyway, I found the exact match Honda rear wheel and scabbed the axle & spacers for $10. They took a cutting torch to the rear wheel to remove it because the nut was bloody FROZEN. I punched a serious hole in my hand trying to free it off; finally managed to get it loose in a vice with a pipe wrench and fork stanchion for a cheater bar.

So, the rear wheel will be 100% as soon as I weld up the brake torque arm root mounts and touchup paint the swingarm.

Mr. Postman was my friend today with 2 more boxes. First box was 2 sets of pushrods from e-bay. With the other one good set I have, I'll select the two best sets for this bike and the rest will go to the parts bike.

 

[grandpaul]

Second box was from Old Britts. Most of the new gasket set will go to my personal 880 engine build, as I "borrowed" from my stash to put the bottom end together, so it's payback time. Also got the (2) remaining cylinder allen bolts, (2) cylinder front long nuts, (3) head steady allen bolts (and 3 more for the parts bike), points & crank seals, tach drive o-ring, (2) points cover screws, (2) oil tank rubber mounts, alternator wiring grommet, (2) points plate pillar bolts (the other 2 are for the parts bike), and (2) Amal rebuild gasket sets. So, the engine build will be complete in short order.

Got most of the wiring done this afternoon. Keyswitch, headlight & marker light, kill switch and ignition. It took quite a bit of head-scratching to use the fewest number of connectors and mis-matched wire colors, but it's all settled now (updated wiring diagram to follow)

It certainly looks much neater now; I used velcro wrap to secure everything where it can be loosened up to manipulate and future changes, then strapped back down. Also scrounged up two Honda rubber wiring boots to cover up the clumps of connectors

Headlight has very few wires & connections; that works out, because the Ducati shell has very little available free space

 

[Tune-A-Fish]

I have a full set (pair) of Amal gaskets and a really nice polished set of Concentrics ready to piss gas if you need any more.

 

[grandpaul]

Always interested in more concentrics; what size, cutaway, jets, etc?

 

[Tune-A-Fish]

Re: 880 Norton Sprint Special - "real - time" build, lots of photos

Sorry chrome not polish:

Sent from my iPhone using Tapatalk

 

[grandpaul]

Nice. PM sent.

 

[grandpaul]

Finalized wiring LAYOUT; the only changes will be to actual wire colors & connections to the tail light which isn't done yet.

 

[grandpaul]

Thanx to Tune-A-Fish, those Amals will be on this build, or the shelf for the parts bike (depending on whether the bores & slides are better or worse than the ones I have on hand).

 

[DohcBikes]

Paul, I am trying to buy your book, but am not very computer savvy and I can't figure out how to order it from your website. Can you pm me or post the info on how to get it here, thank you in advance.

 

[damiansd]

Re: 880 Norton Sprint Special - "real - time" build, lots of photos

Grand Paul, this is a beautiful build. With all pics you'll have an awesome coffee table book.

Thanks for the inspiration
D.

Sent from my SM-G920I using Tapatalk

 

[grandpaul]

Paul, I am trying to buy your book

Just PayPal $20 to grandpaulz@hotmail.com with the note "old bikes book", make sure to include your return address if it's not set up in paypal, and also include a note if you want it signed to: (actual name or forum name, etc)

 

[DohcBikes]

Will do, thanks.