So far,everything has been stripped off and degreased.
Just like the engine, all the bolts were rusty and siezed so little can be saved
in the way of fixings.
First
job was to get the frame on the bench and start fabricating the footrests and
hangers. I already had a pair of trials footrests left over from the
Bantam project so decided to use these. I made the hangers from 1" angle
iron welded and finished with a grinder. Trials regs now stipulate that
footrests must be of the folding type and the fabrication of these was fairly
straightforward. A difficulty arose in mounting these as the original
postion was too far forward. I consequently made the hangers to fit on the
mounts for the original pillion rests. This was somwhat complicated
because the mounting holes were nominally threaded 1/2" BSC but the bolts were
very loose and the heads too big to accommodate the new hangers. It was
common in days gone by for fixings to vary somewhat in size and I surmise that
the original fixing holes were drilled a little oversize to accommodate an
ill-fitting bolt. I overcame this by machining new bolts from stainless
steel Whitworth hexagon bar stock, cutting the BSCY threads at the extreme
opening of the die, hence cutting a slightly oversized thread. The bar
stock was the size for 7/16" thus creating a small head to fit inside the
hangers.
I removed the stand mounting flange which hangs under
the frame. This is superfluous on a trials bike and severely reduces
ground clearance. This was originally brazed onto the frame so it was easy
to grind away the braze on one side and then break the braze on the other side
thus preserving the fitting in case it is required to be refitted at a later
date.