Chip's '72 Combat project

Ron, that's EXACTLY what Chip directed me to source on Saturday when we last talked. They are also exactly like the ones on my Combat, and the ones I installed on Charlie's Norton cafe bike (my first paying client).

Yes, good call on the Tomaselli's, Ron. Paul and I agreed that going that route would offer us the greatest flexibility. Thanks for the input...it's greatly appreciated!

Chip

Good news on the wheels - they are FINALLY in work. I delivered a harsh ultimatum and it must have stirred the pot.

Received the 32mm intakes today (all 3 sets I had were 30mm), so the carbs will get done tonight or tomorrow.

I've been consolidating, tidying, rounding up and narrowing down all the remaining bits and bobs and it's getting mighty close!

Intakes arrived, I beadblased them and got 'em test-fit with the carbs and K&N air filter.

The project is getting close to the fit-up and test-run stage. I'd rather it was rolling before test firing, so STILL waiting on the wheels.

FINALLY got word that the wheels definitely shipped out for Saturday FedEx delivery!

Should be moving right along next week, maybe get to initial startup.

Every dog has his day.

It's your day, dog.



You'll have a rolling project in no time.

On closer inspection, these rims are indeed steel, but they are Excel's best units. Anyway, the tires got mounted up this morning while I worked on the oil tank, filter, and oil lines, as well as the seat mounting hardware, and final nipping up of all exhaust harware with the new retainer nuts. This afternoon I re-assembled both wheels, and installed them after a bit of a fiddle with the front brake and fender needing to be loosened off to maneuver the wheel into place (in hindsight, it MIGHT have worked with just deflating the tire, but I didn't want to chance scratching anything.



Hot tip for you Norton builders - make sure to install the bloody rearend crankcase breather while you've still got the engine off the bike. What a chore!.

Hotter tip for Norton builders.

Plug the rear crankcase breather and vent from timing case, per Old Britts. Much, much better. An engineer who chooses to vent a crankcase at the bottom should be cleaning toilets instead of designing engines, IMO.

http://www.oldbritts.com/n_c_case.html

That is a good tip, but the stock breather is actually a good thing as long as you properly route the tube to serve as a trap, it sure helps pump out a wet-sumped crankcase!

Okay, here's your rolling project.

Filled and bled the front brake, filled and nipped up the forks, installed the rocker feed line and sidestand.





By this evening, it will look a lot more like you'd expect

In case I didn't mention it before, I LOVE polished engine covers on a freshly rebuilt engine.

The clip-ons arrived today, and I got them mounted and semi-adjusted. I ran out of time, as we're going to Killeen for my granddaughter's birthday this weekend.



After a bit of a fidget with my riveting tool, I got the serial number plate mounted to the frame; also got the four new carb mounting screws and got them completely mounted with proper 32mm insulating blocks.

I rebuilt and painted the clutch lever perch, so the clutch & front brake match with original Lucas electrical quadrants. only mismatch is the right side "paddle" is the longer style, the left side is the shorter style; hardly noticeable.

Your kickstarter that I had chromed is all set to bang into the brand new pipes, so I sorted through the other 4 levers that I have, and lo and behold - I have a Mark III kicker in excellent condition (sticks out further to miss the exhaust), so I'll swap it out.

I'm going to get right back on it Tuesday and get the basic wiring done, connect the rear brake cable, fill the oil levels, service the battery, and FIRE IT UP!

I'll probably also be firing up my Roadster project next week, it ought to be pretty cool with three fresh norton rebuilds side-by-side-by-side...

All of the wiring is done with the exception of the tail light and the ignition rotor. If everything goes right,
I'll be firing it up tomorrow and putting some run-in miles on it before the weekend.



I did have to use a right side quadrant electrical pigtail on the left side in order to have a clean matching gray sleeve,
the original was a tape-wrapped bodge-up.

Mounted the zener, capacitor, rectifier, horn and keyswitch (after fabricating a mounting bracket).

I swapped the kickstarter, replaced the pair of rubber iso mounts on the right side for the shortest ones I could find,
then restrained the pipe in the most tucked-in position possible whilst tightening the finned retaining nut; but the
Mark III kicker still just taps the pipe on the way back up. Will need to fiddle with this one some more.

No photos today, but I got the rear brake pedal & cable assembly totally done up with all new parts.

Also serviced the battery and set it to trickle charge overnight.

Should fire it up tomorrow!

Hi Paul

Paul I am in awe of your work rate!
Keep picking up little items I like! I will have a bash at lightening a standard disc later on in the season but for now I need to ask you about your petrol pipe T pieces. They look to be large bore & plastic. Still running on small metal t piece & I am not sure that I agree with them.
Still not sure about the big Dunstal tank but then again I have managed to run out of fuel with a three gallon tank so who am I to talk.
Keep on going.
All the best Chris
ps must start on the flat tracker again as we have just had two dry days with sunshine!

That's an Andover Norton OEM replacement fuel line set, I believe it is spec'd for Interstate model. It has the highest flow of anything out there, and that's beneficial for a Combat at full song with double 32mm Amals.

Guess what I'm doing tomorrow?



My '70 Roadster fired on the first kick after I replaced the ignition stator, I think Chip's bike should only take HALF a kick! Probably tomorrow, using my tank, if all goes well.

Well, no pictures today, but I got a good deal of work done.

Connected all the remaining electrical except the lights, and turned the key on and off with the plugs out of the hole to see if the ignition was firing - IT WASN'T!

Scratched my head for a few minutes, bypassed the original Lucas kill switch (just in case), and tried it again - still nothing!

Scratched my head some more, then started tracing the wiring to the module - BINGO! I had forgotten to add a ground wire direct from the 2nd coil positive terminal. I added a second spade terminal, duplexed the wiring harness ground lug with a wire to the coil and - VOILA! Sparx. I set the static timing at 28 degrees on the ignition stator and nipped it up.

Finished off some minor breather hose routing and plugged off the factory-installed oil leak (chain oiler). Got all the fluids filled, and re-checked all the head bolts (nipped up a couple just a touch).

Went to install my gas tank and realized that the petcocks I'm using won't suit the factory fuel line assembly, so I'm going to wait to fire it up until the Caswell sealer is done and totally cured. Looks like it will be fired up Friday.

Meanwhile, I'm going to get busy on the final installation of the fairing & seat, and work on the clip-on adjustments and lighting.

Good news and bad news-

Good news is YOUR BIKE IS A RUNNER!

Bad news is twofold - the startup video is nearly 18 MB for a 3-1/2 minute video, and it backfired on the first kick, then started on the 2nd kick.

hee hee

It's all good. I need to install the chain and a seat so that I can take it out for it's maiden test ride, that will happen tomorrow if it doesn't rain.

Here's a photo, not much good, but I'll send you a CD of the startup & first test ride in tomorrow's priority mail.

One step backwards.

The head failed to "nip up" with a full re-torquing, I'm going to have to take it back off and investigate. It's bad enough that there is oil weepage, so it's certainly not going to "warm up and seal".

Never mind, I'll get to have a good look at the combustion chambers and cylinders and see how the re-assembly affected everything.

Slow and easy wins the race, I'm going to pace myself and make sure it's as near perfect as possible this time around.

To all who expected to see the finished bike pix by now (ESPECIALLY Chip), Sorry guys...