John Player Special restoration project

grandpaul · Jan 15, 2016

Right side cylinder didn't fully clean up at .020" over, but should be fine; it wasn't smoking the last time it ran. (front faces in view)

Sides are reversed, these are the rear faces of the bores

Bottom of the spigots; sides are reversed (looking at front faces of the bores)

Rear faces of the bottom of the bores.

grandpaul · Jan 15, 2016

Cylinders were boiled clean, scraped and detailed a few spots, then 2 coats of Rust-O-Leum gloss black rattle can.

Drying in the sun; we had a nice warm & sunny day today.

"Before" shot of the chain oiler.

Genuine AN original footpeg rubbers, although incorrect for the JPN; should be "oval" shaped bits.

grandpaul · Jan 15, 2016

Balance of the new fairing parts arrived, including the more original tank. Original JPN extension weld just like my other tank.

Underside of the tank is in near original condition

A bit of surface rust from non-use. Supposedly, this tank never had fuel in it.

Just a bit of "shelf" rust inside the tank...

grandpaul · Jan 15, 2016

Baffles & hump look almost new

Tank looks great from 10 feet, has a few little chips on the paint at the edges here and there and a slightly dinged rear corner lip with a paint crack; no biggie as it gets covered with the shroud. I might have my painter touch it up.

Quick mockup of the tank; chainguard installed.

grandpaul · Jan 15, 2016

Polished bits also arrived on the same UPS truck this afternoon. Now the forks and bottom end can go back together, FINALLY!

All the fairing mounting hardware is present and correct.

grandpaul · Jan 15, 2016

These are not English headlights; but have never had power to them.

Modern dual headlight harness with relays and simplified wiring.

Original JPN dual headlight harness with proper wiring color coding (also includes turn signal wiring)

grandpaul · Jan 15, 2016

Front brake lever & reservoir cap polished and installed

Clutch lever polished and installed. I chose NOT to polish the thumb switch covers; might send them off as they stand out...

Controls looking more complete

grandpaul · Jan 15, 2016

"After" shot of the chain oiler nice and spiffy now; it will be fully pinched off, just for originality.

Left side Z-plate, footpeg, brake pedal & muffler hangar hardware in place loosely

Right side folding peg, z-plate & muffler hangar done, but loosely installed for now

Bloody L-O-N-G day today; also built a small greenhouse for my wyfe, supervised A/C & heater repairs, and cleaned up & photographed the old JPN fairing & tank cowl for eventual sale.

1973x75 · Jan 16, 2016

I've always wondered what the fuel tank looked like under the JPN fiberglass. I think I'd be tempted to ride it around without all the fairing parts for awhile just for fun.

Excellent documentation. I envy your energy and enthusiasm!

travelerjerry · Jan 16, 2016

grandpaul, will it look something like this when finished?

grandpaul · Jan 17, 2016

Almost, but that sure can't be comfortable...

Bob Z. · Jan 17, 2016

Please tell me the girl has been Photoshopped onto the bike photo.
She's got her shoe on the Plexiglas!

rwalker28 · Jan 17, 2016

So she has...I was not looking there...

Bob Z. said:
Please tell me the girl has been Photoshopped onto the bike photo.
She's got her shoe on the Plexiglas!

grandpaul · Jan 18, 2016

Rods cleaned, new bearing shells oiled and rods torqued to 25 ft/lbs. They rotate real nice and smoothly.

Crank main seal pocket cleaned out

New crank main seal in place

grandpaul · Jan 18, 2016

A light smear of flange sealer, thrust washer on the cam, nipped everything in place with every other case bolt till it gets set in the frame

Nice smooth rotation...

https://www.facebook.com/BornAgainBikes/videos/983316948409133/

Ready for the cam drive whirly bits.

gortnipper · Jan 18, 2016

grandpaul said:
nipped everything in place with every other case bolt till it gets set in the frame

What is the advantage of doing it this way? Surely, when originally assembled, the engine cases were properly torqued together and any fettling was done with the mounts??

grandpaul · Jan 18, 2016

gortnipper said:
grandpaul said:

nipped everything in place with every other case bolt till it gets set in the frame

Click to expand...

What is the advantage of doing it this way? Surely, when originally assembled, the engine cases were properly torqued together and any fettling was done with the mounts??

If I torque the cases now, on the bench, it would all have to be loosened off to set it in the frame/mounts, then re-torqued again.

Once it's in the frame, I'll torque the case bolts.