honda305.com Forum

Yes - should be there on Saturday.

G

AlanW wrote:Nice work G, see you at Stafford at the weekend?

The Missus and I are going as well... What are the chances of picking up a tool tray and air-box cover? Slim to none? :)

Look for Governor's Bridge or DK spares - usually outside.

You never know.

G

darboots wrote:The Missus and I are going as well... What are the chances of picking up a tool tray and air-box cover? Slim to none? :)

Finally - a bit of time in the workshop after too much travelling and long days. When I was looking for an early fork slider for a friend I discovered that one of my sets of early forks had the dreaded damaged slider where an overlong fender bolt has been tightened up and distorted the inner bore of the slider.



I managed to get the slider off the tube but the lower fork bush suffered in the process. I will have to find or make a new one.

The bolt had obviously bottomed out and got broken off at some time so the slider waqs in a pretty sorry state,.



The boss that the bolt was in got carefully marked out to locate the centre of the damaged remains.



The centre was marked with a centre punch and I carefully started to drill the hole.



I had a go at heating the boss and inserting a torx bit to see if I could move the broken bolt but it wasn't having any of it. I had to carefully drill the bolt out to M8 tapping size and re-tapped the thread. Depth-wise I had to make sure that the drill didn't break into the fork slider. A flat-bottomed 8mm tap gave me as much thread as I could get.



Because the spring support is quite low down in these early sliders, I was able to get my long-neck Proxxon grinder in there to carefully remove the damage in the slider. I just took small cuts and tried the fork tube with bush in there until it would go in smoothly. Luckilly the bottom bush travels much lower down than this damage and the top buide is above it. Any roughness left is therefore in the dead zone.



These forks are not really part of this project but I thought it would be interesting to include this in the thread as this is such a common problem with these forks.

G

I heven't had much opportunity to do anything substantial on the project lately but I found these photos of my last efforts at trying to clean up the ignition switch lock nut and another that I found. Both the outside and the slots were badly chewed up so I thought I'd have a go at making them presentable.



The outsides came up pretty nicely after getting rid of the corrosion.



The slots were a little harder to deal with.



All in all they look OK but I think if I got hold of the right tap (24 x 1) I could probably make something nbicer out of stainless....




G

Nice job, but I would like to see what you could do from scratch with SS.

Seadog

I've ordered a 24mm x 1 tap to form the internal thread. Anothe 'mini-project' to add to the list.

G