I (Graham) worked on the engine with Jack and between us we were able to re-unite the two halves of the crank case. The only issue we faced was working out the correct torque wrench settings for the 17mm nuts that secure the crankcase from underneath around the crankshaft. Despite spending lot of time searching through the manuals that we have for it, the correct torque settings could not be found. We are still awaiting new piston kits for the engine. At least next time we will be able to refit the generator, starter motor and the components of the clutch etc. etc..

No progress made this weekend. The supplier we thought we had found for the piston kit wouldn’t take our payment and we are now desperately trying to find someone else who can. Irfon also spotted the fact that some of the suppliers warn that their piston is not suitable for our cast iron barrel. With that in mind it may be a case of buying a cylinder barrel and piston kit – The Saga continues and if anyone knows where on earth the missing piston is – Please don’t keep its location to yourself.

I (Graham) spent some fitting the vice securely to the workbench. It is surprising how useful things like this are, when you finally bolt them down. The compressor was already showing just how useful it will be, not only for component cleaning but also potentially for blasting components clean of corrosion, spray painting and a host of other tasks. Alas and alack the brand new compressor developed a fault with a component that regulates its operating pressure and will very likely have to be replaced.

John and others set about cleaning up many of its heavily corroded aluminium components. Andy fastidiously fettled, cleaned and polished its footrest hangers. A decision now needs to be made as to whether or not retain the existing cam-belt tensioner rollers as they have stood idle for so long.

Much progress was on restoring the wiring loom today. Irfon guided Jack’s Mum and sister as they armed themselves with a workshop manual wiring diagram and studiously set about finding where many of the wires needed to go. In addition the rectify/regulator was located amongst parts for one of the other bikes attached to the plate the locates it on the frame, along with the starter motor-relay. It will soon be time to enjoy the sounds of this motor running.

 Mark set about cleaning up the wheels and some of the frame components whilst Jack surprised us with his tyre removal skills. After much deliberation it was decided to keep the restoration of the components in house and where necessary restore the paintwork ourselves. The main driver for this decision was the good condition of the existing paintwork on the replacement frame.