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Fullauto's 850 rebuild

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Fullauto's 850 rebuild

Postby Fullauto » Sun Jun 28, 2015 3:47 am

Well, it's been a long road. Three and a half long years ago I came to grief on my MK 1 850 Commando and considerable damage was done to my "works hack". It was a well sorted and generally a bit untidy bike, but beautiful to ride. It had done plenty of long trips with great joy along the way. Following the crash, it lay, forlorn and neglected while I (slowly) healed, still with some issues today. Finally it was dragged over to British Imports shop in Malaga, here in Perth, Western Australia. A rough timeline was given, a deposit paid for the purchase of parts and labour and the work finally began. A new frame, as the original was bent beyond repair and the bits and pieces put on a stand. Powdercoating went out and came back..............

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The motor was torn down, cases cleaned, one of Jim Comstock's crankcase breathers was added and bits sent everywhere for various jobs to be done. I've never wanted a trailer queen, but, in the end, Ben convinced me that this bike will basically become my calling card, requiring that it remain clean, tidy and polished. I now see the wisdom of this move and should make this bike a cut above the average works hack, which it certainly is. The crankshaft, pistons, big end shells and various other bits plus gearbox bits (complete internals) were sent out for ceramic coating and micro polishing as appropriate.


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Piston skirts and tops coated.

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Camshaft coated with a NASA developed coating which works better with more pressure and heat and becomes very shiny with use.

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Cylinder head. Combustion chambers and both inlet and exhaust ports ceramic coated, and valves.

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That should do to whet your appetites. More to follow. The build should progress fairly quickly from here as I've given Ben until the 1st of August to have it finished.
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Re: Fullauto's 850 rebuild

Postby Fast Eddie » Sun Jun 28, 2015 4:00 am

Looking good.

You seem to have forgotten to include pics of shiny new alloy barrels though...
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Re: Fullauto's 850 rebuild

Postby trident sam » Sun Jun 28, 2015 4:06 am

A very good looking bike behind the Commando ! :D

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Re: Fullauto's 850 rebuild

Postby JimC » Sun Jun 28, 2015 4:52 am

You need transparent cases, barrel and head. Beauty of this bike is far from being skin deep.
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Re: Fullauto's 850 rebuild

Postby Fullauto » Sun Jun 28, 2015 5:49 am

Basic spec as follows, if not mentioned, standard parts are used.

Fullauto Technologies head, number 2. Ceramic coated combustion chambers, inlet and exhaust ports. Unported. Standard size Black Diamond valves, Ceramic coated.
PW3 cam. Lobes coated.
CNW single coil conversion.
TriSpark ignition. Fantastic product.
Maney barrels.
Hepolite pistons, skirts coated, tops ceramic coated.
Jim Comstock supplied conical valve springs.
Lifter blocks and rockers micropolished.
Jim Comstock crankcase breather.
Sparx 3 phase alternator and solid state regulator.
Quartz halogen conversion for headlight.
Belt primary drive by Heyward.
Double sided primary drive adjuster.
Barnett clutch plates.
Dave Comeau clutch pushrod seal.
Gearbox internals micropolished. 22 tooth sprocket.
Production racer forks with Lansdowne conversion. (Thanks John! looking forward to this).
11-5 inch Production racer floating disc with AP twin piston caliper.
Original style Lockheed master cylinder with adapter for standard switchgear.
Ikon rear shocks.
Morad 2.5 inch x 19 inch rims. Avon Roadrider 100/90 - 19 tyres. Great believer in these.
Corbin seat.
Smith's electronic instruments.
CNW LED tail light conversion and tail light mount. 750 style tail light.
CNW turn signal conversion.

Other spec as I remember them.
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Re: Fullauto's 850 rebuild

Postby cjandme » Sun Jun 28, 2015 5:54 am

Fullauto wrote:Well, it's been a long road.........

Piston skirts and tops coated.

Image



That should do to whet your appetites. More to follow. The build should progress fairly quickly from here as I've given Ben until the 1st of August to have it finished.
thanks for posting the thread and these pictures. I love all of this new age technology creeping it's was into our old rides. Like I've said before I think that there has never bee a better time to own and ride a norton. Looking at your pistons though, I have to ask why you stayed with the hepolites instead of lightening things up in there with the JS ones while you had it apart. Cj
Last edited by cjandme on Thu Jul 02, 2015 6:09 pm, edited 1 time in total.
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Re: Fullauto's 850 rebuild

Postby Fullauto » Sun Jun 28, 2015 6:14 am

All in good time. I don't want to start with a perfect Norton now do I? Pistons are something I will turn my attention to in due course. After barrels. And a few other bits and pieces.
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Re: Fullauto's 850 rebuild

Postby Fast Eddie » Sun Jun 28, 2015 2:34 pm

Fullauto wrote:Basic spec as follows, if not mentioned, standard parts are used.

Fullauto Technologies head, number 2. Ceramic coated combustion chambers, inlet and exhaust ports. Unported. Standard size Black Diamond valves, Ceramic coated.
PW3 cam. Lobes coated.
CNW single coil conversion.
TriSpark ignition. Fantastic product.
Maney barrels.
Hepolite pistons, skirts coated, tops ceramic coated.
Jim Comstock supplied conical valve springs.
Lifter blocks and rockers micropolished.
Jim Comstock crankcase breather.
Sparx 3 phase alternator and solid state regulator.
Quartz halogen conversion for headlight.
Belt primary drive by Heyward.
Double sided primary drive adjuster.
Barnett clutch plates.
Dave Comeau clutch pushrod seal.
Gearbox internals micropolished. 22 tooth sprocket.
Production racer forks with Lansdowne conversion. (Thanks John! looking forward to this).
11-5 inch Production racer floating disc with AP twin piston caliper.
Original style Lockheed master cylinder with adapter for standard switchgear.
Ikon rear shocks.
Morad 2.5 inch x 19 inch rims. Avon Roadrider 100/90 - 19 tyres. Great believer in these.
Corbin seat.
Smith's electronic instruments.
CNW LED tail light conversion and tail light mount. 750 style tail light.
CNW turn signal conversion.

Other spec as I remember them.


Steve Maney barrels!?!

Calling card!?!?

Hello...
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Re: Fullauto's 850 rebuild

Postby Fullauto » Sun Jun 28, 2015 4:33 pm

Can't fit something I haven't got. As soon as they come off the production line, don't worry, they will be there.
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Re: Fullauto's 850 rebuild

Postby cjandme » Sun Jun 28, 2015 4:53 pm

Fullauto wrote:All in good time. I don't want to start with a perfect Norton now do I? ........

Understood, again thanks for posting. :mrgreen:
Last edited by cjandme on Sun Jul 05, 2015 7:30 am, edited 1 time in total.
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Re: Fullauto's 850 rebuild

Postby Fullauto » Sun Jun 28, 2015 5:36 pm

This isn't a look at me, look at me thread. It's to show what I'm doing and if anybody has any questions or suggestions, please feel free to post. I've already had one suggestion from Lyell about wrist pins which I intend to follow up. Let's get this thing built.
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Re: Fullauto's 850 rebuild

Postby o0norton0o » Sun Jun 28, 2015 6:07 pm

Fullauto wrote:This isn't a look at me, look at me thread.


Ya know,....... only a certain type of person would read your thread and not enjoy what you are sharing here....


Fullauto wrote: It's to show what I'm doing and if anybody has any questions or suggestions, please feel free to post. I've already had one suggestion from Lyell about wrist pins which I intend to follow up. Let's get this thing built.


When I rebuilt my engine many years ago, I fitted new pistons and they came with bent wire circlips for the wristpins... I didn't think anything of it at the time and installed them. A hundred miles later I am crusing along and I get a pop, and puff of smoke out of one exhaust pipe, I shut the engine down, pulled the clutch and coasted to a stop. One of those shitty wire circlips popped out and scored my cylinder wall. I had to rebuild again from the barrels up. This time I used proper circlips cut out of flat steel. At the time when I first built the engine, I didn't know enough and used a single crappy substandard part and it cost me time and money to tear everything apart and rebuild it again... lesson learned... (I know I still have those wire circlips in a bag in my parts bin with the one of those circlips with a flattened side on it... Its a reminder to me every time I see them)

Your project looks amazing. Please post more as you progress... Thanks
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Re: Fullauto's 850 rebuild

Postby pete.v » Sun Jun 28, 2015 6:18 pm

What about the horn? I did not see a horn on the list. Are you going to have a horn? If so, what kind of horn? Do you have one already? What a bout a relay? A lot of people are using realys with horn. I like relays, and horns of course. Have you started assembly without the horn and do you now have to start over?
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Re: Fullauto's 850 rebuild

Postby Fullauto » Sun Jun 28, 2015 7:39 pm

Forgot the most important part. I too, like horns. Loud ones. Got one from CNW. I was trying to think of a more difficult place for it, but it won't fit inside the oil tank. Relays. I like relays too. There will be a few of them.
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Re: Fullauto's 850 rebuild

Postby CanukNortonNut » Sun Jun 28, 2015 7:57 pm

Ken,
It's coming together. Really nice to see.
Cheers,
Tom
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