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John Player Special restoration project

Member's Norton Restoration Projects

Re: John Player Special restoration project

Postby PeterJoe » Tue Feb 09, 2016 9:27 am

grandpaul wrote: Did they use John Bull rubber wire ties or the solf aluminum ones?


Originally from 1972 the Norton Commando used black nylon cable ties. According to the parts book (in page Group 21) there are a total of 14. One of them happens to be listed as 15 inches long which I assume goes around the frame's top tube. The others are 7 3/4 inches and 5 3/4 inches long. The ones I like to use are .190 inch wide made by Thomas & Betts and called Ty-Rap high performance ties. These have a steel tang in the head that holds the cable tie together. They seem to be more infinitely adjustable and the back side of the tie rap that touches the wiring or frame is a lot smoother than the all nylon type ties and less harsh on the painted surface.

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Re: John Player Special restoration project

Postby grandpaul » Thu Feb 18, 2016 3:40 pm

First reproduction project: main fairing mount.

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Harbor Freight special pipe bender.

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Although the pipes were filled with sand, the first bend resulted in a slightly flattened profile (fixed with the vice)

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Re: John Player Special restoration project

Postby grandpaul » Thu Feb 18, 2016 3:43 pm

Primary parts for the first 3 main mount copies rough cut and ready for sizing.

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First two copies of the main mount welded up.

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Spacers for the lower front mount; a little long so they can be ground and sanded to final size

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Re: John Player Special restoration project

Postby grandpaul » Thu Feb 18, 2016 3:47 pm

Front clamp half blanks prepped to drill, spacers finish sized.

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Will need to use an end mill and some spacers to cut the clamp half profiles

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Drilling the clamp halves. Not as precise as I had hoped; I'm ordering more material to do them right on a better drill press.

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Re: John Player Special restoration project

Postby grandpaul » Thu Feb 18, 2016 3:50 pm

About half of the holes unacceptably off center.

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Top and front mounts drilled and ready for powdercoat.

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Re: John Player Special restoration project

Postby grandpaul » Fri Mar 11, 2016 12:07 pm

I finally received the original pattern JPN Solo seat with upholstery pan-

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Sure looks large...

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Waiting for Airtech to be done copying my fairing, and I'll get all the bodywork on and done!
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Re: John Player Special restoration project

Postby grandpaul » Fri Mar 11, 2016 12:08 pm

Also got back the fairing brackets from the powdercoater. Next I'll reverse-engineer and pattern one made from square tube as shown in the JPN parts supplement; that will be a bit tricky without a part on hand to match...

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Re: John Player Special restoration project

Postby splatt » Fri Mar 11, 2016 10:51 pm

I'm glad you also found the holes unacceptably off center

You could always stamp made in CHINA on them
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Re: John Player Special restoration project

Postby grandpaul » Wed Apr 27, 2016 11:26 pm

Airtech has been dragging with returning my fairings, but the upholsterer made me smile Wednesday with a beautiful job. note the print-outs of photos of every seat that could be clearly seen to get the pattern as clost to correct as possible.

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Very clean upholstery work. One for me, and one for sale with the spare bodywork kit. Only change from original is the slots in the seat base, and the lips on the upholstery pan (unseen). If I can get good clear pix of an original base & pan underside, I'll have a new one made to match.

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(new sticker set on order, these were quite old)
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Re: John Player Special restoration project

Postby grandpaul » Mon May 02, 2016 12:50 pm

Confirmed tracking number on my original fairing and the new Airtech copy; ETA this Friday.

That only leaves one week to assemble, align and trim it all out, then have a shake-down run before the BMOA rallye.

I'm starting to get excited about seeing it together FINALLY. About 6 months since I picked the bike up.
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Re: John Player Special restoration project

Postby grandpaul » Tue May 10, 2016 6:26 am

I'm very disappointed (upset?) with Airtech; they mis-handled the original fairing and it now has visible crazing in several places. This is the worst, and it's VERY obvious on the right side, in plain view. It goes away at 10 feet, but it'll never "go away" without a respray.

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This will be the spare bodywork kit for sale including mounts and gas tank under the shroud. Windscreen, front fender and decal kits will be included if the buyer wishes.

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Re: John Player Special restoration project

Postby grandpaul » Tue May 10, 2016 6:30 am

Points kept giving me fits, the AAU was worn and sticking / "flicking", so I went straight to a new Sparx unit. Set up the crank for static timing.

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Sparx unit static timed here with the white dot in the CCW window.

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Sparx ignition module tucked in neatly and zip-tied to the frame tube. I left all original wiring in place but disconnected and tucked out of view. Buyer will receive the original points with pigtail & AAU.

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Re: John Player Special restoration project

Postby grandpaul » Tue May 10, 2016 6:34 am

Rear view. Needs a bit of tweaking to get better symmetry.

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Top view

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Right side beauty shot, FINALLY. I will be doing a proper photo shoot later this week, probably 2 or 3 venues...

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Re: John Player Special restoration project

Postby grandpaul » Tue May 10, 2016 6:38 am

Right side close-up

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Front shot, also needs a bit of a tweak on the fender

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Overhead front shot, here the fender is obvious.

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Re: John Player Special restoration project

Postby grandpaul » Tue May 10, 2016 6:46 am

Left side close-up

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Left side "not ready for prime time"; missing Union Jack decal on the tail.

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Oblique shot.

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