Basket Case Project - What Have I Gotten Myself Into?

wrecks

wrecks

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In the early 1980s my father and I dismantled this 1971 Norton Commando to move it down some narrow stairs into a basement and fix a cracked cradle. Then in the late 1980's we took it apart a little more in order to start a restoration. Today my father dropped it off at my house and my hope is that I can reverse the progress and actually start putting it back together. Along the way I assume I'm going to need a lot of help and guidance from this forum.

Basket Case Project - What Have I Gotten Myself Into?
 
Wouldn't really call it a basket case. Looks like you have all the parts plus some new ones. Should be a straight forward restoration. Most basket cases are a mismatched pile of parts from a number of different bikes and usually have 3 of the parts you don't need and none of the ones you do. I've bought 5 of them. Put one bike together, finishing another and enough parts to do number 3.
Anyhow, welcome to the forum! Lot's of good help here.
 
Looks like a great project, do you know why it was pulled down in the first place, it looks like all the parts are there for it and some new, pull the head off and see what the bores are like, does the motor turn over, but it probably be a good idea to pull it right down, a new set of bearings and rings if the bores look good, might be a easy rebuild.

Good luck with it and have fun.

Ashley
 
If you can pull it down a bit farther to do a 71 side standectomy and put a 06.3049 72-75 style in it's place. If you keep the original 71 style you will cry when it breaks and most do...
The 68-70 style preceded it and on updating the frame for 71, it was clearly a mistake and was quickly changed for 72.

I have 20 nortons and define a basket case where a pile of parts, or complete bike, as currently unworthy of road use without major reconditioning.
 
I guess that one mans basket case is another mans "easy rebuild." For a guy like me with little to no experience this looks like an insurmountable pile of parts. That said, I'm actually encouraged that you all think this looks pretty straightforward. My wife thinks I'm crazy and when I gleefully told her that my Dad was dropping off the Norton she said, "You know our daughter starts college this year and we need a new roof."

The original tear down was to get to the cracked cradle. We couldn't get the cradle separated from the swing arm so at one point a guy welded a patch from one cradle onto the one currently on the swing arm. I'm not sure this was a good fix so I'm going to have to look at that more carefully and figure out what to do.

Thanks for the suggestions so far. I'm definitely in need of a list of "must do" repairs and replacements. I had intended to pull the motor down farther and replace the main bearings and check the cylinder bores. I'm not sure what dynodave is referring to with the sidestand - but sure - I'm happy to add that to the list. I'd love more suggestions regarding where to begin!
 
The early side-stands weren't quite strong enough and a bit too short as installed on the Commando frame. The bike leaned over too far, putting a bending moment into the shank that caused it to snap. It was a discrepancy not found in prototype testing, as the two prototype bikes didn't have stands at all. We had to lean them up against something to park them!
 
Here is a bad example of how early side stands and repairs can go bad.
Works quite well on a rolling basket case though!
Basket Case Project - What Have I Gotten Myself Into?
 
Welcome to the forum!

If there are various parts in boxes (or baskets), it's a "basket case" alright. You, however, are starting out with at least two advantages over the typical basket case restorer: 1) you are in touch with the person who originally tore it apart and knows the history of it, and 2) it appears quite likely that you will not be missing one or more small batches of screws and bits that invariably get separated from the main project pile.

Take plenty of pictures and narrate your progress, there are many regulars, and many newcomers, that are particularly interested in member's ongoing project threads, especially me!
 
"What have I gotten myself into?"
That's exactly what I said to myself after buying this basket case from a friend in 1983.

There was no internet then, I only had the manual for guidance. No previous bike building experience either.
But I had it on the road in 4 months.
My big advantage was that I wasn't married back then.
Your bike shouldn't be too big a problem, but the wife will.

Suggestions?
For life insurance, replace the layshaft bearing in the gearbox with a roller or improved ball (Mick Hemmings) type.
For easier kickstarting, a folding RGM kick lever. I haven't done this - yet.
Electronic ignition.
Others believe a disc brake is essential, but my drum is fine for my use. I don't have a stiffening kit in it.
There are dozens of mods you can do - big and small - depending on what you desire.

Basket Case Project - What Have I Gotten Myself Into?

Basket Case Project - What Have I Gotten Myself Into?
 
Good luck and patience will produce an enjoyable machine in the end. My only solid advice would be to check out the gas tank. If it's fiberglass, not metal, its best use will be as a wall ornament. You're lucky in that in the last year or so EMGO has been making decent replacement metal Roadster tanks.
 
cyclegeezer said:
Good luck and patience will produce an enjoyable machine in the end. My only solid advice would be to check out the gas tank. If it's fiberglass, not metal, its best use will be as a wall ornament. You're lucky in that in the last year or so EMGO has been making decent replacement metal Roadster tanks.
Click to expand...
Thanks for this tip, I had assumed I could just coat the inside of the tank with something but I just did some reading and people seem to have mixed results. In order to save some money up front I may treat the tank, see what happens, and then if it fails I'll be forced to bite the bullet.
 
Question: I got two different pieces of advice above. One was...

ashman said:
...probably be a good idea to pull it right down, a new set of bearings and rings if the bores look good.
Click to expand...

The other was...

MFB said:
For life insurance, replace the layshaft bearing in the gearbox with a roller or improved ball (Mick Hemmings) type.
Click to expand...

Am I correct in assuming that these are references to two different bearings? Ashman is refering to replacement of the crankshaft main bearing and MFB is refering to replacement of a bearing in the gearbox. Is that correct? I'm nowhere near needing to do this yet - I'm really just trying to get an idea of the list of projects and parts I need to get in the process.
 
wrecks said:
Question: I got two different pieces of advice above. One was...

ashman said:
...probably be a good idea to pull it right down, a new set of bearings and rings if the bores look good.
Click to expand...

The other was...

MFB said:
For life insurance, replace the layshaft bearing in the gearbox with a roller or improved ball (Mick Hemmings) type.
Click to expand...

Am I correct in assuming that these are references to two different bearings? Ashman is refering to replacement of the crankshaft main bearing and MFB is refering to replacement of a bearing in the gearbox. Is that correct? I'm nowhere near needing to do this yet - I'm really just trying to get an idea of the list of projects and parts I need to get in the process.
Click to expand...

Yes, two different bearings. The Norton Commando never went unit construction, so the gearbox is a separate item from the engine. The layshaft bearing is critical, must be checked before you ride the bike. My '74 had the dreaded Portuguese bearing in it, I replaced it before it could cause any trouble.
 
I found a photo of my father with the bike back in the early 1970's - probably shortly after he purchased it. It looks like the bike was an SS with a yellow tank when it left the dealership. He says he swapped the yellow tank out for the red one on it now because the original was too small and he swapped the pipes out to the lower style of pipes because the high pipes made it awkward to ride and were too hot.

I asked him about pants - unfortunately he just recently got rid of them :D .

Basket Case Project - What Have I Gotten Myself Into?
 
A few suggestions that slipped my mind previously:

A dynodave clutch rod seal will keep gearbox oil out of the clutch.
The isolastic rubbers will probably be shot by now. Replace with vernier adjustment type for ease of maintenance.
Use multiple grounds to the engine. The more the better.
I'm a fan of belt primary drive, but that's your call.
Basket Case Project - What Have I Gotten Myself Into?
 
Cool pants on your dad. I would suggest not messing with the F/G tank unless you have a supply of non-ethanol. If the tank melts and gets into the carbs, that's a complete engine job. Just spring for the metal tank, or non-ethanol if available. Looks like you have a complete bike there, there's no magic in putting them together, but figuring out where things go if you can't remember is a slight issue, you will have plenty help here, believe me. New side stand is good idea. Trans layshaft bearing is good idea. New crank bearings of proper type is good idea. Imported parts from UK are sometimes a deal despite the shipping depending on bank rates, like total lower end rebuild parts. If I can rebuild mine in a spare bedroom, you can too. Good luck, I'd like to see it on the road soon.
 
wrecks said:
I guess that one mans basket case is another mans "easy rebuild." For a guy like me with little to no experience this looks like an insurmountable pile of parts. That said, I'm actually encouraged that you all think this looks pretty straightforward. My wife thinks I'm crazy and when I gleefully told her that my Dad was dropping off the Norton she said, "You know our daughter starts college this year and we need a new roof."

The original tear down was to get to the cracked cradle. We couldn't get the cradle separated from the swing arm so at one point a guy welded a patch from one cradle onto the one currently on the swing arm. I'm not sure this was a good fix so I'm going to have to look at that more carefully and figure out what to do.

Thanks for the suggestions so far. I'm definitely in need of a list of "must do" repairs and replacements. I had intended to pull the motor down farther and replace the main bearings and check the cylinder bores. I'm not sure what dynodave is referring to with the sidestand - but sure - I'm happy to add that to the list. I'd love more suggestions regarding where to begin!
Click to expand...

I repaired a cracked cradle similarly many years ago. it isn't pretty, but it's better than having the power unit flopping around like a fish. What Dave is referring to is a poorly-designed sidestand on '71 models that can be properly repaired/replaced with updated parts. It requires a new pivot be welded to the bottom of the frame, but when doing a complete resto, the repair is easy.
 
wrecks said:
In the early 1980s my father and I dismantled this 1971 Norton Commando to move it down some narrow stairs into a basement and fix a cracked cradle. Then in the late 1980's we took it apart a little more in order to start a restoration. Today my father dropped it off at my house and my hope is that I can reverse the progress and actually start putting it back together. Along the way I assume I'm going to need a lot of help and guidance from this forum.

Basket Case Project - What Have I Gotten Myself Into?
Click to expand...

Where are you at? Maybe one of the local Norton guys can stop by and give you a hand? Or at least some advise! Never hurts to ask.

John in Texas
 
MFB said:
A few suggestions that slipped my mind previously:

A dynodave clutch rod seal will keep gearbox oil out of the clutch.
The isolastic rubbers will probably be shot by now. Replace with vernier adjustment type for ease of maintenance.
Use multiple grounds to the engine. The more the better.
I'm a fan of belt primary drive, but that's your call.
Basket Case Project - What Have I Gotten Myself Into?
Click to expand...

I don't see the clutch rod seal in this photo :) Got one on mine also.
 
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