Fork Bellows Installation

Atlas Commando

Atlas Commando

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I want to use BSA/Triumph style rubber bellows on my '72 Commando. It won't be correct but I like the look and it seems practical. I bought a pair of bellows several years ago, and today I finally tried to install them on my newly rebuilt fork tubes. I could readily slide them down the tubes, but the bottom bellow ends are nowhere near wide enough to easily stretch them over the top of the sliders. My present idea is to find some suitable metal rods or screwdrivers or ? that I can insert into the bellow end, not unlike a set of tire irons. I think it could take 5 or 6 of them. I could then use hose clamps to pull the 'irons' in such that they are close to parallel to the fork tube. It might then be possible to slide the stretched bellow over the slider, assuming it doesn't rip due to this abuse.
Does anyone have a better idea? Did I possibly buy the wrong bellows? Any help is appreciated, obviously not urgent based on the rate my restoration is going.... Thanks for your time.
 
Atlas Commando said:
I want to use BSA/Triumph style rubber bellows on my '72 Commando. It won't be correct but I like the look and it seems practical. I bought a pair of bellows several years ago, and today I finally tried to install them on my newly rebuilt fork tubes. I could readily slide them down the tubes, but the bottom bellow ends are nowhere near wide enough to easily stretch them over the top of the sliders. My present idea is to find some suitable metal rods or screwdrivers or ? that I can insert into the bellow end, not unlike a set of tire irons. I think it could take 5 or 6 of them. I could then use hose clamps to pull the 'irons' in such that they are close to parallel to the fork tube. It might then be possible to slide the stretched bellow over the slider, assuming it doesn't rip due to this abuse.
Does anyone have a better idea? Did I possibly buy the wrong bellows? Any help is appreciated, obviously not urgent based on the rate my restoration is going.... Thanks for your time.
Click to expand...
Why not use the gaiters meant for Norton: https://andover-norton.co.uk/en/shop-details-2/23019
 
I brought my Gaiters from RGM fit perfect and also got the slim SS clamps for top and bottom of the gaiters, been on my frontend for 15 years now and they still looking good, keeps the crap out of your fork seals.
You could try some rubber grease on the inside bottom of the gaiters and might be able to stretch and slide them on with a small screwdriver even the right gaiters need a bit of stretch and pull to get them over the wide fork leg, the grease helps with the screwdriver without damaging the rubber.
 
Oh, wait! Wouldn’t a BSA seat and grab bar look better on a Commando than what the manufacturer intended?
 
Atlas Commando said:
I want to use BSA/Triumph style rubber bellows on my '72 Commando. It won't be correct but I like the look and it seems practical. I bought a pair of bellows several years ago, and today I finally tried to install them on my newly rebuilt fork tubes. I could readily slide them down the tubes, but the bottom bellow ends are nowhere near wide enough to easily stretch them over the top of the sliders. My present idea is to find some suitable metal rods or screwdrivers or ? that I can insert into the bellow end, not unlike a set of tire irons. I think it could take 5 or 6 of them. I could then use hose clamps to pull the 'irons' in such that they are close to parallel to the fork tube. It might then be possible to slide the stretched bellow over the slider, assuming it doesn't rip due to this abuse.
Does anyone have a better idea? Did I possibly buy the wrong bellows? Any help is appreciated, obviously not urgent based on the rate my restoration is going.... Thanks for your time.
Click to expand...
What I do is get a plastic 1 gallon milk jug. Cut a section out of it, then wrap it around the fork slider. Pull/push the gaiter over the section of plastic milk jug. After the gaiter is low enough to engage with the slider, pull the piece of plastic. No hammers or tire irons required.:cool:
 
Yeah if you need to put a little lube on the lower section of the gaiter that you stole from your wife's panty drawer, then do what you have to do.:)
 
Modern rubber gaiters do not last as long as they used to. If you stretch them more than intended they’re gonna last even less before splitting. Not advisable IMO.
 
Atlas Commando said:
I want to use BSA/Triumph style rubber bellows on my '72 Commando. It won't be correct but I like the look and it seems practical. I bought a pair of bellows several years ago, and today I finally tried to install them on my newly rebuilt fork tubes.
Click to expand...
Could you please confirm whether you bought BSA/Triumph bellows or Norton ones?
 
Thank you for the interesting array of answers. It's been so long since I sourced these gaiters it's easy to imagine that they are the incorrect parts. I recall the first Fastback Commandos came with rubber gaiters back in 1968. It's interesting that Andover lists their parts as being suitable for 1971 onwards. I think I'll try the milk jug idea and if that doesn't work I'll order from Andover or RGM. I could simply get the 1972 parts but it was never much fun getting stone chips on the sliders leading to fork seal leaks.
 
on the basis that you will already have the wheel out, and the brake caliper and mudguard removed, it's only a matter of taking the top cap out and slackening the pinch bolts on the yokes to drop the fork leg out, then fitting the gaiter is easy. And a good opportunity to drain the fork leg and put new oil in. Agree gaiters are the way to go for stanchion longevity. I usually secure them with black ty-raps.
 
This bike has been in crates since the 90's, no need for any disassembly. My challenge is simply getting the gaiter bottoms stretched over the top of the fork slider. I have a suggestion to cut some strips from a milk jug to use as 'ramps' but then I remembered we don't have those jugs down here south of I-10. I moved south back in 1995. Maybe I'll bring a jug home on my next visit. Meanwhile I am cutting some strips from a plastic tub lid. It doesn't look like they're going to be stiff enough. I did look up my parts order history. I bought these gaiters back in 1998 from Old Britts. It's entirely possible that I've got the incorrect ones. I have two more techniques to try before I give up. Thanks for responding!
 
Windex-type window cleaner is the best lube as it dries clean. I use for tire installation. Heat gun is also your friend. Good luck.
 
I have an outstanding order with British Cycle Supply and it's ready to ship. They reached out to see if I had uncovered any more bits and pieces that I might want to throw in the box. I mentioned rubber bellows and here's what they responded with:

’68-’70 forks: 2-1/4" &2-5/16” ID, 16 RIBS, 9" LONG

’71 on: 1-11/16 & 1-5/16" ID, 20 RIBS, 7-3/4" LONG.

The ones I have been struggling with don't come close to either of these, obviously meant for a different machine altogether. I'm ordering a set for the '68 -'70 forks. Those i.d.'s look a whole lot better. When I get the order placed I'll provide part numbers for anyone else who would prefer to run rubber bellows (gaiters?).
 
hhh said:
Note that it's a nerve toxin, so try not to inhale and wear gloves.
Click to expand...
Dang, too late for me!

Fork Bellows Installation
 
Me too! Probably explains the progress I'm making on getting this bike to run. I was thinking of charting 'parts installed per year'. Meanwhile, if you are fans of the Fastback Commando style fork bellows, here's what I found out from British Cycle Supply:

"The original part number is 02-0463; the ones we can source that will work are our part numbers 531-15 or 531-27/ER, as the ones of the same era for the BSA and Triumph twins will also fit the early Commandos."

I didn't check with Andover or RGM, it was just too easy to place the order with British Cycle Supply there and then.
 
I'm thinking a set that fits a 73 and later Triumph t140 750 would work. The stock Triumph cap is small like a Commando but the aftermarket makes gaiters. As I recall the tops of the sliders on a t140 and a Commando look close to the same diameter.
 

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