The '68 Rebuild Begins - Slowly

maximini · Apr 9, 2011

I spent the winter breaking down my '68 project bike and refinishing/restoring each and every part. I was really starting to wonder whether I would ever get to the point where I could begin assembly, but finally just about every part was done and reassembly has begun. Here are some photos

Powder coated frame

New head race bearings installed and trees on

Trying to attend to every last detail takes a good bit of time

Put the instrument cups on to make myself think I was making some progress

Fork reassembly after installing new bushings, springs, etc.

More to follow

grandpaul · Apr 9, 2011

That's as good a start as any I've seen.

Looks like a possible contender for "Most improved 2011".

Did you take a "before" photo by any chance?

maximini · Apr 9, 2011

Thanks for the encouragement GrandPaul.

The starting point for this project was not too bad. I usually start with much less. The bike was in a display and had not been run in many many years. The tanks and accessory cover were painted with a thick coat of black urethane and the head and most of the alloy parts were painted with some sort of aluminum paint that was extremely difficult to remove. In some areas the aluminum paint was just a fogging coat to make the bike look better for display, but the head had several thick coats on it. All and all the bike was still a pretty good starting point as most everything was original.

This is the bike before I tore it down. It looks better than it was from ten feet, but it was all there.

grandpaul · Apr 9, 2011

Yeah, those "Ten Footers" can be the most deceptive!

KSUWildcatFan · Apr 9, 2011

This is going to be an awesome bike. GREAT start.

Tintin · Apr 9, 2011

maximini said:
I spent the winter breaking down my '68 project bike and refinishing/restoring each and every part.

Just out of curiousity: What does the headstock area look like from the side? My (unfortunatly FUBAR) 1968 frame was very different from my 1970 frame - it had the old tank attachment "ears" welded to the front down tubes, the infamous convex side brackets but also a horizontal tube that was obviously welded in later. Lots of fiddling around the head steady mounting point. And it has the No. stamped into the headstock directly.

And what's that four-wheeled thing with the red live axle? :wink:

Tim

DogT · Apr 9, 2011

Maxi,
You are probably going faster than I was, it took me from about 5 years to sort everything until I got the frame powder coated and then it went fast. I even rebuilt the motor in the last year, so you are not far. Looking good.

Dave
69S

maximini · Apr 9, 2011

Tim -

This is a picture of the headstock area from the side (sorry about the protective pipe insulation on tubes). The original frame was replaced with a new frame by the selling dealer shortly after the bike was sold. The new frame has the serial number stamped in the headstock and the Norton ID tag is over that. I had a new ID tag stamped and kept the original in the restoration binder.

The white and red car in the picture is a 1927 Amilcar race car.

maximini · Apr 9, 2011

Dave -

I had the rare luxury of having tons of time to work on it this winter. Your bike came out great and shows the time you invested.

The '70 'S' is patiently waiting for this bike to be finished so I have an incentive to keep pushing!

Maxi

Foxy · Apr 9, 2011

Gday Maxi, that powder coat sure looks nice. I've never seen nor heard of that bike lift, EAZY RIZER, good thing?
FOXY

maximini · Apr 9, 2011

The bike lift works very well. It's small and stable.

Stephen Hill · Apr 9, 2011

Maxi, it sounds like you have much of the history of your bike. Clearly the original 1968 frame was replaced at some point. I am curious: does the later frame have the original frame number? Do you know if this frame was replaced as part of the factory recall around 1969 or 1970, or do you think it was done much later? I am also curious about the numberplate on the frame. They did not come on 1968 frames. If the frame was replace under the factory recall, would it have come with a numberplate? I admit I am unsure if numberplates were standard issue in 1969. Thanks for any insight you can provide.

Stephen Hill

1968 Fastback
1969 Mercury
1971 Roadster
1972 Combat
1974 Interstate

possm · Apr 9, 2011

Looking good- have you been able to sorce new tank and tail badges as i have a early 69 that is missing the tail badge?
Al

maximini · Apr 10, 2011

Stephen -

The frame was replaced very soon after the bike was sold. The owner was told by the dealer when he brought the bike in for service that the frame needed to be replaced per Berliner. This was within the first six months that he owned the bike. The dealer stamped the headstock with the ID number. I have an old (and very beat) ID tag that was on the bike when I bought it that bears the ID number and is stamped MAY 68. Apparently the original owner had the dealer put this tag on when the frame was replaced, but I did not think to ask him whether the tag had been put on the original frame at the factory.

Maxi

maximini · Apr 10, 2011

Al -

I am still working on the badges for the tank. The type that are currently in production (Andover) are thin flexible plastic things. The new type actually look concave when put into the recess in the fuel tank. These are a poor replacement for the original hard plastic domed type.

I have a couple of emblem restoration guys I am speaking to about it. If I make any headway I'll let you know.

possm · Apr 10, 2011

thanks maxi, i also need to sorce arigonal style mufflers have you puchased any? i see Andover and Armours both list them i am woundering what the quality is like as it is a long way fron NewZealand to England if they are not right.
Thanks Al

maximini · Apr 10, 2011

I bought a pair of silencers from RGM in the UK. The quality is very good. They are made in the UK. Talk to Roger, he's honest and helpful.

maximini · Apr 11, 2011

Well I had three entire days to do nothing but work on the re-assembly - what a rare luxury. Here are some pictures:

Fit-up of tires on re-chromed rims and rebuilt hubs

Rear wheel and suspension

Front wheel rebuilt and fit-up

Rebuilt gearbox goes in

Rebuilt (by Kenny Cummings @ NYC Norton) engine fit-up

Could not resist - had to put the tail on before calling it a day

Tomorrow is another day - we'll see what that brings

KSUWildcatFan · Apr 11, 2011

Wow! That is looking absolutely stunning. That front brake is a thing of beauty. Keep up the great work!

-Jordan

DogT · Apr 11, 2011

It looks like the 'S' and the Porsche is relegated to the dustbins of history?

What is it about these early bikes we like?

Dave
69S

The '68 Rebuild Begins - Slowly

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