two more odd questions.......

Hi folks:

I'm getting closer and closer to firing up the basketcase! two questions that come to mind that I need the collective expertise to figure out:

1. What is the tap size for the front-most inspection cover? (over the rotor) mine was missing and i got a new one from old-britts BUT the threads on the housing are chewed up and I need to chase them (I'm here praying that it's not )(*&()whitworth so I can go to a machinist friend and punch this out)

2. I can't for the life of me find a mounting point for the LOWER rubber grommet that holds the left side cover in place: I found in my bits the upper grommet plate that attaches to the frame but I can't find anything in any manual or on line about where the lower grommet attaches to the frame....I'm sure I can jury-rig something but I'd rather use the stock configuration

as always, thanks

Karl

The lower peg for the side cover is part of the battery tray.

Karl,

1) I hate to be the bearer of bad news, but the points housing is a 2BA thread form. That being said, you can get a 2BA helicoil kit from British Fasteners. I had this same problem when I crashed my Interstate as it pulled the stud from the timing cover. The 2BA helicoil did the trick.

2) The mounting peg for the lower grommet on the side cover is part of the battery tray. If your tray is mounted in the bike, then perhaps it was broken off?

Hope this helps.

71basketcase said:

1. What is the tap size for the front-most inspection cover? (over the rotor) mine was missing and i got a new one from old-britts BUT the threads on the housing are chewed up and I need to chase them (I'm here praying that it's not )(*&()whitworth so I can go to a machinist friend and punch this out)

Click to expand...

It's not Whitworth, I measured a cover plug, and it was just under 1-1/8" (1.116" approximately) x 20 tpi, so that rules out all the commonly known BS threads (1-1/18" BSW would be 7 tpi).


What you could do is find a tap of any thread type that has the same tpi as the cover threads (20 tpi?) and then use one of the tap's cutting edges to carefully clean up the threads by using the tap as a scraper to chase the thread?

71basketcase said:

I can't for the life of me find a mounting point for the LOWER rubber grommet that holds the left side cover in place: I found in my bits the upper grommet plate that attaches to the frame but I can't find anything in any manual or on line about where the lower grommet attaches to the frame....I'm sure I can jury-rig something but I'd rather use the stock configuration

Click to expand...

The lower L/H side panel fixing peg would have been an integral part of the battery tray?: http://www.norvilmotorcycle.co.uk/062557.htm The bracket is shown lower-left in the link photo.

20 TPI was an option on all sizes 1/2" and above on British cycle threads, 20 TPI was used on unf (7/16" maybe) so get this tap and then as LAB suggests use this to recondition the threads by scraping around the thread. This is the same technique I used on a oil filter insert thread on a BSA oil tank and it worked well.

unified thread & brit. cycle are 60 deg so no issues there either.

thanks so much:

the battery tray was an e-bay find, and it didn't have that appendage....back to plan B for that part: no biggie, honestly

20 tpi eh? I'll definitely do as you suggest! off to the basement!!!!!

thanks again all.

kfh

Sorry for the confusion guys, I thought he meant the ignition rotor.

IT WORKED!!!

thanks to all who recommended the 20 tpi tap trick: I used a brand-new(ish) 1/4x20 tap and took my time ........ it cleaned the threads nicely AND I found a small-ish burr on the cap as well.

that baby spins on there like the day it was made!

I'll be fabricating something for the side cover....

thanks, all

Karl