Saturday, August 25, 2012

BSA 441 Board Tracker- Brake stay, exhaust

The front brake stay on this bike was kicking my butt. On most bikes with traditional fork tube, the axle holds the wheel, and the brake stay bolt solid to the brake plate and the lower fork tube, no movement, it all stay in the same relation to each other.
On the Honda Dream front end I am using on the 441 since the axle & wheel travel one a pivot arm at the bottom of fork, the brake stay bolting to the fork housing, and the brake plate in wheel have movement between the two. So the brake stay arm needs to be rubber bushing'ed on the ends, and ideally travel in the same arch as the axle pivot arm. And switch sides from the original Honda set up.

Figured it all out. I Put the new mount in various places with suspension and axle and brake plate in place to test suspension travel with the brake stay travel. The old sheet metal mount on other side will be removed.

And a sexy shot of the exhaust and tail lamp.

Friday, August 24, 2012

BSA 441 Board Tracker, Seat leather 2.0

I had done a seat leather earlier weeks ago, but it was not a desirable unit, so I made seat cover number two and stuck with it a bit more. To make a piece of thick natural leather form to something you soak it through with water for a while and lay it on, or wrap it around what it will need to shape to. Theres is no speedy way to do this, you just keep running fingers over shapes, pulling it around edges, in this case sitting on it on and off so it would press to shape and as a bonus, my jeans would soak some of the water out to speed it a hair.
This one I have about 90 minutes in of every 5 minutes or so working it for a while, and repeating until it dries enough to stay.

Here it is after soaked and rung out a bit, just starting to shape it.

 Here is after a while, and it starting to behave.

 Here its about 60% dry and starting to hold its shape. When it is dry all the way in to morning, I will trim it around the edge, and stain and seal it, then a little stray adhesive and waa laa.

Thursday, August 23, 2012

BSA 441 Board Tracker Exhaust

Im reusing for the most part the stock exhaust from the 441. It looked like it was fairly new not long ago, but was already pitting. I sanded it for an hout or so with 40g then 80g , and welded muffle to pipe so they will be no clamp needed to ugly it up. It will go black, with the brass coated heat shield.

441 BSA Board Tracker fork prep

Getting some details on the fork done before paint. I needed to cut out a bit of the inside sheet metal on the brake plate side to clear when suspension compresses , and I wanted to add a bit of support to lower axle pivot area with some subtle flair.

Bsa 441 Board Tracker assembly. Seat and brake stay.

Heres the final mounting for the seat, rubber bushings to isolate a hair more from the road.

Made a new rear brake stay, thought it should have something a bit more hand made looking then the stock BSA flat steel piece. Its will go semi black, as more accessories surrounding frame will. Im trying to be very careful not to have any parts of this bike look modern in the least. Id like the appearance to be like it could have been made long ago.

Wednesday, August 22, 2012

441 BSA Board Tracker painting and assembly

I made a rear seat support gizmo, the curved looking piece. 

Painted the deat parts and added some new hardware to make it a bit more respectable looking.

First time ever the chain was to right length out of the box, no trimming or addding links. Also the greasiest new chain ever I think.

Tuesday, August 21, 2012

BSA 441 bits and peices

Cleaning a few thing to metal prior to etching primer and paint. The seat consist of 2 seat pans that cradle each other. Originally they would stretch material over top pan around to edges, then press onto bottom pan and it held the material perfectly. I welded the support up a bit to make it stronger.

Monday, August 20, 2012

441 Board Tracker wires, I like.

I will get more relevant pictures up later tomite, but I was thrilled to see this come today. Nice cloth covered wires and water tight cloth wire wrap. Nice.

Saturday, August 11, 2012

BSA 441 Board Tracker.. Coming Together

Its starting to come together nicely. I love Black, Metal, and Gold. I will do a few details to the motor, the oil T tube on top looks a bit out of place as do some of the nuts and hardware, they will be removed and gone over.
This is where all the little fun things start to actually be fun.