VMCC Castle Acre Run

 Sunday dawns and I'm up early to get to the start of the Norwich & District VMCC Castle Acre Run but first, it's a trip on the W/NG to deliver the TS125 tank:

With the tank back on the MZ, son Tom starts the freshly oiled & fuelled SQ4 that he will ride today. I'm on the modern Interceptor, just for a change. 

First stop is at the start of the run, for tea, a chat and to sign on. Lovely barn conversion and outbuildings:

At 11:00, we depart for the 37 mile trip to Castle Acre, following the Tulip route sheets. I make the mistake of relaxing at the back of a line of two bikes who miss a turn and I have to double back, messing up my calculations. We arrive eventually, and I'm not last, though I expect to find Tom and the SQ4 there already. He's not, and it turns out he's stopped to wait for me, witnessed by the missed calls on my phone. He turns up a few minutes later and we have lunch.

Two portions of loaded fries and a chat later we wander out to look at the bikes, and do some more chatting...

The rest of the section will take another 37 mile run back to the start, but since that would be in totally the wrong direction for us we say our goodbyes and head back to North Norfolk.

Totals for the day - 130 miles for me aboard two different bikes; about 100 of those on the Interceptor. The SQ4 is going really well and uses negligible oil, and consumes fuel at 50 mpg!

Have to take it a bit easier next time.

MZ TS125 - Petrol tank rust repair

This is going to be a bit of a leap of faith - my first fuel tank repair. This is an MZ TS125/150 tank from son Thomas and has fortunately been empty for many years, having been stored in the open in someone’s garden - no wonder it’s rusty.

It’s made from two deep pressings, with a third to form the arch over the frame top tube. There appears to have been a butt weld between the two halves, which has corroded to holes. My plan is to take out the whole weld, all the way around, along with a 1/2” strip either side and then let in a 1” strip of 0.9 mm sheet. I make no apologies for mixing units - anarchy is alive and well here in the workshop.

Using the little Dremel discs to cut out the strip makes the job easy. It’s ideal if you can keep the sides parallel, since then you can make a filler with parallel sides and have a minimal gap which will require minimal filler material. 

I held the sections in with magnets while tacking up:

The first section went in OK - I welded in short sections to avoid overheating the material and causing distortion:

It’s quite a slow job, but if you make sure you have a good position as you weld it’s not too difficult.

I used the little belt sander to clean the welds back:

Not a bad result, though it will need a skim of filler:

Pressure testing revealed two pin holes in my welding which were easily fixed. More worrying is a further pin hole behind one of the brackets, which is completely inaccessible and looks like it might turn into a bigger hole:

I’m going to use a tank sealant to fix that. More later.

TS125 - A new bike joins the flock

The trusty L200 earns it's keep again today, first transporting an ancient wooden door to the cottage to be adapted for the kitchen, and secondly to collect my son's latest acquisition, another TS125 - his fourth MZ:

It's in decent nick - the seat and battery cover are missing, but the carburetter is there and the barrel and piston are in good shape:

He has a registration plate for it which shows it is on the DVLA computer and has lain untaxed since 1994.

MZ Frame coming along

The TS125, in another part of Norfolk, is coming along slowly. This week, some reassembly and some painting.

Front mudguard:

Headlamp brackets and fork shrouds:

Here's the centre stand spring being stretch in time-honoured fashion

Back on the frame:

Spanners removed and the stand is back in action:

Fork yokes back in:

First steps

Now that we have a little break from work and a bit more free time, the MZ assembly can start. Today the swinging arm is re-united with the repaired and painted frame:

MZ Sees Light of Day!

Since we did the frame repair, my son Thomas and his family have moved house and the MZ TS125 has moved with them. He's now getting his garage sorted out and the MZ is beginning to see the light of day.

This weekend the Hammerite has been out on the seat base:

You can put this stuff on over mild rust

A bicycle repair stand is a useful aid for painting awkward parts:

Here's the repainted swinging arm

 And here is the repainted frame we repaired way back:

Rusty metal

While it doesn't look too bad from this angle, the battery tray on this MZ TS125 is falling apart due to acid damage. There is a crack from one of the hooks for the battery retaining strap which means that that tab, with the M5 hole for the side panel is quite floppy.

Since it was only going to cost me a few minutes, I tried to braze it up but in practice it is all too thin to have any strength, so the easiest thing to do is cut it off and make a new one. The bracket used to mount the battery tray on the frame is sound, so we can cut the tray away from it retaining as much as possible of the old tray to provide a pattern for a new one.

I have some 18 SWG cold rolled sheet in the shop, which is a good deal thicker than the original which looks like 22 SWG. You can see the extent of the damage in these pictures.

The new one is very simply folded from sheet, cut out with the jigsaw & hacksaw and with 5 mm holes drilled into the corners for clearance and drainage. We'll tack the corners together with the MIG welder.

Here's the hooks folded down and around the old strap.

So now I have transferred the side panel tab to the new tray, and brazed it in place in case I have to move it again. Next, to weld up the corners and finally weld the tray back to the frame:

Welding the outsite of corners is tricky if you are not to blow the material away completely; my welding needs a lot of dressing! Corners done, we'll tack it in place using the old one as a guide:

We'll need to fit some other parts around it to confirm that the side panel mount is in the correct location, and then we will complete those welds underneath. Removing it with those fully welded would probably destroy my new tray.

Just a little U-Pol etch primer to avoid rusting...

A few days later I have the cast aluminium rear mudguard and the coil bracket to mount up and test my new battery bracket. I'll put the lot in the vice and mount the rear end with some 10 mm pins, that are a close fit in the holes and don't allow any wobble:

You can see the three M6 mounting holes for the side panel - one in my battery bracket, one on the coil bracket and one in the mudguard. Here's the side panel mounted up:

Perfect! now we can weld up and apply some paint.

And that's it, ready to be returned to its owner.

Huntmaster - the next steps

Hopefully the next month will see a bit of space appear in the garage when the MZ TS250/1 departs for a new life. When that happens, we will be able to crack into the Huntmaster. This is the general plan:

1. Complete the dry rebuild of the forks & nacelle, leaving cleaning up the oil seal holders until strip down;
2. Get the mudguards, seat base and chain guards grit blasted ready for welding;
3. Build up the frame and swinging arm, dry fit engine plates, gearbox, seat, swinging arm, mudguard etc.;
4. Repair the seat base, chain guards and mudguard while the frame is on the bench & available for test fitting;
5. Strip it all down and prepare for painting;
6. Send the black parts to the Horsford powder coater;
7. Send the tanks and toolbox to Ian Potter;
8. Strip and rebuild the gearbox & clutch;
9. Strip the engine, inspect and send the bottom end to SRM, including the original cases;
10. Recondition the dynamo;
11. Send the magneto for refurbishment;
12. Clean the wheels and fit new Avon tyres;

We can work on the rebuild process later - that is quite enough to be going on with! Feel free to comment.

The only fly in the ointment? This:

Another TS125, whose frame is already in my workshop for a battery tray repair...

Yet another Iron Curtain relic...

My dear son Thomas has a habit of bringing home examples of the finest Eastern Bloc motorcycle engineering available for under a tenner, mostly from eBay.

This was the first one:

It's a Minsk 125 marketed in the '70's under the Neval banner, and is one of those myriads of DKW RT125 copies of which my Bantam is a fine example.

He painted it, serviced it and we spent months fiddling around with a peculiar electrical system with no battery that was never going to drive those indicators without flashing all the other lights at the same time. It went OK though. 

He sold it for a profit, financing the purchase of whatever students drink these days.

It was followed by an MZ TS125, courtesy of eBay, it was the Luxus model (the one with the real hair?) with the rev counter. This was a bit more adventurous as when it arrived it had no wheels, tank or seat. He collected from somewhere in Hertfordshire, on the way to my Dad's funeral. He turned up behind the hearse with this MZ stuffed into the back of our Morris 1000, which was never the same again. And no, it wasn't an estate, or a van, or a pick up - just a regular two-door saloon.

Here it is:

He did a great job with it, collecting all the missing parts, repainting & rebuilding. This is how it ended up:

Strangely enough, it looks just like any other TS125 doesn't it! It ran pretty well once we got it going, which in itself was an adventure because some numbnuts had fitted a home made base gasket without cutting the transfer ports in the gasket. Puzzling - the carburettor had fuel in it, the jets were all clear, but the plug was dry...

He now has this one as well, which like all true enthusiasts he has in his dining room - along with cats & rabbits. His girlfriend, bless her, is just as enthusiastic! It quite brings a tear to my eye, reminds me of the 250 Matchless that used to occupy our living room:

So this is the latest addition, another eBay find. We bought this one together - I paid, he went & collected it - as a kind of joint project & a 'congratulations' for getting a promotion at work:

This is how the advert was worded:

1981 MZ TS250/1 Supa 5 restoration project or for spares.
Both tyres are useless and have punctures, the silencer has the usual case of MZ Rust Scabies, both tank panels have quite good chrome for an MZ but aren't perfect. The grey colour is primer and the general gunky condition is old Waxoyl put on years ago to try and help preserve it.
Engine kicks over freely and seems to have quite good compression, all gears seem to select - but it's not a runner and there's no Tax or MoT so please don't think you can ride it away. (It's happened!).
It has the correct front indicator lenses, sound speedo and tacho brackets and the rare-ish side stand plus a Rear lens and tool-box cover (no lock) come with it.
Originally bought by me (in this state) as a source of spares for my other Supa 5 back in 1994......and there it's sat ever since; and as my ride to work Supa 5 has long since gone this may as well follow it.
Interesting number plate? TEX 6**W
All in all a nice little project that just needs a little T.L.C........you could have it running by the weekend (lol)!
Just to re-iterate this is a non-running project, with no Tax or MoT so you will need a van or trailer to take it away (I'm unable to deliver). We are near Bury St. Edmunds in Suffolk.
Having said that, there is a possibility I could take to Beverley (near Hull) for collection from there on 23rd February - but it is only a possibility, so PLEASE contact me first before assuming it's going to happen!
Any queries, please email before bidding.

And here is another view:

Now that is it at home in my garage (another thing he has learnt - why put stuff in your own house when you could leave it at your Dad's?), I have to say it is a fine machine. The Waxoyl the previous owner (I don't know his name) smeared all over it has made a great job of preserving the alloy and some of the chrome. It has apparently been standing in a garage for the past 20 years.

The rubber is shot to bits though. I was tempted to put some tyre sealant in the tyres just to move it around more easily, but on screwing the can onto the valve I found the valve completely detached from the tube!

So there it is. Waiting a bit of time, for #1 son to buy a battery and for me to take a trip to Leeds, where I understand Wyldes have some tyres at a good price...