FH - inching closer...

 The day seems to have disappeared again without too much workshop time but at least I've got a little bit done. 

The choke cable is now terminated to the right length, with a new nipple at the carburettor end. I didn't have the flat nipple that goes into the lever unfortunately and I didn't fancy making one on the lathe but I did have a little tiny one that goes in the choke slide.

There's not much to see here but at least we have a throttle slide and a choke slide that move independently of each other and don't have any slack in the cables.

The next little job is to make a couple of 5/16 CEI bolts to retain the finned exhaust clamps. Here I'm reducing some 0.445" stainless hex bar to the appropriate diameter for the bolts I need.

They're going to have a chamfer feature where they mate with the clamp - here is the chamfer on the clamp itself. When I have cut the thread on the bolt I will work out what the height of the bolt head above the clamp face needs to be:

That's all for a bit. I've got a 10-hour turn on the railway tomorrow which won't finish until after 11:00 at night, and then my grandchildren are coming for the weekend. Hopefully we will get the speedometer in the post either tomorrow or Saturday, so they'll be plenty to play with next week. I'll order the V-Reg2b voltage regulator as well, so we can convert the RB108.

FH - a bit more done

 Eventually I found the indicator switch in a box marked 'Lucas SSU700' - which had no headlamp in it, but a complete set of Lucas indicators - which allowed me to finish the wiring in the headlamp, and put the wiring tools and materials away. All I have left is the speedo lamp, and for that I need the speedo back - oh, and the indicators work, save for the fact that they are currently fitted with 12 V bulbs. I've ordered some new bulbs.

The choke lever that came with the kit is not an original Amal lever - it looks like a Doherty to me, and it's pretty corroded:

The 1958 Amal catalogue shows levers with ball ends - fortunately I had one in a box of levers:

That's it for the bits and pieces jobs. Now I have this package from Draganfly - with these bits I can do the dynamo chain and close up the timing case, and I can finish and fit the rocker box.

Unfortunately those finned clamp screws are the wrong size - my fault, not Draganfly's, so if I can find some 0.445" hexagon bar in stainless I will make some.

FH - various jobs

 There's lots of little jobs around the bike to be getting on with. This one is the dynamo cork gasket which I bought from eBay. It was a little big and needed 3/8" taking out of the circumference.

That's the dynamo chain in place. I had one with a split link which I think is unusual - but I think that this is the original chain. I replaced it with an endless one from Draganfly. It's very difficult to tension because whilst you can turn the dynamo to tension the chain, as soon as you do up the clamp it pulls the dynamo back into the crankcase and loosens the chain again...

These are the clamps for the head steady. I've fitted them in place with some leather shim between the clamp and the frame to protect the paint. I'll leave these here for the moment until I have made the new studs for the rock box, and then I can fit the head steadies.

I bought all the cables as universal types from Draganfly. When I unwrapped them I was pleased to find the air and throttle cables were complete with their nipples fixed in place at both ends. Whilst the throttle cable fits ok, the choke inner cable is much too long so I will have to move the nipple.

These two pictures show the routing that I have adopted for the clutch cable. I've shortened the outer to suit this routing, and when the gearbox is back together I will fit the nipple.

I've made up two gaskets for the carburettor and the heat shield. 

Perhaps inevitably, the throttle stop is missing from the twist grip. As soon as you slacken the cable these loose stops fall out and can be easily lost. I'll make one on the lathe later - perhaps two, one for the toolbox as a spare.