FH - pillion footrest

This post is to show you how the most simple small problem takes up and inordinate amount of time. You will remember that I mentioned that one of the pillion footrests was damaged and that the screw wouldn't go in. Here's the footrest mounting I'm talking about:

There is or appears to be a burr on the left hand side of the hole. Actually the whole footrest mount has suffered an impact from the left and the hole is distorted. I spent some time with the Dremel and a small grinding bit removing the burr and relieving the hole on both sides. The screw still wouldn't go in and I resolved to take a slightly different approach:

The new approach was to take the screw and stick it in a collet in the lathe and relieve the diameter of the head by a small amount, leaving the original diameter on a millimetre or so of length so that the outward appearance wouldn't change. This allowed the screw to go into the distorted hole, retain the footrest, and for none to be the wiser.

 

FH - baby steps

 Aside from fixing the horn, there were a few more little steps towards completing the Huntmaster today. The package from Draganfly arrived this morning and in it we have the throttle stop which goes straight into position on the twist grip:

There's a few more bits of wiring we can do as well. First off the BPF connector in the headlamp has poor quality wires and undersized bullets so we can replace those by desoldering the terminals, replacing the wire and adding some good quality English bullets for connection to the headlamp wiring. We can also add a splice and a couple of extra bits of wire to earth the BPF connector to the headlamp shell and onward to the main earth and the battery. 

Additionally the pilot lamp holder was in really poor shape. The wire had started to degrade so it was really necessary to replace it. I used a small pop rivet to replace the terminal, and used a new piece of wire crimped into the pop rivet and provided with a bullet connector at the other end. 

I just need to find a full set of LED lamps from Paul Goff to complete the work on the lights.

The last thing was to fit one of the pillion footrest rubbers. The other one is waiting on a repair to the screw retaining the footrest to the frame.

W/NG - Pillion Seat

 In my quest to bring the W/NG back to the condition in which it left the factory - but only in terms of equipment - I'm adding a pillion seat and panniers. The seat is going to take a bit of fitting:

This is a civilian one.....The ones fitted to military bikes are usually less wide than this:

A footnote: this approach has been abandoned for the moment. There is no way a conventional Lycett spring pillion will fit with the military carrier - the military bikes use an 'Acumen' pillion which is much less wide. More on this in a future episode, hopefully!