1978 CCM Replica Build

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midgie
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Re: 1978 CCM Replica Build

Post by midgie »

Looks like the b/e pin is made of goats cheese!
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Re: 1978 CCM Replica Build

Post by Andy Chaos »

At last someone has found a use for goats cheese as it certainly ruins a pizza :shock:
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Re: 1978 CCM Replica Build

Post by stew79 »

hi joe ? i would put money on the big end pin being too soft and causing the problem. can you take it to a local engineering company to get a hardness test taken from opposite to the most worn part ? if its below 62 rock thats the problem. with some evidence of defective manufacture / hear treat meant / etc you should be able to get your money back, and some thing towards all the extra work ahead. (i would take the oil pump apart to see if its scored up in any way, and look at rocker arm bushes, cam bushes, clutch and primary chain for any little bits of bearing)
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Re: 1978 CCM Replica Build

Post by Malcolms Lad »

Hi,

It is seeming that way to me, I'm off with the whole engine on Monday to a recommended firm so will report back on the findings. In the initial clean up everything else seems to have survived un-marked. Quite a miracle to be honest that said I didn't run too much following the audible 'Knock'. ...... also thanks to the blessing of the mag drain plug!

Cheers,

Joe
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JB
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Re: 1978 CCM Replica Build

Post by JB »

We do our own heat treatment and we also send it out depending on the process, if it's case hardened (which it should be) then it should be tested on the Vickers hardness scale, you will get a false reading with Rockwell because it's a much higher load (150Kg Vs 1Kg) and because of this it is meant for testing through hardened parts and not case hardened steel.

Going from your pictures Joe, I still think your piston was running too hot and over expanding and would also have exasperated the big end failure due its own issues...just my thoughts!
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Re: 1978 CCM Replica Build

Post by stew79 »

good reply jb, 62 was only meant as a ball park figure. if its only 40 ish some thing is very wrong, then to get in touch with alpha to see what figure, and scale etc it should be. i have bought parts in the past that have some how missed out on any heat treatment at all !
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JB
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Re: 1978 CCM Replica Build

Post by JB »

You make a very good point there Stew about it being only 40 ish that somethings seriously wrong, a Rockwell C test will give you a clue on the hardness condition and if it's really bad so will a file :shock:
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Re: 1978 CCM Replica Build

Post by midgie »

JB wrote:You make a very good point there Stew about it being only 40 ish that somethings seriously wrong, a Rockwell C test will give you a clue on the hardness condition and if it's really bad so will a file :shock:
Spot on jb.
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Re: 1978 CCM Replica Build

Post by stew79 »

the file test is as old as time, but a hardness number in a brief report on headed note paper, from an engineering company, is better "evidence" for a compensation claim
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Re: 1978 CCM Replica Build

Post by minetymenace »

stew79 wrote:a compensation claim
:shock:
While it may be an expensive exercise to rectify the problems, litigation will use up what little time you have on this planet. Yes, establish the cause in you own mind and present it to the supplier, if you get no joy, name and shame (putting the onus on the supplier to prove your slander). Life is too short to spend time in court, rebuild and ride, and recount your tale of woe over a glass of beer for many years to come.
There is no evidence to support the notion that life is serious.
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Re: 1978 CCM Replica Build

Post by chucksy »

And that's the best advice ,just fettle her up and get on.A small breakdown on old gear is just a blip ,aggravation,nothing more. You,ll sort it and forget about it.
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Re: 1978 CCM Replica Build

Post by stew79 »

ok, my choice of words "compensation" is too drastic, but with rts claiming that its your fault (lack of oil ?) and alpha having some sort of bad track record with there big ends, numbers on a piece of paper might help get some of your money back.
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Re: 1978 CCM Replica Build

Post by minetymenace »

:ok
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Re: 1978 CCM Replica Build

Post by Malcolms Lad »

Hi guys

Thabksnfor your supportive words, I'm setting about cleaning bagging and boxing it all tomorrow for a trip North on Monday.

Hopefully we'll get a plan together and she will live for next season. Tbf as costly as it maybe it'd be boring if it had just worked lol. And also it's an excuse to spend more time chatting and speculating with my old man in the shed which to me, is priceless!

I'm just so very appreciative of this small community that really inspired me to build both the bikes offer these years. It also spurs me to carry on get more miles out of it.

There really is nothing like the feeling if an oif unit single and the 441 is a stunning motor to behold when it's on form!
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Malcolms Lad
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Re: 1978 CCM Replica Build

Post by Malcolms Lad »

Hello all,

Just a quick update, the crank is now in for the second rebuild wooooo!

So on further investigation we found the big end cage to actually be to wide, significantly enough that it appears the bearing was never truly rotating so with the rollers skidding on the journal and outer ring resulting in my record time failure for a B44 road engine big end.

Following the inspection I have to say i'm just satisfied that I have an answer to the issue and it appears it isn't a result of my assembly which is always a comfort. For a few moments i did begin to second guess and question myself.

Anyways its looking likely she will be ready to go back together early in the new year! Can't wait to get some miles!
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koncretekid
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Re: 1978 CCM Replica Build

Post by koncretekid »

Malcolms Lad wrote:Hi guys

Tbf as costly as it maybe it'd be boring if it had just worked lol. And also it's an excuse to spend more time chatting and speculating with my old man in the shed which to me, is priceless!
So very, very true. My Dad died when I was 18 and I never got the chance. Just recently, my oldest son started a new business and I'm getting the chance to communicate with him all over again, a chance that I never had. Priceless!

Tom
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Re: 1978 CCM Replica Build

Post by Andy Chaos »

i know its getting off topic but i have to agree.
My Dad had an heart attack earlier this year and he has now just lost his twin brother, suddenly time seems short and precious.
We have even been looking at the cost of insurance to get him over to Bonneville while he still can.
Last edited by Andy Chaos on Tue Dec 05, 2017 4:37 pm, edited 1 time in total.
Malcolms Lad
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Re: 1978 CCM Replica Build

Post by Malcolms Lad »

Do it guys.....

I went with me dad yesterday and spent the whole day talking about this and the original bike etc. Stuff the metal work and machinery just won't tell ya.

I feel very lucky to be able to spend that time and hear such wonderful things and if its only the cost of repairing a broken engine that prompts this then i'd do it over again several times over!
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Malcolms Lad
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Re: 1978 CCM Replica Build

Post by Malcolms Lad »

Hi guys back again... Will post some photos later... it's finally back together and now having done 308miles seems stronger than ever. This past weekend I took it all over the peak district on a rally with me dad on his van van. Quite alot of fun was had and she never missed a beat. Loving it right now.... bloody loud though!
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Re: 1978 CCM Replica Build

Post by Jango »

Malcolms Lad wrote:Hello all,

Just a quick update, the crank is now in for the second rebuild wooooo!

So on further investigation we found the big end cage to actually be to wide, significantly enough that it appears the bearing was never truly rotating so with the rollers skidding on the journal and outer ring resulting in my record time failure for a B44 road engine big end.

Following the inspection I have to say i'm just satisfied that I have an answer to the issue and it appears it isn't a result of my assembly which is always a comfort. For a few moments i did begin to second guess and question myself.

Anyways its looking likely she will be ready to go back together early in the new year! Can't wait to get some miles!
So where does the blame lie?
Malcolms Lad
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Re: 1978 CCM Replica Build

Post by Malcolms Lad »

Hello everybody,

Been a while yet again, the engine has been fantastic following the visit to PES, not cheap but its a strong old girl now!

Im not for placing blame or pointing fingers but the simple facts are the big end cages have to be blue printed and surface ground to the correct clearance between the fly wheels. The bearing cage measured wider than the available space between them so......

Now fitted with:

New PES big end kit, lightened and balanced crank, re-profiled Rod, new small end.

Rebuilt with my forged piston, GP cam, Chromoly pushrods, unleaded converted big valve head. I have opted to return to the AMAL Mk1 Concentric and I covered a good 800mile run in over last some which was splendid!


In other news I dropped my seat of this afternoon with RK Leighton of B'ham after much disappointment with the quality of the reproduction TR5T adventurer seats. They don't look the same, they're not the same shape and the material just doesn't last so I spoke with Andy this afternoon. he has the original hardboard patterns and an original foam and cover from which to work.

There are some discrepancies with my fibreglass base which he is going to tailor to and its not possible to get the heat set pleats so they will be stitched in instead. The test piece hes shown me looked great!

I'll post photos as soon as I get it back in a couple of weeks.
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Malcolms Lad
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Re: 1978 CCM Replica Build

Post by Malcolms Lad »

IMG_20190401_193948.jpg
Seat pic
Seat pic
More to share and a story or two....

Anyone say fire?

Joe
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Re: 1978 CCM Replica Build

Post by Keefe »

Looking nice.

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Re: 1978 CCM Replica Build

Post by Barry Creary »

Nice B50icon
Malcolms Lad
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Re: 1978 CCM Replica Build

Post by Malcolms Lad »

Just thought I'd give a quick update, so I moved the bike from one side of the workshop to the other... Total pushed not running around 6m and sprung a leak from the back of the primary/output seal...

Nice job for the winter, also got a shiny new Pes kick-start to go on. First class item, I got sick of the cheap repro one knocking lumps out the frame. Say cheap it was still £85 and has bearly lasted the 1200mile I've managed in 3 years...
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Re: 1978 CCM Replica Build

Post by beat »

a beautie in its golden frame....

:thumb :thumb :thumb
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Re: 1978 CCM Replica Build

Post by Malcolms Lad »

Thanks Beat, hopefully many many miles next year!
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Re: 1978 CCM Replica Build

Post by Malcolms Lad »

Quite a few updates to follow.

Had quite a bad leak from the clutch plate seal which is now sorted...

Been suffering with a 1/4 to 1/2 throttle stumble that has gotten progressively worse and my boyer powebox has started to give up the ghost which was playing havoc with the Mk3 EI.

I'm now back on the amal mk2 which I have now got setup bang on for cold start with the cold start circuit which is a miracle in its self...

Jobs ahead are rewire the engine side of things punted for the boyer digital micro power and a shiny new trispark mosfet reg/rec to boot.

And worst of all things I'm installing a baffle as with age comes sensitivity I hear.... Although the wife is not impressed about me making it quieter... Go figure?
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Re: 1978 CCM Replica Build

Post by beat »

Malcolms Lad wrote: Thu Sep 10, 2020 10:52 pm And worst of all things I'm installing a baffle
this has something to do with " education " and " good manners " IMO

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Re: 1978 CCM Replica Build

Post by minetymenace »

I'm afraid beat I share Joshua's opinion on this matter (His triumph was heard throughout the land), but I know it has been a contentious issue for over 3000 years! :???:
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