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Cam tunnel repair

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Cam tunnel repair

Posted by ken_campbell at January 24. 2017

Anyone have any photos of a cam box tunnel repair or any recommendations? I had a look at http://www.norton.uk.com/expert.htm  , but can't get the video to play. I plan on using a mill to remove the old tunnel, so looking for input on boring it out and attaching the new tunnel. Thanks in advance.

 

 

Re: Cam tunnel repair

Posted by jonathan_newton at January 25. 2017

Previously ken_campbell wrote:

Anyone have any photos of a cam box tunnel repair or any recommendations? I had a look at http://www.norton.uk.com/expert.htm  , but can't get the video to play. I plan on using a mill to remove the old tunnel, so looking for input on boring it out and attaching the new tunnel. Thanks in advance.

 

Not a week goes by when I think "George would know..."  I tried the video without success also...

 He did the cam tunnel repair on my '35 CS1 after a rocker spindle lost its  nut and worked its way out.

He machined the remnants out on a milling machine with the cam box held on a jig of his own design.  The tube as  in  his  text, relieved as per an original for the rockers to protrude in to the cam.   Then it was positioned, drilled, countersunk and tapped to take a 2BA (through the relieving for the rockers/ tappets), into the lower body of the cam box (the picture on his site shows it pre drilling), then araldite applied and screwed in place.  All done in a couple of hours with a smile as he showed off his skill, and a rap on the knuckles for not checking the top end enough.

I always had the confidence to run my machines reasonably hard as I knew George was there to help out with parts and knowledge.
 
I don't know what's the situation regarding his lifetimes work with single cylinder Norton's, he had a wonderful collection of machines memorabilia, documents and equipment.  Above all he had a life time of knowledge and contact with the earlier years of motorcycle restoration.  
 
I hope it will serve a purpose in the future but that's for the family to decide. I feel their loss.
RIP George

Jon

Re: Cam tunnel repair

Posted by arne_eftestol at January 25. 2017

Ken

I have done this to my own (and some) and took a few photos of the process. If I post them all here it will probably bring the site onto its knees... Please mail me at : arne.eftestol@gmail.com and I will mail them to you along with any questions you might have.

Regards

Arne

Re: Cam tunnel repair

Posted by ken_campbell at January 25. 2017

Previously jonathan_newton wrote:

Previously ken_campbell wrote:

Anyone have any photos of a cam box tunnel repair or any recommendations? I had a look at http://www.norton.uk.com/expert.htm , but can't get the video to play. I plan on using a mill to remove the old tunnel, so looking for input on boring it out and attaching the new tunnel. Thanks in advance.

 

Not a week goes by when I think "George would know..."  I tried the video without success also...

He did the cam tunnel repair on my '35 CS1 after a rocker spindle lost its  nut and worked its way out.

He machined the remnants out on a milling machine with the cam box held on a jig of his own design.  The tube as  in  his  text, relieved as per an original for the rockers to protrude in to the cam.   Then it was positioned, drilled, countersunk and tapped to take a 2BA (through the relieving for the rockers/ tappets), into the lower body of the cam box (the picture on his site shows it pre drilling), then araldite applied and screwed in place.  All done in a couple of hours with a smile as he showed off his skill, and a rap on the knuckles for not checking the top end enough.

I always had the confidence to run my machines reasonably hard as I knew George was there to help out with parts and knowledge.
I don't know what's the situation regarding his lifetimes work with single cylinder Norton's, he had a wonderful collection of machines memorabilia, documents and equipment.  Above all he had a life time of knowledge and contact with the earlier years of motorcycle restoration.
I hope it will serve a purpose in the future but that's for the family to decide. I feel their loss.
RIP George

Jon

Thanks for the reply Jon

I wasn't aware that he passed away. There was a fellow here locally that passed away recently. He was a guru when it came to Vincents and OHC Nortons. So much knowledge and history gone.

On his web page George mentions 10 years worth in a manual that he hoped to finish and produce on a CD. Hopefully that work gets into the right hands.

Ken

Re: Cam tunnel repair

Posted by ken_campbell at January 25. 2017

Previously arne_eftestol wrote:

Ken

I have done this to my own (and some) and took a few photos of the process. If I post them all here it will probably bring the site onto its knees... Please mail me at : arne.eftestol@gmail.com and I will mail them to you along with any questions you might have.

Regards

Arne

Thanks Arne

Very much appreciated!

Re: Cam tunnel repair

Posted by Andy Marks at January 26. 2017

I had to repair the tunnel on my Inter as well. I have a huge number of photos of the entire restoration on an old computer that has died. If I get the chance this weekend I will look at retrieving them onto a new one (and I'll back them up this time). If this works I'll post some photos of how I repaired my cambox.

In the meantime this was posted on the vintage Norton website a while back. As far as I know it's as much of George's manual as is out there at the moment. Given that it's an older version more of it may well come to light in the future.

http://www.vintagenorton.com/2016/11/georges-notes-on-assembly-of-cammy.html?m=1

Re: Cam tunnel repair

Posted by Barry Carson. at January 26. 2017

Hi Andy.  if you have no luck getting your old computer to fire up as long as the hard drive is ok you can take it out and use something like one of these connect the hard drive to then transfer the files. all the plugs and power supply come with it. i know its off topic just trying to help theres nothing worse than loosing all photos files ect.   Baz

https://www.amazon.co.uk/d/5fn/Magic-Bridge-USB-eSATA-IDE-SATA-Adapter/B004HTIHKA

Re: Cam tunnel repair

Posted by Andy Marks at January 29. 2017

Thanks Barry. I was able to put the hard drive into another laptop to transfer the files onto a memory stick. Nice to see all the photos again, I'd forgotten how much work I'd done to this bike!

Now back on topic....

I've put together a description and a load of photos of how I repaired my cambox. It's by no means the only way to do it. I know other people (including George Cohen) have done it slightly differently in the past but this worked for me and 4 years and 4000 or so miles later is still working with no trouble.

Due to the trouble I always have uploading photos and the like to this forum I've done it in word, saved it as a PDF and uploaded that as an attachment.

If you have any questions fire away but please bare in mind it was 5 years ago and I've been to sleep since then.

 

Andy

Attachments

Re: Cam tunnel repair

Posted by ken_campbell at January 30. 2017

Thanks Andy.  Interesting way you dealt with those two end cover threads. Do you recall what size screws you ended up using? I noticed you are using different needle rollers in your rockers. Are those from Ian Bennett?

Arne sent me some photos showing his set up in the mill. Interesting to see the different ways to skin a cat. I went to get the necessary stock yesterday only to fine out the fellow had retired, so will have to find another source. Anyway... thanks to everyone. The guidance is much appreciated. It should be interesting given the fact that I haven't had much time on a mill or a lathe (that will explain any dumb questions I might ask). That might make some shudder at the thought of me turning a cam box into shavings, but finding someone around here to do it is difficult. I have to deal with sleeving main bearings as well, so that will take some courage.

 

 

Re: Cam tunnel repair

Posted by Andy Marks at February 02. 2017

Hi Ken

I just drilled and taped it back to it's original size. I can't remember but I would have thought I'd have used a slot drill in the milling machine to get the taping size back in the new tunnel as an ordinary drill wouldn't have liked drilling half a hole!

Yes- the needle rollers came from Ian Bennett. As did the big end bearing and the cams and camshaft as mine where worn. All very nicely made and he's great to deal with, very helpful if you have any trouble.

I'm sure there are many ways of doing this, that's just the way I found easiest at the time. Take your time and it's not to difficult a job. Any questions just shout and I'll try and remember how I did it.

Andy

Re: Cam tunnel repair

Posted by ken_campbell at February 04. 2017

Well now I have the material. 2' should be enough to get it right. Now I need to source a new motor for the saw that keeps blowing the breaker.

Attachments

Re: Cam tunnel repair

Posted by ken_campbell at February 17. 2017

Made a mandrel and bored the tunnel out. Decided to use the lathe.

Attachments
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