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1960 Navigator Rebuild Part TWO

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1960 Navigator Rebuild Part TWO

Posted by Ulrich Hoffmann at June 24. 2017

So to make it more comfortable to follow an post  I start part two of the story..

I found No 20873 rocker oilway grub screw(8) in the 1961/62 parts list. Guess these go into the holes on the spindle towers?

Thread size?

Does a sealing ring go between the head and  push in headers?

None mentioned in the parts list.

Re: 1960 Navigator Rebuild Part TWO

Posted by patrick_mullen at June 24. 2017

Grub Screw;  the screw hole pictured seems bigger than the screw hole on a spare head I have here and it looks to be the same size as the rocker cover screws. The rocker cover screws on mine are 1/4" Whitworth but the grub screw is definitely smaller.  It is impossible to measure in position but my guess is 3/16"and I would expect the thread to be Whitworth.  Maybe someone knows better.

Front Pipes;these are just a push fit- no gasket or sealing ring.

 

 

Re: 1960 Navigator Rebuild Part TWO

Posted by andy_sochanik at June 25. 2017

Here are a couple of pictures relating to '20873 rocker oilway grub screw'

There are 8 of them, two on each rocker post. They are normally installed at the factory after making the oilways to blank them off, and would not be expected to come out in service.

Having said that, I found this one had come out on its own on my most recent engine strip.

Attachments

Re: 1960 Navigator Rebuild Part TWO

Posted by andy_sochanik at June 25. 2017

Here are a couple of pictures relating to '20873 rocker oilway grub screw'

There are 8 of them, two on each rocker post. They are normally installed at the factory after making the oilways to blank them off, and would not be expected to come out in service.

Having said that, I found this one had come out on its own on my most recent engine strip.

Re: 1960 Navigator Rebuild Part TWO

Posted by andy_sochanik at June 25. 2017

picture1

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Re: 1960 Navigator Rebuild Part TWO

Posted by andy_sochanik at June 25. 2017

picture2

Thread appears to be less than 3/16" of an inch - about 4.5mm - and around 22TPI - but not quite!

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Re: 1960 Navigator Rebuild Part TWO

Posted by Ulrich Hoffmann at June 25. 2017

Thanks Andy for the posts an pics. I wondered where the other for screws would go.. SInce I have NOS heads from Russell motors none of these grub scres were installed.

I have some Jubilee heads and was able to get two screws out.

 

 

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Then I looked around my spare parts boxes and found one screw with the same size and thread.

 

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I sawed it in half and so I had two other grub screws.

Ok, now I need for more, but no more screws..

Timing:

Seting at 30° I marked the rotor and housing.

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And I installed the pick up disc. There was a modified Commando pickup disc but this one I made for the lightweight ignition housing.

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Re: 1960 Navigator Rebuild Part TWO

Posted by patrick_mullen at June 25. 2017

Hi Uli and Andy,

Your pictures of the grub screw are very useful.  It immediately reminded me that I had seen a screw(as in Uli's picture) identical to this- it is the screw(3 of them) on the float bowl of the HS4 SU carburettors on my 1963 MGB.  So I tried one of these MGB screws on the old Jubilee head and it almost certainly fits. I say almost certain as I cannot unscrew any of the old Norton screws and only a few threads are visible to test on. The screws on this head have been centre punched.

I measure the MGB carb screw as 3/16 of an inch UNC and it is 24TPI. These carbs were fitted to loads of old British motors of the sixties.  So easy to get. Later HIF carbs are different.

 

Re: 1960 Navigator Rebuild Part TWO

Posted by Ulrich Hoffmann at August 13. 2017

Not much progress here.

Managed to find a mudguard on ebay.uk and mounted it with the struts from the NOC shop. Need to weld shut the holes for the pedestrian slicer then ready for paint!


Hosted on Fotki


Hosted on Fotki

Sealing the tank inside with one component sealer what a sticky mess!

Re: 1960 Navigator Rebuild Part TWO

Posted by patrick_mullen at August 13. 2017

Hello Uli,

It looks a decent front mudguard but a 1960's bike looks so much better with a 'proper' front number plate !.  Maybe it is not legal to have this in Germany ?

Have you tried starting up yet?.  You must be close on one year now into the rebuild. Doesn't time fly.

 

 

Re: 1960 Navigator Rebuild Part TWO

Posted by Ulrich Hoffmann at August 14. 2017

Patrick,

I just got back my right header from Armours Ldt. It had a loose fit in the head but the new one is not much better. Will use some sort of sealer I guess. The front fork ist just a mockup with unknown chromed bridges to hold it together for fitting the mudguard. It is from an Atlas/Dominator. Therefore I cannot kickstart the bike. The original fork bridges an other hardware is still at my friend´s paintshop. This morning I asked the local "TÜV" (MOT) tester if a front license plate is allowed. He said if it was fitted originally it´s ok, but you cannot fit one if there was none originally. In Germany only pre-war bikes had the front plate. I don´t like it that much either...

Yes, time flies , hope to get it running soon.. Got all the parts but front and rear mudguard and tank still needs paint and the seat needs to be covered.

Re: 1960 Navigator Rebuild Part TWO

Posted by Ulrich Hoffmann at September 27. 2017

Making some progress! My front mudguard bought on Ebay UK was looking good but turned out to be heavily corroded at the indents for the forks. All was covered with putty.

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But it could be saved thanks to a polish master welder working at my friend´s paintshop.

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These parts were cut out and new indents were welded in.

 

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Other parts are aleady primered, waiting to be fillered and finished.

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Re: 1960 Navigator Rebuild Part TWO

Posted by Dan Field at September 27. 2017

Looking good Uli!

Re: 1960 Navigator Rebuild Part TWO

Posted by patrick_mullen at September 27. 2017

That's a superb painting rig you have.  I am jealous What paint are you using -2K, Cellulose or Water Based ?  or Powder coat?

Re: 1960 Navigator Rebuild Part TWO

Posted by Ulrich Hoffmann at September 28. 2017

Painting is done at my friend's professional paintshop.

Will have to ask what primer he is using.

But it is paint, no powdercoat.

Re: 1960 Navigator Rebuild Part TWO

Posted by Ian Easton at October 06. 2017

That is a nice paint set up. On another note: how did you get the photos to show up in your postings rather than just the usual link we see?

Re: 1960 Navigator Rebuild Part TWO

Posted by Dan Field at October 07. 2017

What like this? ....... !!!

 

You have to click the HTML button above the box and paste in an HTML link from a suitable photo hosting site .. not photobucket ... grrr!

 

dan

Re: 1960 Navigator Rebuild Part TWO

Posted by Ian Easton at October 07. 2017

Yes, like that. It's a pain clicking on the links at the bottom of threads and waiting for photos to open.

Re: 1960 Navigator Rebuild Part TWO

Posted by Ulrich Hoffmann at October 08. 2017

I use postimage.org as a photo host, without costs so far..

Re: 1960 Navigator Rebuild Part TWO

Posted by patrick_mullen at October 08. 2017

Hi Dan,

That is a tidy looking Navigator with a competition number up front.  Is it one that is used for road trials ?

Patrick

Re: 1960 Navigator Rebuild Part TWO

Posted by Dan Field at October 08. 2017

Hi Patrick, the number is a show number, it was at the Great Dorset Steam Rally, I stopped to pick up a M50 engine! It was very tidy, not far up the row there was a over head valve single being shown as an Inter .... couldnt find the owner to ask him about it!

Re: 1960 Navigator Rebuild Part TWO

Posted by Ulrich Hoffmann at October 14. 2017

Before and after:

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After some messy 1,5 hours all four caps are shiny!

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I borrowed a polishing motor with 750 watts which made the job quite easy.

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Re: 1960 Navigator Rebuild Part TWO

Posted by Dan Field at October 14. 2017

You have more patience than me, I just gave mine a quick buff!

Re: 1960 Navigator Rebuild Part TWO

Posted by patrick_mullen at October 15. 2017

That looks shiny.  I agree that it is a messy job - I wear an old full face helmet during polishing.

Re: 1960 Navigator Rebuild Part TWO

Posted by Dan Field at October 15. 2017

Strewth Patrick, I just use a pair of safety googles!

Re: 1960 Navigator Rebuild Part TWO

Posted by Dan Field at October 15. 2017

Strewth Patrick, I just use a pair of safety glasses!

Re: 1960 Navigator Rebuild Part TWO

Posted by patrick_mullen at October 15. 2017

Ah yes but the helmet keeps the dirt out of my hair.  My polisher is only an old drill which I clamp in the vice but it works amazingly well.

Re: 1960 Navigator Rebuild Part TWO

Posted by Ulrich Hoffmann at October 26. 2017

Yesterday I got the painted parts for the fork.

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Today I started assembling the fork. Firstly fixing the balls on the races with grease.

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First try went wrong, two balls fell out the lover race and destroyed it while I was tightening the fork crown nut. These ball races do not seem to be very hard? So I used the better one of the old ones.

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Success on second try!

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No on to the spring cover tubes. I glued the leather seal to the fixing ring or else you go crazy aligning the whole stuff with the screw holes while putting it into the tube!

 

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After sliding in the fork stanchions I fitted the upper bridge and had to shim it to get

everthing aligned. Without the shims the upper bridge does not sit on the crown nut.

I used two washers for the fork tube plugs.

Did I miss something? Upper ball race-dustcover-fork crown nut.

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Not sure if I stick with these handlebars or go for the straight "drag" bars I also have.

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Re: 1960 Navigator Rebuild Part TWO

Posted by Dan Field at October 27. 2017

Hi Uli

what was stopping the top yolk sitting down on the nut?

Re: 1960 Navigator Rebuild Part TWO

Posted by Ulrich Hoffmann at October 27. 2017

I guess I found the solution: When rebuilding the fork I only had the diagram out of the 1961 Navigator parts list for the roadholder fork. Later I looked at the early commando Fastback parts list and at the diagram at the Andover Norton site. There is a spacer between the upper ball race and the dustcover. I did not put that in so the fork crown nut sits too deep. Well, I have to dismantle the fork again praying for the balls not falling into the steering head again.

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