New puzzle

I started the puzzle and made quite some progress..

Yesterday I installed the main bearings with the help of my workshop oven.

They fell right into place in the heated engine halves.

The conrods were installed with new shells. The journals looked good and so standard size shells could be used.

Before that I cleaned the sludge trap and srewed in new sludge trap plugs from the NOC.

It took quite some force to get them in and I had to grind the tops to get the inner races of the bearings seated correctly.

Conrods nuts "(new) were torqued up with 18 Newtonmeters. Picture show the loose nuts.

The camshafts and crankshaft were inserted and I tested the fit of the two engine cases

if they go fully home before using Wellseal and the paper gasket.

So the engine cases are closed and I could mount it on my universal engine stand.

Now I have a better handling of the motor to throw the rest on  it!

I set the timing gear and installed the oil pump .

Then I noticed I forgot to put in the sleeve gear bearing into to gearbox. I was not able

to get the bearing in properly into heated gearbox case . so I had to split the cases once more

to put it into the oven in my workshop and slide the bearing in.Luckily you can split the cases without removing the timing gear.

I also noticed a difference betwwen my Navigator engine and this earlx Jubilee motor: there are no springs in the left side camshaft bushes.

Next was to plug off the original crank case vent. I used a srew and a nut with loctite to close the hole in the sleeve nut for the vent pipe.

Now I  threw in the gearbox innards. Well, I was done after fitting the shafts several times.

Another special early Jubilee feature is the clutch pushrod with soldered on ball for the release mechanism.

A new order at NOC spares was placed because the gearbox sprocket was quite worn

and the nut for it was missing .

The motor has been completed except the primary drive which will be added when positioned in the frame.

The parts arrived just in time from the NOC shop.

I will keep the patina but not the dirt since 1959!

The parts will be protected with Owatrol later on.

I cleaned up the frame  and mudguards, chainguards etc. with petrol.

Then I took of the front frame member with the forks and wheel to lift in the engine.

It took some persuasion to get the holes for the new stainless studs and frame spacers aligned.

There are two tones of blue on the fork I guess the yokes were repainted.

My deluxe has 340 stamped on the right engine case behind the cylinder so it is bike No 340 ever produced. The other late Jubilee standard I also bought i is one of the last 14 bikes ever built.

I will take pics of most of the details listed in Peter´s comment. Except the position of the original rectifier. The square rectifier was in the parts box and not mounted on the bike so I also have no idea of it´s location.

 I am converting the Jubilee to a 12 Volt system with positive ground to run a Boyer ignition.

I shamelessly copied Stan Pyke´s idea of using one switch at the headlamp as an ignition switch.

I bought a simole on/off ignition switch on Ebay and

 glued the key for it into an internally  broken original Wipac switch with JB Weld.

The other switch is for turning on and off the lights.

Here is the plug with the hopefully correctly soldered on cables.

Test fit into the lampshell but I have to fix some electrical gremlins. E.g. lights are always on.

I used a wiring diagram drawn by another NOC member for a 12 Volt conversion of

the Norton Lightweights but I guess I mixed up some connections.

The horn is a German HELLA one, as mentioned the bike was originally imported into Germany .

Don´t know if it was a dealer conversion.