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Jean Des Rosiers | profile | all galleries >> Norton motorcycles >> Evolution of a Norton Featherbed café racer tree view | thumbnails | slideshow

Evolution of a Norton Featherbed café racer

I will update this gallery with pictures of my café racer project as I make progress. I plan to put a belt drive both on the primary (easy) as well as the secondary (less easy). There will be a lot of fabrication of special parts because nothing like this exists as a commercial product.

May 2015 update. I am putting an Alton electric starter on my café racer so for now, the primary belt is gone and replaced with the stock triple row chain. I am keeping the rear belt drive.
5571-Norton cafe racer, initial measurements
5571-Norton cafe racer, initial measurements		 5573-Norton cafe racer, initial measurements
5573-Norton cafe racer, initial measurements		 5574-Norton cafe racer, initial measurements
5574-Norton cafe racer, initial measurements		 5575-Norton_cafe_racer, initial measurements
5575-Norton_cafe_racer, initial measurements
5691-Norton_cafe_racer, gearbox sprocket
5691-Norton_cafe_racer, gearbox sprocket		 5692-Norton_cafe_racer, gearbox pulley modification
5692-Norton_cafe_racer, gearbox pulley modification		 5695-Norton_cafe_racer, gearbox sprocket
5695-Norton_cafe_racer, gearbox sprocket		 5696-Norton_cafe_racer, gearbox pulley modification
5696-Norton_cafe_racer, gearbox pulley modification
5699-Norton_cafe_racer, rear belt in place
5699-Norton_cafe_racer, rear belt in place		 5701-Norton_cafe_racer, rear belt in place
5701-Norton_cafe_racer, rear belt in place		 5703-Norton_cafe_racer, rear belt in place
5703-Norton_cafe_racer, rear belt in place		 5707-Norton_cafe_racer, realising a new swing arm is needed
5707-Norton_cafe_racer, realising a new swing arm is needed
5922-Ourigger bearing version 2
5922-Ourigger bearing version 2		 5923-Ourigger bearing version 2
5923-Ourigger bearing version 2		 5924-Ourigger bearing version 2
5924-Ourigger bearing version 2		 5926-Swing arm, preliminary swing arm placement
5926-Swing arm, preliminary swing arm placement
6047-01-Norton_cafe_racer
6047-01-Norton_cafe_racer		 6048-01-Norton_cafe_racer, side view
6048-01-Norton_cafe_racer, side view		 6051-01-Norton_cafe_racer, right side view
6051-01-Norton_cafe_racer, right side view		 6052-01-Norton_cafe_racer, swing arm pivot
6052-01-Norton_cafe_racer, swing arm pivot
7039-oil tank
7039-oil tank		 7040-oil tank
7040-oil tank		 7041-oil tank
7041-oil tank		 7042-oil tank
7042-oil tank
9227-swing arm
9227-swing arm		 9228-swing arm
9228-swing arm		 9238-swing arm with rear wheel
9238-swing arm with rear wheel		 9239-swing arm
9239-swing arm
9240-swing arm
9240-swing arm		 9242-swing arm
9242-swing arm		 9245-swing arm
9245-swing arm		 0137-ready for welding
0137-ready for welding
1584 Kubota alternator in place
1584 Kubota alternator in place		 0206 swing arm back view
0206 swing arm back view		 0208 swing arm close up
0208 swing arm close up		 6922 seat base and battery box
6922 seat base and battery box
6923 seat mounted on base
6923 seat mounted on base		 6933 front wheel (Suzuki GT750 drum brake)
6933 front wheel (Suzuki GT750 drum brake)		 6936 front wheel (Suzuki GT750 drum brake)
6936 front wheel (Suzuki GT750 drum brake)		 0232 making a manifold for Keihin FCR35 carburators
0232 making a manifold for Keihin FCR35 carburators
0233 making a manifold for Keihin FCR35 carburators
0233 making a manifold for Keihin FCR35 carburators		 0234 making a manifold for Keihin FCR35 carburators
0234 making a manifold for Keihin FCR35 carburators		 0236 making a manifold for Keihin FCR35 carburators
0236 making a manifold for Keihin FCR35 carburators		 0237 making a manifold for Keihin FCR35 carburators
0237 making a manifold for Keihin FCR35 carburators
0242 making a manifold for Keihin FCR35 carburators
0242 making a manifold for Keihin FCR35 carburators		 0244 making a manifold for Keihin FCR35 carburators
0244 making a manifold for Keihin FCR35 carburators		 0251 gas tank modification
0251 gas tank modification		 0252 gas tank modification
0252 gas tank modification
0253 gas tank modification
0253 gas tank modification		 0254 gas tank modification
0254 gas tank modification		 0256 gas tank modification
0256 gas tank modification		 0259 gas tank modification
0259 gas tank modification
High beam and flasher pilot lights on light switch
High beam and flasher pilot lights on light switch		 0273 gas tank modification
0273 gas tank modification		 0274 gas tank modification
0274 gas tank modification		 0291start with this
0291start with this
0293 cut and glue together
0293 cut and glue together		 0294 add resistor and wiring
0294 add resistor and wiring		 0295 running light (dimmed a bit)
0295 running light (dimmed a bit)		 0296 brake light (standard brightness)
0296 brake light (standard brightness)
0300 brake light on
0300 brake light on		 0301 running lights on
0301 running lights on		 0303 lights with seat
0303 lights with seat		 0305 tach and speedo - old and new
0305 tach and speedo - old and new
2252 Rear wheel and pulley in place
2252 Rear wheel and pulley in place		 2253 Rear wheel and pulley in place
2253 Rear wheel and pulley in place		 2254 Rear wheel and pulley in place
2254 Rear wheel and pulley in place		 2258 checking belt tracking
2258 checking belt tracking
2261 checking belt tracking
2261 checking belt tracking		 2264 gas tank with gas cap on
2264 gas tank with gas cap on		 0351 Stock upper triple tree
0351 Stock upper triple tree		 0349 Modified upper triple tree (still to be welded)
0349 Modified upper triple tree (still to be welded)
2612 Align rear wheel with front wheel
2612 Align rear wheel with front wheel		 2613 Align rear wheel with front wheel
2613 Align rear wheel with front wheel		 2614 Align rear wheel with front wheel
2614 Align rear wheel with front wheel		 2615 Align rear wheel with front wheel
2615 Align rear wheel with front wheel
2616 Align rear wheel with front wheel
2616 Align rear wheel with front wheel		 2617 Align rear wheel with front wheel
2617 Align rear wheel with front wheel		 2618 Rear wheel in place
2618 Rear wheel in place		 2620 Rear wheel in place
2620 Rear wheel in place
2621 Rear wheel in place
2621 Rear wheel in place		 2622 Looking good :-)
2622 Looking good :-)		 2624 Looking good :-)
2624 Looking good :-)		 6992 I think I will go for a more traditional look.
6992 I think I will go for a more traditional look.
0481 Shortened front brake cables
0481 Shortened front brake cables		 0482 Shortened front brake cables
0482 Shortened front brake cables		 0525 My welder Steve at work (Aluminox)
0525 My welder Steve at work (Aluminox)		 0526 modified kick start lever version 2 (stepped out more)
0526 modified kick start lever version 2 (stepped out more)
0527 modified kick start lever version 2 (stepped out more)
0527 modified kick start lever version 2 (stepped out more)		 0532 Making sure it will look good
0532 Making sure it will look good		 0534 Making sure it will look good
0534 Making sure it will look good		 0535 Making sure it will look good
0535 Making sure it will look good
0591 Reopened the tank and glassed in the filler correctly
0591 Reopened the tank and glassed in the filler correctly		 0592 Reopened the tank and glassed in the filler correctly
0592 Reopened the tank and glassed in the filler correctly		 0593 Rear brake torque arm
0593 Rear brake torque arm		 7035 Frame mods (footpeg mounts - muffler brackets)
7035 Frame mods (footpeg mounts - muffler brackets)
7037 Frame mods (brackets removed, holes filled in)
7037 Frame mods (brackets removed, holes filled in)		 7040 Swing arm mods (braces and torque arm attachment added)
7040 Swing arm mods (braces and torque arm attachment added)		 0645 Closing up the gas tank
0645 Closing up the gas tank		 0646 Closing up the gas tank
0646 Closing up the gas tank
0647 Closing up the gas tank
0647 Closing up the gas tank		 0648 Closing up the gas tank
0648 Closing up the gas tank		 0706 Rear sets version 3
0706 Rear sets version 3		 0708 Rear sets version 3
0708 Rear sets version 3
0707 Rear sets version 3 (everything clears, no need for folding footpegs)
0707 Rear sets version 3 (everything clears, no need for folding footpegs)		 0711 Rear brake linkage
0711 Rear brake linkage		 0712 Rear brake linkage
0712 Rear brake linkage		 0713 Rear brake linkage and brake light switch
0713 Rear brake linkage and brake light switch
0714 Rear brake linkage
0714 Rear brake linkage		 0715 Rear brake linkage
0715 Rear brake linkage		 0716 Primary belt guard and ignition pickup
0716 Primary belt guard and ignition pickup		 0720 Primary belt guard and ignition pickup
0720 Primary belt guard and ignition pickup
0721 New front brake torque arms and speed sensor
0721 New front brake torque arms and speed sensor		 0722 New front brake torque arms and speed sensor
0722 New front brake torque arms and speed sensor		 0725 Using 3 magnets (Koso speedo can use from 1 to 6)
0725 Using 3 magnets (Koso speedo can use from 1 to 6)		 0727 New front brake torque arms and speed sensor
0727 New front brake torque arms and speed sensor
0732 Taking shape slowly
0732 Taking shape slowly		 0733 Oil manifold, change from top feed/return to bottom feed/return
0733 Oil manifold, change from top feed/return to bottom feed/return		 0735 Oil manifold in place
0735 Oil manifold in place		 0748 Oil Manifold with feed and return lines
0748 Oil Manifold with feed and return lines
0737 oil tank feed line and drain plug
0737 oil tank feed line and drain plug		 0741 Oil tank return line
0741 Oil tank return line		 0742 Horn hidden in tail section
0742 Horn hidden in tail section		 0744 Horn hidden in tail section
0744 Horn hidden in tail section
0750 Oil tank filler cap and breather hoses
0750 Oil tank filler cap and breather hoses		 7667 Poor man's milling machine
7667 Poor man's milling machine		 7668 Lathe milling the front brake torque arms
7668 Lathe milling the front brake torque arms		 7670 Milled torque arms
7670 Milled torque arms
7671 Milled torque arms
7671 Milled torque arms		 0752 Alternate exhaust (the chrome downpipes are not symetrical so the peashooters look lopsided)
0752 Alternate exhaust (the chrome downpipes are not symetrical so the peashooters look lopsided)		 0755 Milled rear set shifter
0755 Milled rear set shifter		 0756 Alternate exhaust pipes
0756 Alternate exhaust pipes
0758 Milled rear set brake pedal
0758 Milled rear set brake pedal		 0823 Battery hold down strap
0823 Battery hold down strap		 0824 Seat brackets
0824 Seat brackets		 0825 Seat in place with new hold down system
0825 Seat in place with new hold down system
0826 The single knob will release the seat
0826 The single knob will release the seat		 0828 Rear brake linkage (final)
0828 Rear brake linkage (final)		 Wiring diagram
Wiring diagram		 0829 Fork covers. The tie wrap holds both the gaiter and the brake cable.
0829 Fork covers. The tie wrap holds both the gaiter and the brake cable.
0830 View of the forks
0830 View of the forks		 0831 View of the forks
0831 View of the forks		 0832 View of the forks
0832 View of the forks		 0833 Aluminuim spacer between the headlight bracket and the clip on (hides the fork tube which is not chromed)
0833 Aluminuim spacer between the headlight bracket and the clip on (hides the fork tube which is not chromed)
0834 Front view
0834 Front view		 0835 New better looking outrigger bearing support plate
0835 New better looking outrigger bearing support plate		 0836 With clutch in place (taking measurements for the top gearbox bolt which will be fixed, no primary belt adjustment)
0836 With clutch in place (taking measurements for the top gearbox bolt which will be fixed, no primary belt adjustment)		 0837 Using a fly cutter to machine a large hole
0837 Using a fly cutter to machine a large hole
0838 Using a fly cutter to machine a large hole
0838 Using a fly cutter to machine a large hole		 0839 New better made engine support plate (no unused holes, better fit on engine crankcase)
0839 New better made engine support plate (no unused holes, better fit on engine crankcase)		 0844 Better designed belt cover (I was afraid the belt would rub on the studs with the other design)
0844 Better designed belt cover (I was afraid the belt would rub on the studs with the other design)		 0846 Ignition pickup wires routing (to hide them)
0846 Ignition pickup wires routing (to hide them)
0847 Ignition pickup wires routing (to hide them)
0847 Ignition pickup wires routing (to hide them)		 0852 Fuse panel and main relay
0852 Fuse panel and main relay		 0854 With clutch installed
0854 With clutch installed		 0855 Alloy (home made) fork crown nut (my old one was damaged and needed chroming)
0855 Alloy (home made) fork crown nut (my old one was damaged and needed chroming)
0857 Alloy fork crown nut in place
0857 Alloy fork crown nut in place		 0858 Stainless steel inserts in lower shock mounts
0858 Stainless steel inserts in lower shock mounts		 0859 Stainless steel inserts in lower shock mounts
0859 Stainless steel inserts in lower shock mounts		 0861 A bit of fantasy, the frame is 1961 and so is the dime.
0861 A bit of fantasy, the frame is 1961 and so is the dime.
0864 Trimmed front fender
0864 Trimmed front fender		 0869 Keihein clip to hold the idle adjuster
0869 Keihein clip to hold the idle adjuster		 0871 Keihein clip to hold the idle adjuster
0871 Keihein clip to hold the idle adjuster		 0874 New coil (5 ohms) and new bracket which is the bottom part of the head steady.
0874 New coil (5 ohms) and new bracket which is the bottom part of the head steady.
0875 This is the second part of the head steady. I will have to wait until the engine is done because the height can change.
0875 This is the second part of the head steady. I will have to wait until the engine is done because the height can change.		 0879 Side stand bracket to be welded on the frame (not finished)
0879 Side stand bracket to be welded on the frame (not finished)		 0882 Side stand retracted (ready to be welded)
0882 Side stand retracted (ready to be welded)		 0883 Side stand actually supporting the bike (will be weded soon)
0883 Side stand actually supporting the bike (will be weded soon)
0889 New oil manifold. Feed from the bottom, return towards the top. This will simplify oil line routing.
0889 New oil manifold. Feed from the bottom, return towards the top. This will simplify oil line routing.		 0890 Sturdier engine plates (need to be trimmed)
0890 Sturdier engine plates (need to be trimmed)		 0891 Sturdier engine plates (need to be trimmed)
0891 Sturdier engine plates (need to be trimmed)		 0892 Oil manifold polished up
0892 Oil manifold polished up
0894 Engine plates new vs old
0894 Engine plates new vs old		 0895 Engine plates new vs old
0895 Engine plates new vs old		 0899 Exhaust port repairs, the aluminium insert is screwed in the head using threads from a previous repair.
0899 Exhaust port repairs, the aluminium insert is screwed in the head using threads from a previous repair.		 0901 Exhaust port repair, done my way (different)
0901 Exhaust port repair, done my way (different)
0907 Kick start lever back from the chrome shop
0907 Kick start lever back from the chrome shop		 0908 Machining the gearbox cover for oil seals
0908 Machining the gearbox cover for oil seals		 0910 Machining the gearbox cover for oil seals
0910 Machining the gearbox cover for oil seals		 0912 Machining the gearbox cover for oil seals
0912 Machining the gearbox cover for oil seals
0914 Machined and polished gearbox cover with oil seals in place
0914 Machined and polished gearbox cover with oil seals in place		 MAJOR SETBACK! I broke my left collar bone. It will take a couple of weeks before I am able to do ANY work :-( (stock photo)
MAJOR SETBACK! I broke my left collar bone. It will take a couple of weeks before I am able to do ANY work :-( (stock photo)		 0034 My own shoulder, three weeks after the incident.
0034 My own shoulder, three weeks after the incident.		 0916 Painted some parts (couldn't sit still)
0916 Painted some parts (couldn't sit still)
0928 Polished timing cover (I must be getting better)
0928 Polished timing cover (I must be getting better)		 0930 Polished lower fork sliders
0930 Polished lower fork sliders		 0933 Frame freshly powder coated
0933 Frame freshly powder coated		 9896 Rev counter with powder coated shell
9896 Rev counter with powder coated shell
0934 More polished bits (brake torque arms and rearsets)
0934 More polished bits (brake torque arms and rearsets)		 9907 Front fork mods (relocated damper tube hole, bronze damper tube caps, longer aluminum rods and helper spring)
9907 Front fork mods (relocated damper tube hole, bronze damper tube caps, longer aluminum rods and helper spring)		 0956 Rebuilding the transmission
0956 Rebuilding the transmission		 0957 Took alternator apart to paint it black
0957 Took alternator apart to paint it black
0958 Black alternator back together
0958 Black alternator back together		 0963 Exhaust port repaired (screwed, gluded and held on with the six hex head bolts)
0963 Exhaust port repaired (screwed, gluded and held on with the six hex head bolts)		 0965 Gearbox all back together, ready to slip in the frame
0965 Gearbox all back together, ready to slip in the frame		 0975 Putting the cart before the horse (starting to put it together, in no particular order)
0975 Putting the cart before the horse (starting to put it together, in no particular order)
1000 Crankcase breather valve and housing
1000 Crankcase breather valve and housing		 1001 Crankcase breather valve and housing
1001 Crankcase breather valve and housing		 1002 This assembly will be bolted to a modified crankcase
1002 This assembly will be bolted to a modified crankcase		 1004 New clutch plates (Barnett), bead blasted steel plates, new clutch hub center.
1004 New clutch plates (Barnett), bead blasted steel plates, new clutch hub center.
1020 Clutch rod oil seal and radial throwout bearig (not finished)
1020 Clutch rod oil seal and radial throwout bearig (not finished)		 1023 Clutch rod oil seal and radial throwout bearig (not finished)
1023 Clutch rod oil seal and radial throwout bearig (not finished)		 1026 Clutch rod oil seal and radial throwout bearig
1026 Clutch rod oil seal and radial throwout bearig		 1027 Clutch rod oil seal and radial throwout bearig
1027 Clutch rod oil seal and radial throwout bearig
1028 Clutch rod oil seal and radial throwout bearig
1028 Clutch rod oil seal and radial throwout bearig		 1029 Clutch rod oil seal and radial throwout bearig
1029 Clutch rod oil seal and radial throwout bearig		 1030 Clutch rod oil seal and radial throwout bearig
1030 Clutch rod oil seal and radial throwout bearig		 1031 Clutch rod oil seal and radial throwout bearig
1031 Clutch rod oil seal and radial throwout bearig
1057 Gas tank fresh from the painter (front fender and headlight shell are the same color)
1057 Gas tank fresh from the painter (front fender and headlight shell are the same color)		 1059 Painted swing arm
1059 Painted swing arm		 1058 Left hand case modification for engine breather
1058 Left hand case modification for engine breather		 1060 Plugged holes in RH case and oil drain hole
1060 Plugged holes in RH case and oil drain hole
1061 Crakcase breather in place
1061 Crakcase breather in place		 1077 Engine rebuild, new pistons, new cam chain. 850 bottom end, old style timing cover.
1077 Engine rebuild, new pistons, new cam chain. 850 bottom end, old style timing cover.		 1078 Head almost done, new guides, valve springs, seats cut...
1078 Head almost done, new guides, valve springs, seats cut...		 1089 Transmission and engine plates, ready to mate to engine
1089 Transmission and engine plates, ready to mate to engine
1091 Engine and transmission finally in the frame :-)
1091 Engine and transmission finally in the frame :-)		 1095 More assembly done today
1095 More assembly done today		 1101 Head and carbs installed
1101 Head and carbs installed		 1102 Close up of engine
1102 Close up of engine
1108 Head steady / coil bracket (not finished)
1108 Head steady / coil bracket (not finished)		 1109 Head steady / coil bracket (not finished)
1109 Head steady / coil bracket (not finished)		 1121 Rear wheel in place
1121 Rear wheel in place		 1124 New ignition (hall effect sensor, selectable ignition curve, easy start)
1124 New ignition (hall effect sensor, selectable ignition curve, easy start)
8390 Vent and oil return
8390 Vent and oil return		 8389 On wheels :-)
8389 On wheels :-)		 1128 Damaged threads in timing cover
1128 Damaged threads in timing cover		 1130 Fixed threads with a threaded insert
1130 Fixed threads with a threaded insert
1131 Side view of timing cover with tach drive in place
1131 Side view of timing cover with tach drive in place		 1132 Side view of timing cover with tach drive in place
1132 Side view of timing cover with tach drive in place		 1133 Pressure oiler on top end
1133 Pressure oiler on top end		 1134 Hard to see, but oil is coming out of all rocker shafts
1134 Hard to see, but oil is coming out of all rocker shafts
1135 oil coming out of left side too, only one oil line is used and intake rocker shafts are drilled
1135 oil coming out of left side too, only one oil line is used and intake rocker shafts are drilled		 1140 Curve #7 selected
1140 Curve #7 selected		 1142 Timing is easy to set with LED on pick up plate
1142 Timing is easy to set with LED on pick up plate		 1144 Spark at TDC from 0 to 400 RPM
1144 Spark at TDC from 0 to 400 RPM
1146 Spark at set advance from 400 to 1000 RPM
1146 Spark at set advance from 400 to 1000 RPM		 1147 Maximum advance
1147 Maximum advance		 1160 Gas tank ready, sealed (http://www.hirschauto.com/), cap on, petcock on.
1160 Gas tank ready, sealed (http://www.hirschauto.com/), cap on, petcock on.		 1161 New pickup rotor / spacer (not finished)
1161 New pickup rotor / spacer (not finished)
1171 Ignition box in place (under the gas tank)
1171 Ignition box in place (under the gas tank)		 1172 Aaaaaak
1172 Aaaaaak		 1173 Looking better
1173 Looking better		 1174 Electrics done (except flashers and taillight)
1174 Electrics done (except flashers and taillight)
1175 Ignition wired up
1175 Ignition wired up		 1176 Headlight on :-)
1176 Headlight on :-)		 1177 Speedo on, headlight on high beam
1177 Speedo on, headlight on high beam		 1178 Speedo with front wheel given a spin
1178 Speedo with front wheel given a spin
1179 Ignition pickup
1179 Ignition pickup		 1185 Getting close to completion
1185 Getting close to completion		 1186 Getting close to completion
1186 Getting close to completion		 1189 New LED bar end flashers, load resistor is inside the handlebar, the brass plate is the ground
1189 New LED bar end flashers, load resistor is inside the handlebar, the brass plate is the ground
1190 New LED bar end flashers
1190 New LED bar end flashers		 1191 New LED bar end flashers and pilot light
1191 New LED bar end flashers and pilot light		 1192 Finding TDC
1192 Finding TDC		 1193 Finding TDC with temporary indicator
1193 Finding TDC with temporary indicator
1194 Backside of pick up / belt guard
1194 Backside of pick up / belt guard		 1195 Sensor connector
1195 Sensor connector		 1196 Removeable TDC indicator
1196 Removeable TDC indicator		 3085 Side view with temporary exhaust
3085 Side view with temporary exhaust
3086 ¾ view with temporary exhaust
3086 ¾ view with temporary exhaust		 3087 ¾ view with temporary exhaust
3087 ¾ view with temporary exhaust		 3088 Frontal view with temporary exhaust
3088 Frontal view with temporary exhaust		 8562 Head steady, one of my first welding jobs.
8562 Head steady, one of my first welding jobs.
1203 New design breather... still not quite right, but on the right track
1203 New design breather... still not quite right, but on the right track		 1205 New design breather... still not quite right, but on the right track
1205 New design breather... still not quite right, but on the right track		 1206 New speedo mount so I can see it while riding (impossible with the old one)
1206 New speedo mount so I can see it while riding (impossible with the old one)		 1207 Starting on the exhaust pipes
1207 Starting on the exhaust pipes
8610 Collector ordered from SPD Exhausts
8610 Collector ordered from SPD Exhausts		 8611 Downpipes pretty well done
8611 Downpipes pretty well done		 8612 Downpipes pretty well done
8612 Downpipes pretty well done		 1216 Baffle (the front part will be wrapped with fiberglass)
1216 Baffle (the front part will be wrapped with fiberglass)
1219 Muffler in place
1219 Muffler in place		 1222 Hold down springs and rear bracket in place
1222 Hold down springs and rear bracket in place		 1224 Frontal view showing how narrow the bike is
1224 Frontal view showing how narrow the bike is		 3311 DONE!!!
3311 DONE!!!
3312 DONE!!!
3312 DONE!!!		 3316 DONE!!!
3316 DONE!!!		 3319 DONE!!!
3319 DONE!!!		 3322 DONE!!!
3322 DONE!!!
1248 This breather works! no more oil out of the vent tube.
1248 This breather works! no more oil out of the vent tube.		 1249 I was only 13 when this coin and the frame were made :-)
1249 I was only 13 when this coin and the frame were made :-)		 1528 New license bracket and relocated flashers (old bracket broke off)
1528 New license bracket and relocated flashers (old bracket broke off)		 1481 Taken out December 29 2010, now the constant pain is gone and I have better arm motion
1481 Taken out December 29 2010, now the constant pain is gone and I have better arm motion
00001-5316 Time to resurrect this project. Took it out of storage in a sorry state
00001-5316 Time to resurrect this project. Took it out of storage in a sorry state		 00002-5323 Some parts taken out in preparation for the addition of an Alton electric starter
00002-5323 Some parts taken out in preparation for the addition of an Alton electric starter		 00003-5324
00003-5324		 00004-4128 Drive side
00004-4128 Drive side
00005-4131 Alton inner chaincase test fit
00005-4131 Alton inner chaincase test fit		 00006-4134 Had to shave the front pulley a bit
00006-4134 Had to shave the front pulley a bit		 00007-4137 Milled the slots for chain adjustment
00007-4137 Milled the slots for chain adjustment		 00008-4138 Fits :-)
00008-4138 Fits :-)
00009-4145 Test fitting the Alton inner chaincase on the bench
00009-4145 Test fitting the Alton inner chaincase on the bench		 00010-4146 Really tight, I had to move the transmission with 1/16 shims to clear
00010-4146 Really tight, I had to move the transmission with 1/16" shims to clear		 00011-4147 Shims on engine side
00011-4147 Shims on engine side		 00012-4148 Chain adjusters (one on each side)
00012-4148 Chain adjusters (one on each side)
00013-4149 Rib milled off to clear the pulley which is much bigger than a sprocket
00013-4149 Rib milled off to clear the pulley which is much bigger than a sprocket		 00014-4150 Rib milled off to clear the pulley which is much bigger than a sprocket
00014-4150 Rib milled off to clear the pulley which is much bigger than a sprocket		 00015-4151 Rib milled off to clear the pulley which is much bigger than a sprocket
00015-4151 Rib milled off to clear the pulley which is much bigger than a sprocket		 00016-4172 Swing arm support
00016-4172 Swing arm support
00017-4173 Swing arm support
00017-4173 Swing arm support		 00018-6793 Alton rotor and sprag
00018-6793 Alton rotor and sprag		 00019-6795 Modified with flat screws
00019-6795 Modified with flat screws		 00020-6796 Ignition pickup mounted
00020-6796 Ignition pickup mounted
00021-6798 Had to mill the timing scale bosses off in the outer chaincase
00021-6798 Had to mill the timing scale bosses off in the outer chaincase		 00022-04180 Battery tray hogged out a bit for Ballistic lithium battery
00022-04180 Battery tray hogged out a bit for Ballistic lithium battery		 00023-04181 Battery tray hogged out a bit for Ballistic lithium battery
00023-04181 Battery tray hogged out a bit for Ballistic lithium battery		 00024-04182 Battery tray hogged out a bit for Ballistic lithium battery
00024-04182 Battery tray hogged out a bit for Ballistic lithium battery
00025-6854 Starting reassembly
00025-6854 Starting reassembly		 6855 Alton starter in place
6855 Alton starter in place		 6857 Adjusting Alton alternator gap with supplied shims
6857 Adjusting Alton alternator gap with supplied shims		 6860 Primary chain adjusters in place
6860 Primary chain adjusters in place
6866 Clutch nut secured and locked in place
6866 Clutch nut secured and locked in place		 6867 Sachse ignition pickup in place with slots to see timing marks
6867 Sachse ignition pickup in place with slots to see timing marks		 6820 Building my own regulator (see http://www.accessnorton.com/voltage-regulators-t22113.html for reason)
6820 Building my own regulator (see http://www.accessnorton.com/voltage-regulators-t22113.html for reason)		 6821 Building my own regulator
6821 Building my own regulator
6822 Building my own regulator
6822 Building my own regulator		 6823 Building my own regulator
6823 Building my own regulator		 6835 Building my own regulator
6835 Building my own regulator		 6836 Building my own regulator
6836 Building my own regulator
Regulateur-Linéaire Regulator circuit diagram
Regulateur-Linéaire Regulator circuit diagram		 6932 Making a good daytime running light using LED strips
6932 Making a good daytime running light using LED strips		 6934 Making a good daytime running light using LED strips
6934 Making a good daytime running light using LED strips		 6935 Making a good daytime running light using LED strips
6935 Making a good daytime running light using LED strips
6936 Making a good daytime running light using LED strips
6936 Making a good daytime running light using LED strips		 6937 Making a good daytime running light using LED strips
6937 Making a good daytime running light using LED strips		 6938 Regulator in place
6938 Regulator in place		 6939 Electrical wiring mostly done
6939 Electrical wiring mostly done
6940 Making a good daytime running light using LED strips
6940 Making a good daytime running light using LED strips		 6941 Making a good daytime running light using LED strips
6941 Making a good daytime running light using LED strips		 6945 Making a good daytime running light using LED strips
6945 Making a good daytime running light using LED strips		 6947 Making a good daytime running light using LED strips
6947 Making a good daytime running light using LED strips
6948 Making a good daytime running light using LED strips
6948 Making a good daytime running light using LED strips		 6949 Daytime running light on
6949 Daytime running light on		 6950 Battery box
6950 Battery box		 6951 View from the back
6951 View from the back
6952 Starter button (old kill switch)
6952 Starter button (old kill switch)		 6953 Timing scale
6953 Timing scale		 0574 Homemade exhaust system
0574 Homemade exhaust system		 2358_fini.jpg
2358_fini.jpg
2359_fini.jpg
2359_fini.jpg		 2361_fini.jpg
2361_fini.jpg		 2362_fini.jpg
2362_fini.jpg		 2363_fini.jpg
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2364_fini.jpg		 2365_fini.jpg
2365_fini.jpg		 2367_fini.jpg
2367_fini.jpg		 2369_fini.jpg
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2370_fini.jpg		 2371_fini.jpg
2371_fini.jpg		 2372_fini.jpg
2372_fini.jpg		 2373_fini.jpg
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2374_fini.jpg
2374_fini.jpg		 2376_fini.jpg
2376_fini.jpg		 2377_fini.jpg
2377_fini.jpg		 2378_fini.jpg
2378_fini.jpg

comment | share
Laurent Husquin 11-Jan-2012 08:15
Félicitations Jean ! Great job !

J'ai une Dominator 1960 (slimline featherbed) et voudrais y mettre un moteur de Commando. Je me demande s'il vaut mieux faire re-équilibrer l'embiellage pour qu'il vibre moins et l'installer comme toi, ou le monter en "featherlastic" (comme Bob Cox, Randy Ullery et d'autres l'ont fait aux USA). Merci pour ton avis et tes conseils pour trouver quelqu'un qui me fournirait les 3 isolastics (Front / rear / Head-steady) si je suis cette piste.

Laurent (j.husquin@orange.fr)
Tom 20-Nov-2011 06:25
Thank you for your pictures. i am in the middle of a slimline / 71 750 motor build. you have given me many fine ideas and inspiration. Now if I only had your talent! Congratulations on building a beautiful motorcycle. Tom McCullough, Las Vegas Nevada
erwin 15-Jun-2011 17:52
I want that exhaust setup - any tips?
WOW! 12-Apr-2011 09:29
Just found your gallery by pure luck and what an amazing job you have done, she is a stunner!.
Jean Des Rosiers24-Nov-2010 06:52
To: secret admirer

1- It would be nice to leave an e-mail address to answer on a more personal level

2- The breather is my own design, at firstI tried a pipe sending vapors to the oil tank and another next to it (do direct connection) venting to the athmosphere, after a few minutes, oil was moving up the outlet so I added a section on top with a filter made out of steel wool and with a larger outlet pipe, this was better and took longer for oil to seep past so I added a deflector to send oil vapors directly down in the oil tank with a smaller section going to the steel wool filter and out to the athmosphere trough a larger vent pipe and it worked. Perseverance paid off :-)
Secret Admirer 23-Nov-2010 21:11
Just stumbled across your photo montage. What an mazing thing you've done here: taking an old warhorse of a Norton, introducing all manner of new technology, painting it a color never before seen on such a bike, and making it work as if it was nothing more than an afterthought. Bravo. One question: The breather you decided on. The one that finally worked. What kind of breather is that?
rob94010 18-Jul-2010 04:35
Jean,
I had to look through the build of the bike. I am in awe of the details and innovative designs.
I have questions about the swing arm Is the swing arm and oil tank a single unit? and
how is the rear axle held for the final drive belt adjustment?
rob94010
accessnorton
H2 Owner Mike B. 09-Jul-2010 13:05
Sure would look awesome in my garage. Nice job.
Guest 01-Jul-2010 03:16
I am in awe, Jean! You are truly brilliant!
Danielle
Guest 12-Feb-2010 04:56
Great work! Thanks for taking the time to post all the photos - it was very enjoyable to look through them and follow your progress. I live a couple of hours south of you in Vermont and ride a stock 1971 Commando Roadster. I'd love to build a cafe bike some day but it won't be as "trick" as yours because I don't have the skills.Congratulations on building such a fine motorcycle.
Paolo Peggi (aka Bracciodiferro)06-Dec-2009 16:37
Speechless......BIG VOTE!
Ciao,
Paolo
Dave 24-Nov-2009 12:27
So nice to see someone putting time, effort, and obviously, love, into such a fine motorcycle. You surely have a right to be proud, So many good ideas but to use. From a former Norton owner,
Titain 09-Oct-2009 19:53
Salut,
Un super boulot, bravo !!!!!!!!!!!
Guest 06-Oct-2009 22:14
Still following your excellent work. Any chance of a youtube video of the bike in action? David B.
André Mailhot 13-May-2009 03:19
Superbe de travail d'orfèvre Jean, félicitations.
Xavier 08-May-2009 11:37
Bonjour Jean,
La qualité du travail réalisé est extraordinaire. Je suis en train de restaurer ma Commando, mais je suis à des années lumières d'un tel savoir faire :/ . Bravo!
GrandPaul 16-Apr-2009 13:14
You are putting me to extreme shame. What awesome work; keep it up and I hope your collarbone s healing fast.
Guest 03-Apr-2009 22:38
I hope you get better soon. I can't wait to see how this project goes. Great job so far!
Jean Des Rosiers14-Mar-2009 20:31
Those skis are the cause of my broken collar bone. The base was as hard as concrete and on a fast slope, I tried to slow down, my ski edge caught and I went down. In an instant, my bone snapped and condemed me to inactivity for weeks.
pascal14-Mar-2009 19:57
Magnifique restauration ! Merci de nous la faire partager. Cette moto sera superbe. Un prompt rétablissement...
Guest 23-Dec-2008 21:12
tres fort! many good ideas and very clever and inconventionnal way and i like the skis in the back
thanks
pierre from france
Ray 19-Nov-2008 17:38
Greetings Jean!
Just curious to see how your project is coming along. It is truly an inspiring undertaking! I am accumulating parts for a Royal Enfield 750 twin powered Norton Hybrid and have been keenly following your progress. In similar fashion, I hope to try both primary & final belt drive set-ups. Is the machine operational yet?

Keep up the good work!!!
Monte Dodge27-Oct-2008 04:11
NIce job here!!!! big vote
Jean Des Rosiers10-Oct-2008 18:14
Hi David,

Thanks for the nice comments. I can be reached at jeandr at videotron dot ca

I encourage you to go forward and finish up your Norton, especially if there is not much work left to be done (yeah right, I'm still in the whirlpool with mine). Posting pictures of my progress gives me the incentive to keep going and if it gives ideas to others, so much the better.

The reasons for my alternator setup are 1- because I am putting a race type belt which is wider than a belt meant for the street and a stock alternator does not fit anymore. 2- the electronic ignition pickup will be at the end of the crankshaft, just where the alternator would be. 3- To keep the bike as narrow as possible.

Sorry to disapoint you, the exhaust will be low level. I think they will look more "period" like that.

Best regards

Jean
Guest 02-Oct-2008 23:33
Hi Jean,

I am impressed by your work. I have a 1959 Norton that started off as a 650 Triton until I replaced the Triumph engine with a Norton 750 Atlas engine (full race spec.). The bike was never properly finished and has been lying neglected in a shed while I brought my family up. I am going to start restoring it soon and have taken inspiration from your photos.

I really like the alternator idea - I had something similar in mind so that I could fit a belt primary drive. Hadn't thought of a belt final drive as well though. Genius! Can you tell me what you have done with the magneto and points. I'm guessing they will be replaced by electronic ignition.

Please go back to the upswept exhausts they look so much better Fastback style. Can't wait to see the rest of the photos. Keep up the good work, David B.
Guest 14-Jul-2008 03:26
Hi Jean, My name is John Gustafson. I am a member of Caferacer.ca. I saw your post a while back, and was very impressed. Now that I've had a chance to really view your site, and the detailed work. I am humbled and impressed. I too have done some serious mods to my bike, but your craftsmanship is truly something to behold. My daughter saw your bike and thought it was Roger Goldammer's "Nortorious" custom.
I really love the belt drive. I wanted to do this, but the cost seemed much too high for my first build. Now that I am at the end, and I am getting ready to build my second bike, I too will use a belt drive system. My bike also has the "double sprocket" in the middle like yours. Mine is to allow the electric motor assist the engine. A bike like yours would be PERFECT for a hybrid project. I am curious, what model is it, and how much should I expect to spend for a fairly decent model? Also, what is your background? Are you an engineer or machinist? Whatever you do, your work speaks volumes of your ability. I can be reached at
intrubble@gmail.com
I hope you will respond. Thank you for your time.

Sincerely, John Gustafson
Jean Des Rosiers08-Apr-2008 03:41
Wawadave,

Look behind the cylinders on some of the pictures, you will see a small alternator driven by a small v-belt. This alternator came off a Kubota stationary engine and is rated at 35-40 amps or close to 500 watts which is about 5 times more than a stock Norton alternator and over twice as powerfull as the three phase Norton alternators. This alternator has the rectifier/regulator built in and requires only two wires, one switched (to turn it on) and one power output.

Jean
wawadave 05-Apr-2008 06:42
i,m wondering how you plan on charging the electrical system since the primary belt and sprocket occupies where stator and rotor used to be?
still this is an interesting project. i have a 1972 750 commando combat motor and a 69 i cannot remember what model 750. started the combat motor up about 5 years ago runs like a top.
click on thumbnails for full image