Build a Bultaco TSS from scratch

[blaine.hale]

Originally Posted by stainlesscycle

call up la sleeve. i'm guessing $200ish and they got it. or you could get a universal fit, and have your cylinder guy cut/port it etc. you have enough of the old sleeve to get a port map.

I'm thinking this may be my best route.
I'm going to keep looking around to see if anyone has a spare cylinder as one of the cooling fins is missing a chunk anyhow but they seem rare as hens teeth.

I'm not, by any means, in a rush to get this done. I have a matador, an r90 and a 63 vespa to tend to this year.

I got these parts all waaaay before I actually expected too! I'll proceed with the bottom end and test out some new "in house" blasting methods. The bottom end actually spins freely and very smooth, so that's a nice relief. Hoping I didn't damage anything else!
The sleeve could have actually been fractured before I began freeing it up but that's neither here nor there :)

[PSchrauber]

Originally Posted by blaine.hale

I'm thinking this may be my best route.
I'm going to keep looking around to see if anyone has a spare cylinder as one of the cooling fins is missing a chunk anyhow but they seem rare as hens teeth.

I'm not, by any means, in a rush to get this done. I have a matador, an r90 and a 63 vespa to tend to this year.

I got these parts all waaaay before I actually expected too! I'll proceed with the bottom end and test out some new "in house" blasting methods. The bottom end actually spins freely and very smooth, so that's a nice relief. Hoping I didn't damage anything else!
The sleeve could have actually been fractured before I began freeing it up but that's neither here nor there :)

I always try to rebuild the existing parts, I do search to get a spare, but in my experience they just don't show up when you need them, (Murphy's law?). If I find something I need and it's affordable I buy it, as it's always good to have a spare, the spare parts for rare birds are mostly not very cheap and may have other issues, (btw. as I know Bultaco changed the displacement between the first to the last Bandido model, sadly no information when they did it).

As you have time, look up a good welder that is specialiced in aluminium/magnesium welds for the cylinder, even very difficult stuff, finns can be rewelded, have seen pre-war machines with rewelded ironcast fins. Likewise look up someone that will make a you custom build sleeve, piston, rings, con-rod and pins for the piston lower con-rod together with piston rings, at least here in D no big issue, the costs will be around one and a half to two in expense as you would pay for parts in stock, you will get a fine balanced crank assembly too.

Riding later is much cheaper.

[yeha22]

So how does the AHRMA look at/receive replicas? In looking at the handbook replicas seem to fit with the spirit of the organization (from the roadrace mission statement: "AHRMA’s mission is to recreate and preserve the vintage era of roadracing, including the sights, sounds, smells and camaraderie."), however I cannot find anything that specifically speaks to replicas. One thing I did see is a reference to specifically NOT allowing the AJR Bultacos in the 350/250 Grand Prix classes. The real question here is: where could you properly exercise a 360cc TSS replica?

My knowledge is from SCCA autocross/roadrace rules and vintage car racing and rallies, I have no perspective on the vintage motorcycle front, so maybe my approach to the handbook isn't correct. With automobiles, some organizing bodies strictly prohibit replicas whereas others will allow them in if they fit the "spirit" of the event.

[PSchrauber]

Any update's ? ... and for your idea collection ...


... when speed doesn't matter

[nachtflug]

Originally Posted by PSchrauber

[blaine.hale]

No updates at the moment. It's going to be one of those looong projects when I have money.
The current crisis is getting the cylinder re-sleeved.

[Tanshanomi]

How are your crankcases? There's a set of gear-primary cases on Ebay that ends in two hours with no bids. The opening bid is $129.

http://www.ebay.com/itm/120929463371

No connection to the seller, just passing it along.

[blaine.hale]

My girlfriend scanned in the shop manual for the montedero (bandido) if anyone wants to take a look at the engine and frame I'm working with.

http://dl.dropbox.com/u/18858855/Man...toCrop.pdf.zip

I need to run a batch process on it in Photoshop and pull just the line art and text out but this will do for now.

[Tanshanomi]

FWIW, here's the motor section of the parts manual for a standard chain-primary 5-speed Bul (Lobito Mk3 in this case). Might help you figure out which ones are standard parts and which are unobtainium unique to the gear-primary bikes.

http://www.tanshanomi.com/temp/Bulta...rts-engine.pdf

[Mark/Foggy]

Little toy that I've been playing with for a while.

[DrSard]

Water cooled................

I too plan to build a TSS from scratch.... I have a Matralla roller and want to shoe a Pursang motor into it ...

also have a sherpa S ...... early model that I want to build a tralla out of...

also have 2 early Matadors (radial heads) and a nice Astro 360 Mod 106 ....and a Mercurio. Mod 13 ...

BUT... the above post takes the cake.....

Keep us posted on the build....

Thanks