Stage Four: Frame, forks & wheels

With the engine mounted in the newly powder coated frame the rebuild can begin in earnest. Taking the bike to "rolling frame" stage is always a significant point in a restoration. Suddenly a motorcycle starts to emerge from the parts.


The engine is in the frame. The new powdercoat looks great and we start to find those hidden threads that we missed masking for the powdercoat. A set of metric taps is vital here!



Marzocchi forks are things of beauty but just how do you get them apart and back together? I've been lucky, the allen screw in the bottom of the fork has always released using an air impact wrench. However, reassembly has required some ingenuity. First I cut a slot in the top of the damper like this photo (hacksaw + faithfull dremel!)


Then I machine a piece of threaded rod and drill it horizontally and insert a roll-pin. This can now be passed down the fork and slotted into the slot I cut in the top of the damper. I actually also put a handle on the other end of the threaded rod (not shown) and I can hold the damper in place while I screw the allen screw up the bottom of the fork leg. Without this tool everything rotates and nothing seems to happen. I'm sure Marzocchi have some secret method for doing this but I can't work out how! If you know, do email me.



Now the wheels. I built this jig and spoked, trued and balanced my wheels. It is not hard to do and there are plenty of instructions on the net. Patience and taking lots of photos and measurements of the original wheel are the key to success. Don't forget to measure offset before you take anything apart!


Wheels done. A couple of hours spent sitting in front of the wheel jig. The alloy rims from Central Wheel are very good to lace and finished up with less than 0.1mm run-out. Much better than equivalent steel rims.



Rolling frame. Forks fitted, wheels in place and those beautiful polished Inox stainless steel guards bolted in. I had a plastic tool tray (just visible) which is good news because these can be a bit hard to find.