Musky's Plunger rebuild.

[BagONails]

G'day BON
Thanks for the encouragement. I have a new stick/mig/tig welder, I've only ever done stick. I'll get #2 son over to show me how to use it.

Now to start spending the kids inheritance 
The SRM web site is a pain. Click on A7 A10, click on bottom end, 39 pages of mostly Notrun or Trihard stuff. 
My list so far = $2071.90AUD + the $1000 already spent.
Cheers

Good man. It is tricky to start with, requiring hand eye coordination and you are doing different things with both hands at the same time so if you can play a piano you'll be fine! It really is all practice though and once it has clicked you'll never look back.

I had the same experience the other night looking for my clutch items, assumed it must be me doing it wrong. Wrote an email to them instead as I just couldn't find everything although they must have the parts as you can get the whole assembly if you want to take out another mortgage.

[BagONails]

Seems like a replacement standard head and barrels would just add to your costs and bring along their own new set of problems there Musky, better the devil you know I say.

I tend to agree with RD that seeking a suitable repair of the original cases might be best.  Maybe have another think about the repair method, I like RD's idea of machining out the damaged holes and welding in new inserts that can then be drilled and tapped anew. Once you are clear as to exactly how you want it repaired try to get another 2 quotes and see how they stack up although last time I checked 30 quid was about $55 AUD so I'm not sure about how current his prices are! 

Hang on to the new/old cases just in case you still need them and then if not put them back on the market down the track.

I do however appreciate we are all living this from our lounge rooms and only trying to help...that's the thing with these forums, lots of free advice which is great (and has certainly helped me) but in the end "you da man" who has to make it all happen!

[Kickaha]

The SRM web site is a pain. Click on A7 A10, click on bottom end, 39 pages of mostly Notrun or Trihard stuff. 
My list so far = $2071.90AUD + the $1000 already spent.
Cheers

Those are rookie numbers, you need to up your game 

[muskrat]

G'day BON.
Yes that's my problem! Blind right eye and deaf in left ear. So not only 1/2 blind but I have little balance to boot. Once she's rolling, no problem!

G'day Kickaha.
That price list included SRM con rods (no stock) so that would shave $800 off. I figure SRM might be a few $$$ more for most parts but they have a rep to uphold.

Tonight I'm just polishing the HD for a show on Sat. Polishing the BSA in no time, the HD takes all night 
Cheers

[muskrat]

G'day Fellas.
Not sure if it worked but I merged the last few reply's from the Wanted topic as it was going astray.
Cheers

[RDfella]

I checked 30 quid was about $55 AUD so I'm not sure about how current his prices are! 

The 'updrive' case in the pic that I gave as an example of my pal's welding - all the welding on that case plus a couple of other bits was £20. This week. 

[Seabee]

Musky,

I happened upon an A10 aluminum head that has been modified for through bolting. Do you need one? I have no plans to do that to any of my engines. I was going to see about restoring the original bolt pattern and using it down the road.

[muskrat]

G'day Seabee.
I'd certainly be interested. I was thinking of doing the same. The alloy head would be easier than the barrels. With mine I threaded the outer 4 holes and made threaded alloy plugs. Then drilled new holes 1/2 in the head, 1/2 in the plugs. Could do the same again in reverse. Worth a try. Then I'd need to find a set of big fin A7 barrels.
PM me to discuss $$$
Cheers

G'day RD.
My fella charges $100 (￡55 per hour). To do it properly the two bad ones would need to be broken out completely then re-made. He recons 8-10 hours work then the re-machining.
Cheers

[RDfella]

Understand your work estimate now, Musky.
I was assuming that with your machining ability and engine building experience you'd be doing the preparation / refinishing and all that had to be farmed out would be the 1/4 hr or so alloy welding required.

[muskrat]

G'day RD.
Most of my engine modification work was done whilst I worked in a machine shop. Now I only have a cheap Chinese lathe and drill press.
The ZA10 cases should be here by Wednesday so will focus on building that first. Yet to decide if to go standard or the full roller route.
https://cybermotorcycle.com/archives/bsa-a10/    https://cybermotorcycle.com/archives/bsa-a10/convertingcam.htm
Cheers

[RichardL]

55 GBP/hr sounds about right for a professional welder (based on US prices), mabe even cheap. I think RD's pal, if a professional,  was just charging him as a friend for the welding rod. The certifieed welder that  built up a new boss for one of my sump plate screws told me that with aluminum casting about 75% of the time is in prep, mostly cleaning. He also told me not to bother with any of the prep because he would just have to redo it to be confident with his work.

Richard L.

[RDfella]

Not so, Richard. From my previous post you'll see I estimate the actual welding would take around 15 - 20 mins. So 1/3 x £55 =?

[muskrat]

G'day Fellas.
I had a nice big box on my doorstep when I got home from work. The ZA10 cases have arrived. The engine number dates to 52 but I can't see a date stamp anywhere. My old cases have one inside the primary. Another difference is the sump pickup tube. Mine had a tube up the side, these have a hole down near the sump plate.
It's late and after a hard day at work I'll look closer tomorrow.
Let the fun begin.
Cheers

[RichardL]

Not so, Richard. From my previous post you'll see I estimate the actual welding would take around 15 - 20 mins. So 1/3 x £55 =?

I stand corrected.

Richard L.

[Swarfcut]

 A pick up pipe low down seems strange. All Plungers I've seen have the pipe bolted to the inner crankcase. Possible someone has modified the case to mimic the later S/A design, or worse a S/A crankcase half  that has been modified and matched to a standard Plunger drive side. Have a good look at what you have before reaching for the tools.

 This sounds a bit unusual as from my experience I have never seen or heard of this.

Cheers

 Swarfy.