Hi from the UK - INDIAN Board Tracker tribute, my first build
- Thread starter PeteMcP
- Start date
PeteMcP
Well-Known Member
Keeping busy with some of the smaller jobs on the latest build. Only minor details - but it's stuff like this that makes a difference to me.
Painted and fitted the waterjet-cut steel ignition bracket to the speedo.
Added some rivets to the headlight's chrome bezel so it ties in with those already added to the speedo's bezel.
Cobbled together the hand shifter mechanism which will eventually transfer gear-shift from the left to the right side. This will connect to the foot shifter's lever cam and the bearings and collars on the shifter's main shaft will locate into a waterjet-cut steel cradle that will hang under the motor's crankcase, substantially reinforcing the frame's drop loop by tying the front motor mount to the bottom bracket.
I mentioned in an earlier post that this build's riding position is downright uncomfortable. Leaning forwards on the Lepper saddle to grasp the boardtrack style dropped bars is just too hard on the old family jewels, so I've gone and purchased a set of pull back bars to get me and my tackle back into a more comfortable upright riding position. I guess this will be a more 'roadster' than boardie look. The vintage handlebar clamps I'm using are for 22mm bars, so these were the only 22mm (7/8") dia. bars I could find on eBay that didn't come with an expanded 24.8mm (1") central portion. Had to source them from an Italian seller on eBay. Thankfully they arrived without any import duty or VAT now that Brexit means we Brits are no longer part of the European Union. I also took the opportunity to fit tan-coloured handgrips which I reckon co-ordinates better with the bike's tan Lepper saddle. And of course the vintage vibe has been continued with the fitment of a lovely pair of chromed reverse levers - courtesy of an Indian seller on eBay. Absolute bargain at a mere 21 quid including free airmail shipping which took less than two weeks to be delivered. They arrived today, with no duty or tax levied. Back of the net!
Painted and fitted the waterjet-cut steel ignition bracket to the speedo.
Added some rivets to the headlight's chrome bezel so it ties in with those already added to the speedo's bezel.
Cobbled together the hand shifter mechanism which will eventually transfer gear-shift from the left to the right side. This will connect to the foot shifter's lever cam and the bearings and collars on the shifter's main shaft will locate into a waterjet-cut steel cradle that will hang under the motor's crankcase, substantially reinforcing the frame's drop loop by tying the front motor mount to the bottom bracket.
I mentioned in an earlier post that this build's riding position is downright uncomfortable. Leaning forwards on the Lepper saddle to grasp the boardtrack style dropped bars is just too hard on the old family jewels, so I've gone and purchased a set of pull back bars to get me and my tackle back into a more comfortable upright riding position. I guess this will be a more 'roadster' than boardie look. The vintage handlebar clamps I'm using are for 22mm bars, so these were the only 22mm (7/8") dia. bars I could find on eBay that didn't come with an expanded 24.8mm (1") central portion. Had to source them from an Italian seller on eBay. Thankfully they arrived without any import duty or VAT now that Brexit means we Brits are no longer part of the European Union. I also took the opportunity to fit tan-coloured handgrips which I reckon co-ordinates better with the bike's tan Lepper saddle. And of course the vintage vibe has been continued with the fitment of a lovely pair of chromed reverse levers - courtesy of an Indian seller on eBay. Absolute bargain at a mere 21 quid including free airmail shipping which took less than two weeks to be delivered. They arrived today, with no duty or tax levied. Back of the net!
PeteMcP
Well-Known Member
Those pull-back bars and inverted levers are great - but using them means I've had to drill the bars to run the brake and clutch cables internally. Which in turn means I've had to shelve the Honda CG125 front brake cable I was using in favour of a 6" longer one. And would you believe it, out of the hundreds of brake cables I looked at online, the only one I could find that was the correct length AND had compatible hardware that fit into the Honda CG125 front hub brake plate on this build was listed by a Hong Kong seller on eBay...
Another case of two steps forward, one step backwards....
Another case of two steps forward, one step backwards....
PeteMcP
Well-Known Member
Agree Rick,
Still love the dropped bars look on this build, so I can always swap out the bars depending on how I feel.
I can probably tolerate short rides with the dropped bars fitted, without wincing too much.
Tom from Rubicon
Well-Known Member
Building one of's is such fun. Yer pussy is likely not the application engineer you hoped for.
On my home front. Ed, my neighbor that plows the snow from my 300ft. drive. Has commissioned me to resurrect a unloved Mountain Bike. Ed tells me his mates at the tavern have impressed on him that this is a quality machine. But he won't go no higher than $200.00 to make it right. I told the daft bugger, his budget would get a new one at Wally World. Well he says can you mount new tyres on it? I don't know. Ed did help me split almost 3 cords of firewood. Fire going right now.
Tom
On my home front. Ed, my neighbor that plows the snow from my 300ft. drive. Has commissioned me to resurrect a unloved Mountain Bike. Ed tells me his mates at the tavern have impressed on him that this is a quality machine. But he won't go no higher than $200.00 to make it right. I told the daft bugger, his budget would get a new one at Wally World. Well he says can you mount new tyres on it? I don't know. Ed did help me split almost 3 cords of firewood. Fire going right now.
Tom
indian22
Well-Known Member
Yep one offs are fun and present many challenges some of which, like the cables, take time to source & others have to be designed, fabricated and fitted properly. Some more than once. Pete has the emotional and creative mentality to create great projects over time which are unique yet functional.
Tom that's a really nice firebox! I like helping others and with bikes that means assisting them in the process while teaching them to do the work themselves.
Rick C.
Tom that's a really nice firebox! I like helping others and with bikes that means assisting them in the process while teaching them to do the work themselves.
Rick C.
indian22
Well-Known Member
Agree Rick,
Still love the dropped bars look on this build, so I can always swap out the bars depending on how I feel.
I can probably tolerate short rides with the dropped bars fitted, without wincing too much.
Pete that's a good point. Of course low, narrow bars look the part better, yet long rides for most aren't easy while quick trips are fine.
There are many great looking examples of vintage bikes which combine road bars and large period headlights as well, on track style bikes and they look wonderful.
In the end we build them as we want them and that's how it should be! Keep up the great work.
Rick C.
PeteMcP
Well-Known Member
SUPER-EASY CARBIDE TO LED LAMP CONVERSION
Just achieved the easiest and quickest LED conversion ever on my latest vintage Powell & Hanmer 'HOROSCOPE' carbide bicycle lamp purchase.
Didn't even have to alter the vintage lamp itself in any way. The only work required involved sawing/filing off the pair of moulded-on lugs for the rubber securing strap from the LED light's plastic housing, resulting in the light's body being a snug interference-fit into the reflector ring inside the lamp. Conveniently, the LED light's on/off switch is then easily accessible through the flip-up hinged lid of the lamp's red sidelight. 10 minutes work in total, if that.
The neat little USB rechargeable, multi-function, LED bicycle light cost a mere 4.25 uk pounds, including free shipping, from a China seller on eBay. Selectable modes include: slow flash, quick flash, half brightness, full brightness. Terrific result at an absolute bargain price.
Just achieved the easiest and quickest LED conversion ever on my latest vintage Powell & Hanmer 'HOROSCOPE' carbide bicycle lamp purchase.
Didn't even have to alter the vintage lamp itself in any way. The only work required involved sawing/filing off the pair of moulded-on lugs for the rubber securing strap from the LED light's plastic housing, resulting in the light's body being a snug interference-fit into the reflector ring inside the lamp. Conveniently, the LED light's on/off switch is then easily accessible through the flip-up hinged lid of the lamp's red sidelight. 10 minutes work in total, if that.
The neat little USB rechargeable, multi-function, LED bicycle light cost a mere 4.25 uk pounds, including free shipping, from a China seller on eBay. Selectable modes include: slow flash, quick flash, half brightness, full brightness. Terrific result at an absolute bargain price.
Tom from Rubicon
Well-Known Member
But Pete, it doesn't do the side lites. 
What sort of pattern do you get from the source fed through the convex lens?
I am still soaking a carbide bike lamp in lacquer thinner. Afraid of the bloody fumes. Even outdoors.
Your Powell & Hanmer 'HOROSCOPE' carbide bicycle lamp is a beauty.
Tom
What sort of pattern do you get from the source fed through the convex lens?
I am still soaking a carbide bike lamp in lacquer thinner. Afraid of the bloody fumes. Even outdoors.
Your Powell & Hanmer 'HOROSCOPE' carbide bicycle lamp is a beauty.
Tom
PeteMcP
Well-Known Member
Tom,
Using double sided adhesive tape to attach the LED light to the lamp's rear reflector ring would ensure the light's beam also illuminated the lamp's red/green sidelights.
I've a soft spot for these shaped vintage bicycle lamps. Vast majority of this style are Lucas 'Silver King', as shown at right in the attached pic. Made by a couple of different manufacturers such as Lucas, Miller, etc. but this nickeled Powell & Hanmer lamp is the only one I've seen with a round base. All others I've seen have square bases.
I reckon repros of these kind of vintage lamps would be another product for those metalwork craftsmen in India to add to their range of repop brass compasses, sextants, telescopes etc.
Using double sided adhesive tape to attach the LED light to the lamp's rear reflector ring would ensure the light's beam also illuminated the lamp's red/green sidelights.
I've a soft spot for these shaped vintage bicycle lamps. Vast majority of this style are Lucas 'Silver King', as shown at right in the attached pic. Made by a couple of different manufacturers such as Lucas, Miller, etc. but this nickeled Powell & Hanmer lamp is the only one I've seen with a round base. All others I've seen have square bases.
I reckon repros of these kind of vintage lamps would be another product for those metalwork craftsmen in India to add to their range of repop brass compasses, sextants, telescopes etc.
Tom from Rubicon
Well-Known Member
Just saying Pete.
I recall a couple of years ago when MotoMags was primping his Excelsior tribute, that his LED combo did a dandy job of full illumination.
Tom
I recall a couple of years ago when MotoMags was primping his Excelsior tribute, that his LED combo did a dandy job of full illumination.
Tom
PeteMcP
Well-Known Member
Begun silver soldering the reinforcing gussets to the frame.
Prefer to use silver solder here rather than welding in order to avoid an unsightly weld bead. (Planning on leaving the frame clear-coated bare metal - but that could change). However, I'm going to arc weld the pair of dropout reinforcing gussets because I can hide the weld on the inside of the frame. My wire welder is in storage along with most of my workshop gear, but to be honest, my work-space in this apartment is so very limited I couldn't contemplate using it here anyway, so I've decided I can justify one of the latest hand-held mini leccy welders I've been seeing reviews of online, pics attached. More akin to a hair-dryer in size, I opted for the 5500w version. As usual, AliExpress came to the rescue with a price point almost half that of what the few UK sellers are listing these at. Worth checking out the YouTube reviews. I'll report back here with my findings after giving it a try-out - but I know one thing's for certain; my weld beads definitely won't turn out anywhere near as uniform and perfect as those pictured in the tool's ad blurb...
Prefer to use silver solder here rather than welding in order to avoid an unsightly weld bead. (Planning on leaving the frame clear-coated bare metal - but that could change). However, I'm going to arc weld the pair of dropout reinforcing gussets because I can hide the weld on the inside of the frame. My wire welder is in storage along with most of my workshop gear, but to be honest, my work-space in this apartment is so very limited I couldn't contemplate using it here anyway, so I've decided I can justify one of the latest hand-held mini leccy welders I've been seeing reviews of online, pics attached. More akin to a hair-dryer in size, I opted for the 5500w version. As usual, AliExpress came to the rescue with a price point almost half that of what the few UK sellers are listing these at. Worth checking out the YouTube reviews. I'll report back here with my findings after giving it a try-out - but I know one thing's for certain; my weld beads definitely won't turn out anywhere near as uniform and perfect as those pictured in the tool's ad blurb...
Hi Pete,
The parts are a going to look excellent on the bike. Head light and handle bars are going to be the perfect combination. I like the rivet accents, The shifter is great. Makes everything easier.
I have been looking at eBay from time to time for head lamps for the Indian but wanted to find a matching pair got sale. Seems there is a better chance of finding a Unicorn. Did find some nice reproduction lamps on a high wheel bike site. Went back to order them and they took a big price jump so by the time they land here they would be over $200 Canadian each. Back to the vintage lamp search.
Your lamp conversion is perfect. I like the Chief Inspector giving it the once over. I trust she gave it the OK.
Never saw that type of welder before. Excellent when you don't have a lot of room. They never include the person who does those perfect welds. I presume they feel that if you are using their welder you will naturally be able to weld like that from the start.
Steve.
The parts are a going to look excellent on the bike. Head light and handle bars are going to be the perfect combination. I like the rivet accents, The shifter is great. Makes everything easier.
I have been looking at eBay from time to time for head lamps for the Indian but wanted to find a matching pair got sale. Seems there is a better chance of finding a Unicorn. Did find some nice reproduction lamps on a high wheel bike site. Went back to order them and they took a big price jump so by the time they land here they would be over $200 Canadian each. Back to the vintage lamp search.
Your lamp conversion is perfect. I like the Chief Inspector giving it the once over. I trust she gave it the OK.
Never saw that type of welder before. Excellent when you don't have a lot of room. They never include the person who does those perfect welds. I presume they feel that if you are using their welder you will naturally be able to weld like that from the start.
Steve.
Tom from Rubicon
Well-Known Member
Pete, you are not kidding about not replicating sample welds. Robotic welds are just about that perfect.
Two handing that stick welder might produce a decent weld. Weld penetration is an unknown. But if your pussy signs off on the welds, I am not the one to argue.
Tom
Two handing that stick welder might produce a decent weld. Weld penetration is an unknown. But if your pussy signs off on the welds, I am not the one to argue.
Tom
PeteMcP
Well-Known Member
Steve, finding a matching pair of vintage lamps for your Indian is a tough ask. Good luck coming up with the goods.
But there's an alternative that may work for you which is currently listed on AliExpress - who bombard me with at least three emails a day to try and tempt me to buy more stuff from them. This particular vintage-style lamp (looks like it's made from brass but is listed as copper) can be seen on one of the overly-blinged-up, ready-to-ride motorized bicycles frequently advertised on AliExpress, but in this case, the brass head and tail lamps are listed for sale separately. Retail price is touted as 53 and 26 UK pounds respectively. Inclusive of free shipping. If you think this is worth a look, search for 'Retro Bicycle Copper Light' in the Cool-one Bike Outdoor Store on AliExpress. If not, feel free to ignore....
(tried uploading the lamp pic from the AliExpress site but it won't let me)
34.31US $ 14% OFF|Retro Bicycle Copper Light / Bicycle Headlight Vintage Bicycle Bells Retro Bicycle Copper Accessories|bicycle bell|bike bellbells copper - AliExpress
Smarter Shopping, Better Living! Aliexpress.com
www.aliexpress.com