Headset Repairs

[Littlewheels]

I am stripping the headset on my 63 Special but there are some problems

It is fitted with early housings with the raised area around the pivot pins

https://www.flickr.com/photos/135994003 ... ed-public/

Problem is someone has drilled out the hole to 9mm so my question is can it be welded and re drilled/reamed? Can you buy the correct thickness levers?

Also the headset top needs welding where a part of the lip has broken away.

https://www.flickr.com/photos/135994003 ... ed-public/

Anyone know a good aluminium welder?

Thanks

[nickw]

You can get oversize lever pivot pins from MB. They are 8mm size though not 9mm. Probably easier to get a second hand shroud off eBay or Facebook. The headset can be repaired . With it being a special a replacement headset would be fairly high . I know again MB does ally welding but a couple of years ago his labour cost was around £1 + vat a minute. There will be others who can ally weld. Not sure about the thickness of levers. Presumably original ones would be the correct thickness?


https://www.lambrettaspares.com/spares/hydraulic-sundries/lambretta-headset-(handlebar)-lever-pivot-bolt-8mm-oversize-with-washer-and-nyloc-nut-stainless-steel-mb/mbp0094k.html

[MK Monty]

Is me but £60 quid an hour is not expensive for anyone who is skilled at the job they do. At least having an idea will help you decide to keep it original or buy a replacment

[Warkton Tornado No.1]

Lever housings can be fixed by good.engineering methods. In fact, bushing is better than boding with oversize pivots. Far better than welding too!

Meticulous drilling & reaming the holes further oversize to fit plain bearing bushes (Oilite type) will result in a better pivot hole than original. Oilite bushes are sintered & the deliberate porosity contains oil & also allows relubrication.

Oilite fitting information is available concerning the fitting, which should be done with a pin fitted to control the bore's finished size. They should not be reamed after fitting as the bore will then be 'smeared' & defeat the whole purpose.

I've used this method on race hydraulic master cylinder lever pivot holes as the things take a right hammering. Some of you will need to do the same fix to your bling alloy gearchange mechanisms mounted on the crankcase in place of OEM steel I reckon......

[Littlewheels]

Thanks for the replies. I will post pics when I have repaired.