New Wheels and Tyres
The tyres on the Sportster were done, aged out. Passes MOT as there are no cracks, and no test for age, but the rubber was no longer the best and...
Camber and Caster Adjustment
I've had some questions how how the camber and caster are adjusted on the Sportster. The following images are not dimensionally accurate, they represent the adjustments available. The Sportster has...
Fuel filters and one way valve
The fuel filter elements are the originals from 2005, so it was time to change them. The good thing Sytec still make the bullet filters and the elements are available...
Wiper Motor Smoked
Took a test drive after swapping the shock top mounts. It's a few days until MOT time and this is obviously when things like to break. I had no wipers,...
Shock Refurb Part 2
The ball joints in the gaz shocks were worn out, they didn't have an upgrade unit available with stock BMW top mount/shock positioning. I therefore looked for an alternative which...
Shock Refurb Part 1
Last year the MOT person mentioned there was excessive movement in the rear shock mounts. After some testing it was mainly the top mounts. They are from Gaz Shocks, purchased...
Differential Bushes
The differential has been sqeaking and nods up and down under load so it was time to get some new bushes. Both sets of bushes are from https://www.powerflex.co.uk/ - the...
Engine and Gearbox mounting bushes
Recently the alternator hit the chassis when I changed direction, a good indication that the engine and gearbox mounts might need some attention. Unfortunately the alternator bearings were damaged due...
Brake Fluid Reservoir / Expansion Tank
Recently tried to flush the brake fluid with a pressure bleeder. It uses a chain to hold a top on the fluid reservoir/expansion tank. That doens't work at all well,...
Heater Fan Fix
For a number of years now the heater has caused problems with the fans moving out on the shaft and scraping against the side of the outer casing. The tick...
Radiator Return Pipe
Since the car was built the return radiator hose as been a long flexi pipe, this was never a good solution. At some points the pipe rubs which eventually would...
All the Brackets
Bracket Number 1: The return pipe from the radiator to the header tank has always been attached with a zip tie holder, but only double sided taped on. Every time...
New front wing stays
The front wing stays rusted and broke again, did a temporary fix a few months ago, but finally it's time to make some new ones which will hopefully be more...
Upper wishbone refresh and wishbone mounting rod
I changed the upper bushes today. They were rally design ones, which I've now replaced with Powerflex. I thought the bushes had worn as things didn't look straight anymore. Turns...
3 point reel seat belt conversion
ziptie test, safety 3rd! Hole cut for threaded belt insert Test fit of new piece Use the lathe to clean up these spacers Reel mount Reel mout welded in Upper...
Rear rust clear up
Doing some clean up work, the Sportster has been on the road for a while now so it was time to check for rust and clear anything up Little bit...
Rear brake pads
I fitted ATE brake pads to the front some time ago, they bite much better than the Jurid ones and generally feel better. The rear was still on Jurid and...
Varex exhaust build part 5
Video (obligatory no exhaust clip right at the end when everthing was off): https://youtu.be/KXJBKerTiNI
Varex exhaust build part 4
As I was busy Richard sorted the wiring out for the control box: Wiring, inside the tub running along the tank with the rest of the rear loom Wiring running...
Varex exhaust build part 3
Built the other side of the exhaust today. Welding is 'better' than when I started but still pretty uneven. I can't weld too far consistently around the curve yet. Did...
Varex exhaust build part 2
Step 14: Cut down the output pipes, otherwise the tips would stick out too far. Step 15: Tip test fit, could move these back further by cutting the tip input...