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The rebirth of Lazarus

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Oddjob:
Most likely the dowels are welded into the cases, you could try a little heat in those areas, whilst you hit the cases with a dead blow hammer.

I'd just buy a second hand swinging arm Mick, I'd never trust welding in that area unless the metal was brand new, the problem is you cannot see the inside of the arm which could be rusting through.

I have loads of spares for the 500 Mick, let me know if you need anything and if I have you can either have it FOC (just postage) or for a small fee if it's rare.

I have at least 2 sets of crankcases, I was going to throw them soon as the shed is coming down early next year and I'll be binning a ton of stuff, most rusty etc so probably no good but the scrapman was very interested and offered to clean the shed out for me. I threw a stack of A/F spanners/sockets out, they just get in my way.

mickwinf:
cheers Ken, i would be interested in a pair of crankcases, and i have considered getting another swingarm. I am at a crossroads with this restoration,as a lot of parts will have to be replaced including the crankcases so it will not be a correct numbers bike when done. Do i still spend loads of money and get it to original or rebuild to a slightly non standard spec which would be cheaper to do, much like my original 500 in the seventies.

mickwinf:
The engine is now stripped down and i can make an assessment of the work needed. The crank and shells seem to be in very good condition, but the gearbox has some damage with two of the gears that the selector forks fit into having chips out of them where the forks fit. at first glance the forks themselves seem ok, will check closely later. The cylinder head looks ok and the bores are rusty and it was already .5mm oversize. The main issue is the crankcase has been damaged on the front engine mount and i don't know if it will be repairable or not or what it would look like after repair. I will put a pic up to get the opinion of any welding experts out there.

mickwinf:
pic of crankcase damage

royhall:
Blimey Mick that's one rough starting point, you must be up for a challenge. Hope it all goes well for you mate (although from the last pics it's clearly not). Will be keeping an eye on this one.

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