Mike Waller builds a BSA C15T replica but not a full trials bike.

Mike Waller finds himself with a BSA C15 swap bike.

And decides to built it into a

BSA C15T Copy Bike....

This is the BSA C15T very much how it left the factory.

And no one can say that it was not a pretty little bike....with the Blue steel tank...and chromed steel guards ...

But as a trials bike it was no lightweight...

The bike was nearly as heavy as the Gold-Star it sort-of replaced.

The front wheel fitted had to have a 20" rim for the wheel not to touch the frame on braking.

The 65 degree head angle was 2 degrees steeper than the road bike, this was not a different frame but just jacked up at the back slightly with longer rear shocks.

The frame was just a modified swan neck road frame.

The only difference was that the cast engine mountings were machined so to move the engine over an 1/8" to the left for chain clearance on the rear tyre.

(this could have been done by just fitting an 1/8" (2mm) spacer on the gearbox main-shaft before the 14 tooth sprocket.)

The footrests were moved back from the road position and held in place by a through rod passing between the two cast mountings.

I remember these always coming loose.

Side stand on the left was just reversed and fitted on the shortened pillion footrest mounting tube on the right.

The swinging arm was always said to be longer and wider, but this was just a tale from the works riders... as far as I remember it was the same as fitted to the road bike.

Front forks were a mixture of parts from the A series Heavyweight forks and from the Triumph parts bin, if I remember. And started life on the the C11-12 some would say...The exhaust system was the biggest problem riding the bike as it always burnt your Barbour bottoms, or worse your leg...

These outside the subframe pipes were fitted on all the first batch BSA C15Trials and it was only the works guy's again that eventually had enough and tucked the pipe inside the subframe.

Fuel tank and both mudguards (fenders) were steel, that again added to the weight. Worst problem we had with ours was the poor starting and the Rugby clay bunging up the back wheel..

But you know what I now think of the BSA unit C engine. How many have I got....

Good luck Mike I am sure it will turn out a good job like they all are...

Project Outline...

Episode ONE...

Mike still a bit undecided?

Episode Two...

An Exhausting situation...

Mike makes a Stain-Less Steel exhaust system...

Here Jeff Smith shows off probably the second inside frame C15T Exhaust system Second? Yes Brian Martin would have had the first...

Note Modified oil tank...

Episode Three...

20/09/2020...

Understanding Footrests.

And suffering the IT gremlins..

Just looking at the badly brazed prop stand joint that BSA did, shows how the industry had gone into decline even then 1959.

I have found joints just as bad on frames I have cut up, (did you notice the rust in the joint.)

It only came to my notice a couple of years back that the 14-12 gauge tubing used was in fact welded seam and very much of a iron basis...

But they held the wheels and engines apart, and although most frame were at least 3/8" out of line the bike sold in vast numbers to get people to work. If Lucas had wound the electrics correctly? Good Olde Great Britain...

Episode Four...

later got IT problem...

Episode Five...

05/10/2020...

Those little jobs that give you grief...

And makes the air "Blue"...

You need a good Black and White dog to shout at Mike...

Episode Six...

Forking out again...

Mike the fork legs are in the wrong way around, but don't worry Harry Foster used to fit them that way around on the Foster BSA Otters...

Episode Seven...

Mike starts to strip the engine, but it does not want to cooperate...

Spots back showing an interest, and somehow thinks he can catch the Covid...

Good little chap for taking care...

Episode Eight...

Engine strip-down continues...

And a search for a replacement big-end and con-rod...

Episode Nine...

Big Press Needed...

Episode Ten...

Mike struggles with the back hub...

You were a brave man Mike spinning that Cast back drum on the lathe...

I had a cast drum break just after I tightened it in the chuck, bits flew everywhere...

And it looks like the Competition hub should be a fit...?

BUT you probably would not get a sprocket that was a stepped one made for the job...

Episode Eleven...

Christmas comes early for Mike, with a few disappointments.

Then some milling about, and it looks like he may have to get the slippers changed...Just part of nature...

Episode Twelve...

Mike starts the final build up of the BSA C15T copy bike, and after a few problems with pattern parts ends up at the end of the day with a rolling chassis...

Episode Thirteen...

Did we expect everything to go right?

Episode Fourteen...

Catching up, and going back...

Episode Fifteen...

Balancing Act, with Spot putting in an appearance...

Do toy dogs get Covid?

Episode Sixteen...

The engine starts to take shape...

Mike it would have been easier to have fitted the oil pump with the engine out of the frame and laid onto its side, always fit the greased gasket when the pump is located-into the hole.. It is tricky, and I sometimes forget the technique...

By the way swap the cam-followers around, the holes should face the rear of the motor...

Hope you have a good Christmas with the circumstances we have...

And am looking forward to the next project...

Episode Seventeen...

Getting there with the engine with a few glitches on the way...

Mike I was sat here shouting "Turn-the-kick-start", so frustrating knowing you could not hear me...

I think there is a spacer on the end of the camshaft before the lock-washer and nut...?

The hole is for the timed breather into the cover, this is where most of the oil through the kick-start shaft comes from... Like you say very poor design but the industry at the time did not care about oil leaking did they...

I have been asked the same question about a cure...

You can see why I do the "F" type conversion now...

Episode Eighteen...

A Bit of Electrexisity clutching for straws...

Episode Nineteen...

Bit of a crafty conversion to the timing cover this week.

And a mistake that passed me bye, when I heard Mike mention crossing the oil pipes...

Don't On a C15 only the B25 are Crossed.

Sorry Mike I was not 100% concentrating...

Episode Twenty...

Getting There...

Mike, there should be a Tufnel spacer from the head to the carb to stop heat transference, and helps stop the carb warping...Should be two gaskets in the kit...

Carb studs are usually BSC into the head BSF for the nuts...

But I have known some to be BSC into the head...

More Later...Stay Safe Take Care..........

Episode Twenty one...

Bit of Cable laying...