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The seal on the Bonnie is still holding. It’s been over 100 miles of not showing it any mercy and it’s still bone dry. I’m at the stage now where I’m not worrying about it. I think that if the process can get me a rock solid seal for 100 miles, even if it fails, in principle there is no reason why repeating the process, but with more epoxy putty and more liquid gasket, won’t fix it permanently. As a precaution I dropped some oil and took my time filling it to just over minimum. That should reduce the risk of pressure causing a failed seal. While I was at it I lubed the chain. The drought is supposed to be ending, so I need to be prepared for rain.

I’ve done a quick job on the Sportster. After realising the clutch lever position was the same on all my previous bikes as it is on the Harley, I looked in the manual to see if I’d set it wrong. I had. I had it taught, you’re supposed to leave 1.6mm slack between the cable end and the clutch lever block. That sounds like nothing, but it has to be pretty slack to get that gap. It means the first part of the pull of the lever is without resistance. Which is a definite improvement when it’s such a reach and so hard to pull. The cable lube arrived today but I’ve not applied it yet. There are a list of jobs I want to do to it for the aesthetics, but right now the only practical thing is to sort out the handlebar position. Once I’ve done that I’ll have to get appropriate sized front brake line and throttle cables. I also need to fix the bar end mirrors, but that’s probably not a purchase. I can probably do that with washers and silicone sealant. Again, I don’t want to make a permanent fix if I’m going to be changing handlebars.

All the jobs are dependent on money, obviously. There is no rush to buy all the bits for the Sporty. The Harley has been running fine, so it is a good backup for work as it is. All the work I want to do on it can wait for the money.

I’ve been thrashing the Bonnie for a week now, back and to to work, and the seal has stayed bone dry. The bolt seems to be secure and holding. Yay! That’s a big weight off my mind. We were out of money, the Bonnie is my work wheels, and the next steps to repair it were looking expensive and time consuming. With the bike off the road. That’s a huge relief.

Work have been beasting me. I think it’s mostly psychological. It’s 10, 11, up to 12.5 hour shifts. That isn’t that long for a lorry driver. The thing is, it’s in two runs. You do the first one, you’re out 6 hours, you come back to the yard, have your break, swap vehicles, and start again. The other day I was given a bunch of jobs straight away. I was out all day, but because I didn’t have to go back to the yard it felt loads quicker and easier. I’m just going to have to adjust. At least the driving isn’t freaking me out as much. Or rather, I’ve reached a plateau of freaked outness and I just get on with it. It’s all tough and stressful, but that’s what it is. On the bright side, I got 4 shifts last week, and even with a surprise short shift (yay!) I should be taking home about £630. If I can get that every week it won’t take us long to have a a safety buffer in the bank again. And it saves me from having to get another job.

Another thing is the Harley. It’s been weighing on me. It’s been sat in the garden in mute reproach. I decided I didn’t like it and I didn’t want it. This morning (day off) I was woken by a headache and I was lay in bed wording the advert to sell it. I was squirming with remorse because I’ve seen some much better condition Sportsters for sale for what I paid for that 20 year dead rustbucket. I bought it on impulse after seeing what were frankly very flattering pictures of it. Since then I’ve spent thousands on the project. The list of new parts is vast. I’ve got it riding and running right, but as I was wording the advert in my head I couldn’t get away from the fact it’s still old and scruffy. People (who aren’t impulsive idiots) buy Harleys to pose on. Mine is actually a pretty sorted bike (it only had 10,000 miles on it, I’ve replaced all the consumables, and upgraded the engine and loads of the electrical components) but it still looks rough. I was thinking of asking what I paid for it. It would have filled me with shame at wasting all that money, but I couldn’t see another option.

I’ve been working on the split engine casing on the Bonnie. Look at it!

I tried squeezing epoxy putty in the gaps between the surfaces and leaving it compressed.

That was a big no. As soon as I put the engine cover back on the magnet snatched it out of my hand, jarred the join, and the errant piece fell off. I tried again. This time making a bridge over the snapped off part. Better, but when I screwed the bolt in it lifted off again.

After saying last time out that I only got one shift in a week, and that I definitely needed a new job, I’ve got 3 out of the 4 I put myself as available, this week. The thing is, I don’t want to put myself as available for any more shifts in case I get them all. They are generally 11 to 12.5 hour shifts, and the driving is incredibly stressful. I want 3 days off. 3 shifts of work is well enough to pay the bills, so I’ll wait another week before I have to make any decisions.

My opinion of the Harley has been swinging back and forth. I’ve fitted the wider bars, with bar end mirrors, and it’s much more useable now, unfortunately the angle of the bars means I’m now straining my wrist to pull the levers. I’ve not got around to taking the forks out to fit the new oil seals and covers yet. I definitely need to make it comfortable to ride. Some guy online has whipped off the tank, mudguard and seat then fitted Japanese motorbike components. It’s made it look loads more useable. It’s a thought. As is a Japanese front end. Just unbolt the headstock and fit a decent front end and bars. If I knew of one that was a straight swap I’d have it on my ebay watchlist.

Because we live in an arbitrary yet vindictive universe, I’m also having issues with the Bonnie. After the oil and filter change I put in the workshop manual specified 3.3 litres of oil. Which was too much. I noticed a small drip of oil and realised I’d blown a seal. Idiot. I drained some off, but riding into work I noticed it had sprayed oil on my boot and there was oil dripping on to my pipes. Very not good. I ordered a new gasket and fitted it today. It turns out it wasn’t the excess oil (well, that won’t have helped) but a broken bit of the engine casing. Where one of the alternator cover bolts screws into the engine casing, the two sides of the thread are bust apart. I’ll post a picture tomorrow, but instead of it being a circle of metal with a thread in the middle, it’s two half circles, split open. There is no thread for the bolt to gain purchase and it doesn’t form a smooth seal against the gasket. That is so not good. Especially as it’s cast alloy, so it’s brittle, I’m worried when I try to bend it shut it will snap. I’ve ordered some high heat epoxy resin (and another gasket) that says it’s good for engine blocks. On Monday I’ll whip the cover off again, clean and dry the surfaces, squeeze some resin into the split metal and clamp it shut with mole grips. If it snaps, it snaps. As long as the epoxy does its job and fixes the two halves back together smoothly, I can work from there. I can slap more epoxy on to try and build it up. It doesn’t have to be pretty, just functional. What’s done my head in is how they did it? It’s a screw thread for an 8mm bolt that is supposed to be torqued to 8Nm. How the hell do you split the engine casing open doing that? It’s a 15 year old bike, but come on, that is above and beyond level of cowboy crap. I’m a bit miffed, truth be told. The epoxy should do it, but if not, it’s not the end of the world. I will have to find a welder who can do it. It would be a small weld and it’s easily accessible. Pain in the arse though, I hope it doesn’t come to that. Oh noes. I just looked. They say you have to pre-heat the alloy to 350c to avoid shocking and cracking it with the weld. That sounds like something you’d need to have a bare engine case for. If I have to strip the whole engine for this little job I am going to be so miffed.

The nights lark just did not work for me, as I said last time out, so I’ve switched to days. Yay!

I’ve done a full week of days, including the busy weekend period, and got one shift. To be fair, when I applied to the agency I asked about days and the guy said “We have a lot of drivers who want days and not many shifts.” I don’t know, after getting six shifts in a week on nights I was hoping there would be enough to keep me going on days. Nope. Back to the job hunt. Nights fail, days fail. At least there is symmetry.

There are plenty of jobs out there, but none are great. Nights or stupid o’clock start times, adding a lot to my day in commute time, or poor pay. For instance, I was thinking of doing Iceland. It’s a tough job, with tough driving and long hours, but it’s local and it’s full time. But it’s 04.00 – 06.00 starts now. That’s less than ideal. For 43K. Which sound good, but for, say, an average of an 11 hour day, that’s about £15.50 per hour, and it’s a weekly take home of £633.