I found this Model 49 Bultaco on e-bay in the fall of 2004. Though it appeared pretty ratty, I couldn't help but notice a few things that perked my interest. The rear fender though a disaster, was the original, as were the fender brackets on the front. The fiberglass was intact though obviously in need of paint, it still had the original tool box, and the outward appearance of the motor was good. No large gashes, bent or broken fins. I was already regretting selling the last mode 49 I had restored, so I convinced myself this was the right bike to use as my next project. At less than $500 I had my wife convinced it was a "great deal".
Bike as seen on e-bay. Rough looking but mostly there and very restorable.
This is how the bike looked when I got it unpacked. Parts other than the frame only had light suface rust here and there. Good forks, straight frame, clean engine, good fiberglass and a nice muffler guard.
Left side of the engine looked pretty clean with nice straight fins, and the tool box was in very good condition. Someone had fooled with the electrics and the coil was missing, but I have an extra in my "spares". The engine kicked over and had some compression but I've already decided to do a complete engine rebuild.
The right side of the engine looked good as well. The cases were clean and without any major marks. The parts that do need to be replaced I generally replace anyway unless they are perfect. So this bike is shaping up to be a good restoration project. After removing the outer left cover and flywheel it was obvious the motor had gotten a little water in it. The crank bearing was pretty rough. Once dissassembled completely everything looked okay though. It will get all new bearings and seals. I'm having the lower rod bearing checked by Tim Taylor. Flywheel separation is beyond my limits. I'll have more photos in the future as assembly begins. The frame now has new paint and is ready to have things attached to it.
Beginning to reconstruct: the 244cc motor has had the bottom end completely rebuilt with all new bearings and a new rod. the top end is done and will be installed soon. It got a new bore with rings and piston. Though the engine was not in as good shape as I had hoped, it is now.
Wheels have been taken apart, cleaned, painted and relaced. Other bits are going on as they get cleaned and painted. Fender stays I had noticed as original now appear to be a little short unless I find an original fender that wraps around the tire a little. More photos coming.
Here are photos (below) of the final bike. Somehow the documentation of this project took a left turn some where when everything else turned right.
This was pretty much a clean up, repaint project with the exception of the engine. Anyway... on to the photos.
