They can also be forged/pressed, which is I suspect how Kingswood did it. I did this for the 3-speed, small tapered spline. See this post HERE.

It probably ended up being just as difficult as cutting the splines...

-Doug

Any machine shop that has a milling machine equipped with a dividing head and slotting head should be able to produce the correct splined boss for the kickstart. Some years ago, I undertook a similar job when I produced a sprocket adaptor for a DT rear wheel.

Regards,
             Eddie.

Great detail photo.

It might be worth enquiring if anyone in the Club has a broach to suit that spline.
Its the sort of thing that someone may have had made to sort out spline problems. ?
Until you locate the real thing, it might get you mobile if thats the last part needed

Hi again and thanks for the replies

Mine is the smaller brother of the Z1 the 1934 600cc Model Z, later to become the 1935 Wessex I believe. 
I've attached a photo of kickstart taper and the dimensions are:
length, start of taper to casing - 9/16"
Largest diameter - 7/8"
smallest Diameter 23/32" (this may warn smaller than original)
and the thread is 1/2" 20tpi BSCY (CEI).

Thanks for the list of Bikes Doug, as I said looking specifically a Model Z kickstart is fishing in a very small pond, this will at least broaden the pond, wish me luck.

Thanks again 
Chris

It is the same kickstart lever as all the other 1934-35 4-speed models (sv & ohv), as well as the 500-600cc Aero models 1936-38. Probably the same as the 4-speed S6 option (c1932) though I would have to check to make sure that had the large tapered spline (pretty sure it did).

-Doug


[fix syntax. 02Jan25 Doug]

Is this what the LDMCC is calling a Z1 model ?

https://douglasmcc.co.uk/wp-content/uploads/2018/06/z1-1934-1280x796.jpg



What size does your spline measure - externally. ?
It looks like something from a C11 might clamp onto ??

You might be able to find an engineering shop that has a broach,
that they could run through something suitable.
Someone locally had some unobtanium kickstarters cast up.
Wasn't that expensive, although the waiting time was l-o-n-g.

Hello EW-Ron,

thank you very much for your help.

Everything is fantastic what I do not know !

Now I can complete the work on the Lamp.

The Vincent BTH description is very helpfull.

Thank you

Christian ( who now can kill the copper worm )

Hi there, firstly wishing you all a happy new year.
I'm currently working on my 1934 Model Z, with the end target in sight. My biggest hurdle is the lack of a kickstart pedal / lever. My gearbox is a 4 speed and has a splined, tapered shaft from the gearbox to accept a suitable lever / pedal which I'm sure  is not unique to the Model Z and was fitted to previous and possibly later Douglas models. Could anybody point me in the direction of some of the other models this is likely to have been fitted to as this would allow me to broaden my present fruitless search for one.

Regards
Chris

Quote from: EW-Ron on 01 Jan 2025 at 04:15 Charge will bypass the resistance wire/coil there.

Only to be used when you know your battery is low. ?

If you feed power into your switch, you should be able to figure out where
power is coming out of it, in various switch positions - and wire it accordingly.
This may require some trial-and-error. And maybe lots of it !

It will be a bit simpler if someone has a factory diagram of this.
Hopethishelps.

P.S. The VOC  has this for a mid 30s BTH system.
Maybe some is common with your arrangement. ?
https://www.vincentownersclub.co.uk/attachments/diagram-pdf.22635/

There must be an equivalent diagram somewhere in the Douglas world.

Aren't old electrics fun !

OCDF  is Off, Charge, Dim, Full   as you suggest.

This 4 position switch is an improvement over the previous 3 position, 
which was always charging the battery - and thus often boiled it.
Charge will bypass the resistance wire/coil there.

Dim will supply power to the small auxiliary (pilot) light, and Full will supply power to the main globe.
You may or may not have a dipswitch on the handlebars, to a 2 filament main globe.
Such may be an update to the earlier system.

I'm afraid I've not met your actual BTH switch.
There are many words on this forum about them, but no actual makers info/schematics ?