1906 Rex 465cc

The remains of this machine were sourced from the pile of parts that remained after the rebuilding and restoration of the 1905 Rex for a friend. The original parts were in fact eventually identified as a late 1906 Rex, this because the bottom of the petrol tank was straight, and in completely original condition, and no longer had the usual total enclosure of the carburettor below it as was the case of the usual 1906 models. The 1907 models of course dispensed with this enclosure.

There was another clue, I had identified differences in the design of the rear brake, which during 1906, had apparently advanced from an internal brake hub back pedalling device, to a similar back pedalling arrangement but with a small conventional drum brake. By late in 1906, the whole design had been changed to a drum brake where the outer friction surface was apparently steel to a steel band (but may have been brass!).

None of these had survived it seemed, but there was a drawing of the wheel hub and drum, and integral frame brackets proved the dimensions to be correct, and so a new hub/drum was made, but of a lesser diameter to allow the outer brake band to be fitted with friction material. Even the left handbar operation of this brake was changed, the early design obviously not giving enough leverage, and a new longer hand lever, cable operated to a point on the frame tube under the seat where it attached to a small pivoted arm which doubled the leverage that was transferred to the rear brake band via a steel rod. This was all identified on old magazine pictures dated through 1906-7

Even though the petrol tank was original and unaltered, it was decided to restore the bike with the unique petrol tank shape of earlier 1906 models, and so this machine has a separate 'add on' carburettor enclosure rather than the integrated construction of earlier petrol tanks.
The totally different design of the 1906 engine proved to be in much better condition than the 1905 machine, and required little refurbishment. The frame was in good condition, but had been modified with the addition of rear stand brackets which were removed. The spring forks, though complete, were badly worn, and broken with crude repairs. The lugs were salvaged and machined to take bronze bushings to suit the re-machined original 'sliders', and new forks were built with a modern design head stem bearing arrangement to replace the original push bike parts.

The missing battery and coil box was made, copying the design details of the 1905 battery box which had also been replaced, and guards and stays, handlebars, footbrake pedal and other missing parts were all made up as well as the unique hinged Rex rear parcel carrier and rear stand arrangement, that had survived on the 1905 machine. There was also a host of small fittings and clamps, as well as the provision of the 'through the tank' controls of the choke, throttle, mixture and petrol tap. Another missing item was the ignition control on the left side of the petrol tank, where only the base remained soldered to the tank, this small gate and it's lever was detented by a tiny spring and ball arrangement and all parts were made up to fit the base plate, as well as the linkages and cross shaft in front of the crankcase to attach to the timing arrangement on the right side of the engine.

The original ignition points arrangements had long ago been discarded and a magneto fitted – part of the timing case cut away in the process, so this had to be rebuilt as close as possible to the original. A modern points and condenser set was adapted to give the 'points closed' for ignition requirements
I had new old stock Dunlop beaded edge rims to hand, and new spokes of 1 gauge heavier than original were sourced.

Nickle plating was an expensive outlay, but was done with initial copper plating and polishing on all parts. I did the painting myself, as well as the intricate lining, which was painstakingly reproduced using specialist masking tape. The marvel of this was that the 1905 Rex had been heavily hand painted all over with a drab green, and careful removal of this had revealed all the original lining and transfers. It was pretty much proven that the 1905 machine had seen service in the 1914-18 war in company with it's owner, and in fact it is officially recorded that one Rex machine was sold in Britain by army disposals after WW 1, and this machine was in fact sourced from a London dealer who had owned it for many years in a very rough and rusted state.