Late to the party again! I'm loving all of this.
@LunarBike you are doing everything exactly as Mike would do in regards to machining. He would be very impressed with your efforts for sure. If you were not in any doubt before you will definitely know that no 8 Freight is exactly the same - at all!
I should have probably told you that helicoils are your friend. Mike had a habit of using steel bolts directly into alloy threads which wasn't ideal for heavy duty cargo stuff. I have used these in tthe past in areas such as the little block that mounts that mech hanger arm.
As for any manual, I never came across one. If I broke something I would normally call Mike and his response was normally along the lines of "It's just the way you ride it"
@Rikoned That chap on the yellow 8F was my old boss! He added the bikes as transport in the early days of the company I work for.He also discussed the addition of the 'batwings' so we could carry projection screens. These were unique to our fleet as far as I am aware.
The wheel covers were a pain so they ended up being lost. At one point we had 4 yellow near identical versions. IIRC that particular bike ended up being scrapped (not my decision) or was rewelded and used as dog transport...
We also had a yellow Ratcatcher briefly for express deliveries, but that was sold just before I started working there - I would have loved to have had a go on that!
I have a load of images of me up to all sorts of mischief on these. I'll have a poke around and add some on this thread if the OP doesn't mind