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Finished the headlight assembly on 71 Daytona #296763
01/31/10 6:26 am
01/31/10 6:26 am
Joined: Jul 2009
Posts: 227
Nebraska, USA
E
ed_h Offline OP
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ed_h  Offline OP
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Joined: Jul 2009
Posts: 227
Nebraska, USA
I've loaded some pics of rebuilding a headlight shell on a 71 Daytona:

http://bullfire.net/Triumph/Triumph23/Triumph23.html



For just a little more, you can do it yourself!
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Re: Finished the headlight assembly on 71 Daytona [Re: ed_h] #296772
01/31/10 7:38 am
01/31/10 7:38 am
Joined: Aug 2007
Posts: 4,542
Kent UK
Blapper Offline
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Blapper  Offline
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Kent UK
WOW! you sure lose a lot of the space inside the headlamp with that new reflector don't you. Probably a better light beam, but it would make relays and fuses in the headlamp tight!

Nice work.

Re: Finished the headlight assembly on 71 Daytona [Re: Blapper] #296790
01/31/10 11:04 am
01/31/10 11:04 am
Joined: Nov 2005
Posts: 737
Reading UK
twinspin Offline
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twinspin  Offline
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Joined: Nov 2005
Posts: 737
Reading UK
Nice job Ed and good photos.
I found that 'o' rings that are recommended for sealing the warning lights into the shell are too high in profile and that a better solution is to use a thin sheet of rubber or similar material punched out with appropriate sized punches. Also the securing pips on the body of the assemblies do little to hold them in position. I have used rubber 'bungs cut to about 1cm depth suitably holed with a punch and then slid up the body when in position give a firm hold on the assemblies.
Mike

Last edited by twinspin; 01/31/10 11:04 am.

1971 T100R
1970 T120
Re: Finished the headlight assembly on 71 Daytona [Re: ed_h] #296794
01/31/10 12:10 pm
01/31/10 12:10 pm
Joined: Jun 2002
Posts: 9,875
Scotland
S
Stuart Offline
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Stuart  Offline
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Joined: Jun 2002
Posts: 9,875
Scotland
Hi Ed,

Been following your restoration saga. bigt Perhaps I can offer some help here?

Originally Posted By: ed_h
There are only a few devices that still didn't have an explicit return wire: turn signals, points, oil pressure switch, and spark plugs.

Apart from the turn signals, all the other things earth/ground into the engine; you should have a connection from somewhere on the engine into the loom's Red wires network. Fwiw, on my T100, I attached one on a 10mm i.d. ring terminal to one of the rocker box studs that takes the head steady.

Turning to the turn signals (sorry), you can sometimes shove an earth/ground wire all the way down each stem and solder it to the bulb holder, but it's always a pita. Fwiw, I make up leads with a bullet on one end and a ring terminal on the other, attaching the ring under the turn signal's 7/16"UNF mounting nut (a 10mm ring will just about fit over the thread) and the bullet into one of the loom's existing Red wires connectors.

Digressing slightly, while your bike's in bits, does the bike's rear light unit have a separate Red earth/ground cable or just the two cables for the tail and brake filaments? My '70 T150 has the same rear light as a standard '71 T100 and it didn't have an earth/ground lead. Again, I made up a lead with a bullet on one end and ring terminal on the other, albeit this time a 5mm ring attached under one of the bulb holder 'frame' 2BA mounting screws.

Originally Posted By: ed_h
a couple of pigtails in the bucket with quasi-bullet connectors. I thought a true bullet wold be a good idea. These bullets can be crimped or soldered. I soldered them.

Soldering was probably the best idea. Ime, crimp-on 'true' bullets only work long-term with the cable size they're spec'ed for, and all the Far Eastern makers seem to delight in supplying weird cable sizes. mad I can't solder to save my life so, for the weird cable sizes, I keep some 3/6" o.d. bullets that crimp like Lucar tabs.

Originally Posted By: Blapper
you sure lose a lot of the space inside the headlamp with that new reflector

Ime, they're a modern-size reflector with the old-style lens stuck on the front and a BPF bulb holder on the back. The Lucas lens thread is recent enough to make reviving those arguments here futile, but you can still fit a couple of modern 'cube' relays, and their sockets, in the standard 'half-egg' shell with a modern reflector, bulb and its 3-pin socket. Alternatively, there are these micro relays.

Originally Posted By: twinspin
I found that 'o' rings that are recommended for sealing the warning lights into the shell are too high in profile and that a better solution is to use a thin sheet

Fwiw, the original 99-1210 rings are just that - a thin oblong-section. You can sometimes find nos because some parts persons don't know what they're looking at, assuming the normal O-rings (that have been around for years) are the 'correct' part.

Hth.

Regards,

Re: Finished the headlight assembly on 71 Daytona [Re: Stuart] #296901
02/01/10 12:52 am
02/01/10 12:52 am
Joined: Jul 2009
Posts: 227
Nebraska, USA
E
ed_h Offline OP
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ed_h  Offline OP
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E
Joined: Jul 2009
Posts: 227
Nebraska, USA
Thanks, Blapper. Yes, I forgot to mention the difference in depth of the new reflector. It wasn't too big a deal, but yes, it is a little more crowded inside. Hopefully the light will be better.

twinspin--
The original indicator light seals and the ones I got from Baxters are flat section as you describe. I did have trouble with one of the lamp assemblies being sort of a loose fit in the hole. It wouldn't fall out, but would sit a little cocked with the wires pushing it to one side. I might have tried your method if I'd thought of it, but I ended up putting a few dabs of hot-melt glue in the inside of the shell to steady it. Seems to work OK.

Stuart--
Yes, electerical stuff mounted on the engine probably aren't good candidates for individual ground return wires. Grounding the engine explicitly does seem like a good idea, and I think I'll do it. In fact, the ring terminal that connects battery positive to the frame would serve better if it connected to the engine. That way the frame would get its ground from the engine rather than the other way around.

I might look into providing a return wire from the signals as you mention.

As to you question about the rear lights, my harness does have a red wire back to the tail lamp assembly, but it connects to a ring terminal under the turn signal stalk, so the tail lamp housing is actually used for the return from there to the lamps. I plan to fix that.



For just a little more, you can do it yourself!
Re: Finished the headlight assembly on 71 Daytona [Re: ed_h] #297228
02/02/10 8:00 pm
02/02/10 8:00 pm
Joined: Nov 2005
Posts: 737
Reading UK
twinspin Offline
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twinspin  Offline
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Posts: 737
Reading UK
Hello Ed,
I was perusing some of your previous good work on former pages and noticed that pages 13 and 14 are missing. Is this deliberate?
Mike


1971 T100R
1970 T120
Re: Finished the headlight assembly on 71 Daytona [Re: twinspin] #297318
02/03/10 3:34 am
02/03/10 3:34 am
Joined: Jul 2009
Posts: 227
Nebraska, USA
E
ed_h Offline OP
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ed_h  Offline OP
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E
Joined: Jul 2009
Posts: 227
Nebraska, USA
Originally Posted By: twinspin
Hello Ed,
I was perusing some of your previous good work on former pages and noticed that pages 13 and 14 are missing. Is this deliberate?
Mike


Mike--

I just checked, and pages 13 and 14 appear to be working. Must have been a glitch.

http://bullfire.net/Triumph/Triumph13.html
http://bullfire.net/Triumph/Triumph14.html



For just a little more, you can do it yourself!
Re: Finished the headlight assembly on 71 Daytona [Re: ed_h] #297344
02/03/10 9:40 am
02/03/10 9:40 am
Joined: Nov 2005
Posts: 737
Reading UK
twinspin Offline
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twinspin  Offline
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Joined: Nov 2005
Posts: 737
Reading UK
Hello Ed,
Yes working here too now!
Mike


1971 T100R
1970 T120
Re: Finished the headlight assembly on 71 Daytona [Re: twinspin] #297419
02/03/10 5:45 pm
02/03/10 5:45 pm
Joined: Oct 2003
Posts: 11,200
North Georgia, USA
RF Whatley Offline
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RF Whatley  Offline
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Posts: 11,200
North Georgia, USA
Ed -
When you plug all that back up, you should coat each of the bullets and receptacles with electrical grease, which you can get at any electrical supply house or Home Depot type stores. This will exclude water and actually help electrical flow by preventing the formation of oxides on the connector surfaces.


Don't hide 'em, Ride 'em !!

RF Whatley
Cornelia, GA

"Shop Boy" at Rodi British Bikes
Re: Finished the headlight assembly on 71 Daytona [Re: Blapper] #297450
02/03/10 10:14 pm
02/03/10 10:14 pm
Joined: Oct 2008
Posts: 4,998
Gnashville
DavidP Offline

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Joined: Oct 2008
Posts: 4,998
Gnashville
Originally Posted By: Blapper
WOW! you sure lose a lot of the space inside the headlamp with that new reflector don't you. Probably a better light beam, but it would make relays and fuses in the headlamp tight!

Nice work.


Good thing you're not trying to fit all this in the bogus flat-back shell on the 71-72 650s.
I remember fitting a car sealed-beam unit to my Trident. Toughest part was getting the retaining clips in place.


Stepping on others doesn't make you stand tall.

71 A65L "Zelda"
92 BMW K100rs "Gustav"
72 T120V cafe project "Mr. Jim"

Moderated by  John Healy 


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