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Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #478977
02/28/13 2:42 pm
02/28/13 2:42 pm
Joined: Mar 2007
Posts: 1,164
Winona, MN
Swan Offline

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Posts: 1,164
Winona, MN
Very nice!


1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
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Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #479002
02/28/13 5:13 pm
02/28/13 5:13 pm
Joined: Jan 2006
Posts: 7,205
Laredo (South) Texas, USA
GrandPaul Offline
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Laredo (South) Texas, USA
I am only offering a hint that has served me extremely well over the years: cases heated in a 250 degree oven for 12 - 15 minutes while bearings cool in a ziploc in the ice tray of the freezer ALWAYS yields drop-in ease of installation.

Also, I no longer drill holes in the cases to punch out the loose outer primary side race, I simply weld a bolt in place inside the race, let it cool for just a minute, then tap it out while the surrounding case is still fairly hot.

[Linked Image]

(for what it's worth, that was my first try at a wire feed welder, I've gotten better!)

Excellent work cleaning up all the threads, not everyone goes through the tedious process...

Last edited by GrandPaul; 02/28/13 5:18 pm.

GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, some BSA & European
"The Iron in your blood should be Vintage"
Re: 1967 Triumph Bonneville Restoration [Re: GrandPaul] #497719
07/14/13 5:43 pm
07/14/13 5:43 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
I made two mounts for the oil filter and Boyer box.
[Linked Image]

[Linked Image]
Needs paint and final adjustment.

[Linked Image]

Many things to do prior to joining the engine cases:

[Linked Image]
New hollow locating dowels, one was missing.

[Linked Image]
Oil plugs tightened.

[Linked Image]
Breather hose attached.

[Linked Image]
Through stud holes sealed.

[Linked Image]
Parts for the high gear.

[Linked Image]
High gear seal being installed.

[Linked Image]
High gear in and nut being tightened.

[Linked Image]
Secured.

[Linked Image]
The sludge tube cleaned, was about half full.

[Linked Image]
Sludge tube installed, securing bolt torqued.

[Linked Image]
New bearings and bolts.











66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #497720
07/14/13 5:57 pm
07/14/13 5:57 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
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Joined: Aug 2001
Posts: 765
USA
[Linked Image]
Shells installed.

[Linked Image]
Assembly lube.

[Linked Image]
Big ends being joined.

[Linked Image]
Big ends torqued.


66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #497725
07/14/13 6:08 pm
07/14/13 6:08 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
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Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
[Linked Image]
Drive side roller bearing to be installed on the crankshaft.

[Linked Image]
Cams lubed and in case.

[Linked Image]
Cam wheels being installed.

[Linked Image]

[Linked Image]
Cases to be joined.

[Linked Image]
Applying Yamabond.

Last edited by Dave M; 07/14/13 6:16 pm.

66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #497727
07/14/13 6:13 pm
07/14/13 6:13 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
[Linked Image]
Cases being joined.

[Linked Image]
Engine in the frame, a small victory!


66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #497762
07/14/13 9:41 pm
07/14/13 9:41 pm
Joined: May 2010
Posts: 2,602
Illinois, USA
TR6Ray Offline

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Posts: 2,602
Illinois, USA
Looks very nice, Dave!

I didn't think the easily removable sidecover came along till '68. Will you need to unbolt your cover to change the oil filter? Maybe that's not a big deal on the '67. Mine would be a bugger to deal with.

Good you remembered to fit the breather hose before the cases were together (I didn't). I'd be torn as to whether the clamp on the breather is a good idea or not. You'll probably never need to change the hose, but if you do, there will be the devil to pay to get at that clamp.

Your exhaust headers must attach differently than on my '64. The lower engine cross-stud at the front of the gearbox on mine stands proud of the nut on either side to allow attaching the tabs on the header pipes, while yours appears to be flush?

I'm not nitpicking -- just following with great interest and trying to learn some of the year-to-year differences.

Ray


'64 TR6R Plus some Twins from other countries (U.S., Germany, Japan)
Re: 1967 Triumph Bonneville Restoration [Re: TR6Ray] #497922
07/15/13 11:32 pm
07/15/13 11:32 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
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Joined: Aug 2001
Posts: 765
USA
Ray, 67 side cover bolts to the battery tray and front tab. Not so much trouble really. I change the filter every other oil change.
Exhaust pipes bolt to a front case stud with an "L" bracket, second stud from top in front.
I like stuff secure, hence the hose clamp. It's not as though I know what I'm doing Ray. I am in fact the Barney Fife of Triumph restorations.
Thanks for your comments Ray.

[Linked Image]
Time to install the barrels, a few things to take care of first.

[Linked Image]
Guide blocks in 67 didn't have "o" rings and they leaked. Learned of "Morries Place" from TR6Ray, a motorcycle shop where a groove was machined for the ring. The turn around was very quick, I can recommend them.

[Linked Image]
The guide blocks went in fine and I was careful to get them square.

[Linked Image]
Tappets are in with assembly lube.










66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #497924
07/15/13 11:48 pm
07/15/13 11:48 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
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Joined: Aug 2001
Posts: 765
USA
[Linked Image]
Following John Healys' method I washed the bores with hot soapy water.

[Linked Image]
I removed the rings, placing each in the bore to measure the ring gap at three locations, top, middle and bottom.

[Linked Image]

[Linked Image]
Gaps were slightly large. I'm not going to worry about it.

[Linked Image]
Marked "top", I made certain the rings were installed that way. Very small and difficult to read, I needed a magnifying glass. Being old does not help!

[Linked Image]
Fitting a circlip. Ring gaps were placed 180 degrees apart.



Last edited by Dave M; 07/15/13 11:51 pm.

66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #497926
07/16/13 12:17 am
07/16/13 12:17 am
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
[Linked Image]
Both pistons are on the rods, circlips fitted.

[Linked Image]
Base gasket is wrong way around in this pic. It was corrected.

[Linked Image]
As per the Healy method, a coupla drops of oil, API SG, were applied to the piston faces and bores. No oil on the rings themselves.
My shop lacks the proper ring compressing tool so the barrels were suspended, then lowered in small increments while the rings were compressed one by one by hand.

[Linked Image]
Rings covered, none broken.

[Linked Image]
Barrels home, cylinder base nuts finger tight.

[Linked Image]
Head and boxes placed to get an idea of a finished engine. Beginning to look like something!


66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #498186
07/18/13 12:43 pm
07/18/13 12:43 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
[Linked Image]

Having read on BritBike, in a post by John Healy, that connecting rod big ends can become ovaled, our local machine shop measured mine. Found not to be mis-shapen, fine and good, but they honed them. I didn't request it, wasn't aware it was needed. Is this standard practice?

[Linked Image]
Never having been in a machine shop before, I found it interesting. For those of you who work in a shop, just ignore these!

[Linked Image]
These guys are not used to having their picture taken at work I suppose. The accuracy of the work done in this shop is amazing.


66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #498231
07/18/13 9:16 pm
07/18/13 9:16 pm
Joined: Mar 2013
Posts: 361
Irene, South Africa
robcurrie Offline
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robcurrie  Offline
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Joined: Mar 2013
Posts: 361
Irene, South Africa
A strip of coffee can and vicegrip pliers is a good substitute for a ring squeezer!
Rob

Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #498281
07/19/13 12:44 pm
07/19/13 12:44 pm
Joined: May 2010
Posts: 2,602
Illinois, USA
TR6Ray Offline

BritBike Forum member
TR6Ray  Offline

BritBike Forum member

Joined: May 2010
Posts: 2,602
Illinois, USA
Originally Posted by Dave M
Having read on BritBike, in a post by John Healy, that connecting rod big ends can become ovaled, our local machine shop measured mine. Found not to be mis-shapen, fine and good, but they honed them. I didn't request it, wasn't aware it was needed. Seems proper that the shells would bed in. Is this standard practice?
Dave, I know you read the Triumph Forum extensively, so you are probably aware of this thread regarding con rod reconditioning, but I'll reference it anyway in case you missed it. I believe that it is quite common on steel rods to grind the cap faces to take the big end bore undersize, then hone it back to size, making it round in the process. I have a friend who does this on Harley rods all the time. He was quite surprised when I told him John Healy's views on this subject (relative to alloy rods). The guys in your shop probably also do this on a routine basis and think absolutely nothing of it, hence the work done that you had not requested. I opted to reuse my rods as they were, after checking per John's advice. In any case, I assume you checked for bearing crush before you assembled your rods? There are soooo many ways to lose sleep and obsess over these old bikes, aren't there? eek

All that aside, your skill and work methods as an artist are showing up throughout your build project. I'm enjoying the pictures and the story. Thanks for posting it up.

Ray


'64 TR6R Plus some Twins from other countries (U.S., Germany, Japan)
Re: 1967 Triumph Bonneville Restoration [Re: TR6Ray] #498334
07/19/13 11:18 pm
07/19/13 11:18 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
Ray, very interesting read. Should have asked the shop to explain. At the time the honing indicated bedding in to me, similar to piston rings on a cylinder wall. That's not it at all!

I do trust the shop, not a machinist myself and they had all related parts. I'm certain they did the necessary work. The bill was not small!
Thanks for the kind words Ray, the photo aspect and telling the project story has been a pleasure. Dave


66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #498741
07/23/13 1:08 pm
07/23/13 1:08 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
A useful tip RE the ring compressor, thanks for weighing in Rob.

[Linked Image]
I dismantled and inspected the oil pump and the oil junction block. The balls were reseated and since the corners of the spring retaining bolts were very much rounded, they were replaced.

[Linked Image]

[Linked Image]
The rear thrust washer in place and a replacement camplate in first gear position. The tracks of the original camplate were badly worn.

[Linked Image]
Layshaft being inserted.

[Linked Image]
The selector forks and splindle are in.

[Linked Image]
The oil pump and oil junction block are in with oil lines attached. The gearbox is ready for the mainshaft.



66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #498744
07/23/13 1:34 pm
07/23/13 1:34 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
[Linked Image]
A miracle of precision, the Triumph 650cc gear cluster. It's a beautiful thing!

[Linked Image]
Both the inner and outer gearbox covers were readied for installation.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]
The inner and outer gearbox covers ready to install.

Thanks Morgan for this great site!



66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #498746
07/23/13 1:41 pm
07/23/13 1:41 pm
Joined: Nov 2011
Posts: 4,938
U.S.
Magnetoman Online content

BritBike Forum member
Magnetoman  Online Content

BritBike Forum member

Joined: Nov 2011
Posts: 4,938
U.S.
Originally Posted by Dave M
[Linked Image]
Oops, installing a bearing by pounding on the inner race is a definite no-no because it puts undue force on the balls and from there to the actual races. Too late for this bearing, but for future ones always drive them in using a socket (or large dia. drift) slightly smaller than the OD of the outer race, making sure the inner part of the drift is recessed so it doesn't put any force on the inner race.

Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #498751
07/23/13 2:17 pm
07/23/13 2:17 pm
Joined: Mar 2005
Posts: 10,270
Boston, Massachusetts
J
John Healy Offline
BritBike Forum member
John Healy  Offline
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J

Joined: Mar 2005
Posts: 10,270
Boston, Massachusetts
Heating the ENTIRE casting to 200F to 210F will allow the bearing to DROP into place.

200F is well below any temperature that will cause any problems over heating the bearing.

Because these castings are large heat sinks, they quickly draw heat away where it is applied locally.

If a stove or hot plate isn't available, a MAPP gas torch is preferred. They will heat up a crankcase where the typical propane torch will not. I use one of the inexpensive electronic temperature guns to check my progress. Failing one of those, a bit of spit, or couple drops of water, will start to bubble when you reach the right temperature.


Re: 1967 Triumph Bonneville Restoration [Re: John Healy] #498759
07/23/13 3:56 pm
07/23/13 3:56 pm
Joined: Nov 2011
Posts: 4,938
U.S.
Magnetoman Online content

BritBike Forum member
Magnetoman  Online Content

BritBike Forum member

Joined: Nov 2011
Posts: 4,938
U.S.
Originally Posted by John Healy
Heating the ENTIRE casting to 200F to 210F will allow the bearing to DROP into place.
Excellent point. It's always better to apply finesse than it is a hammer. But, if you were to apply a hammer despite this good advice, you also would want a block under the housing directly behind the bearing cavity. As it is shown in the photo the relatively thin Al casting is being subjected to the full force of the blows (unless the backside of this cavity is actually higher than any of the other surfaces on the back, in which case it is making direct contact with the bench).

Re: 1967 Triumph Bonneville Restoration [Re: Magnetoman] #498766
07/23/13 4:36 pm
07/23/13 4:36 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
Thanks John and M-man. A few points,the bearing went in with ease and was tapped on the outer portion of the bearing only. The case was heated. No portion of the bearing was "pounded" in any way.

I think elements in the photo mis-led. For the pic, the hammer wasn't being swung. Getting the clear pic often means holding the camera in one hand and props/parts in another, gets bit hairy sometimes!

I'll certainly use your methods in the future. Thanks for keeping us all on track! Dave


66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #499602
07/29/13 9:29 pm
07/29/13 9:29 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
While waiting for the transmission oil seal and other parts to arrive some areas were given attention.

[Linked Image]
Loosely assembling the oil tank, the side cover, the head and rocker boxes, the cylinder bolt holes needed to be tapped clear. I like them clean enough so the bolt bottoms out by hand.

[Linked Image]

[Linked Image]

[Linked Image]
The rocker box bolt holes in the head were also cleared.

[Linked Image]
The oil tank and side cover were installed. They fit OK but will come off to apply the decals. I haven't decided to clear coat over them, I'd welcome any opinions pro or con.

[Linked Image]
Here's a shot of my bench at the moment. It shows a few sub-projects happening, all Bonneville related.

[Linked Image]
Rocker box components, it's time for assembly.


66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #499607
07/29/13 10:02 pm
07/29/13 10:02 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
[Linked Image]
The rocker box surface of the cylinder head had been leveled by machinist Lee Young and I linished the boxes. It's all flat!

[Linked Image]
The sharp edge of the spindle opening was chamfered to ease entry of the spindle "O" ring.

[Linked Image]
Encouragement of the ring with a dental tool.

[Linked Image]
The spindles are home. Preparing to fit the 6 rocker box studs.

[Linked Image]
This milder form of Locktite will hold the studs in place.



66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #499611
07/29/13 11:02 pm
07/29/13 11:02 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
[Linked Image]
The transmission parts of this engine show little wear, even the primary chain. Seems likely that some are replacements as the odometer of this bike shows 16,000 plus.

[Linked Image]
Filing ridge areas of the plain plate tangs. The plates are nice and flat.

[Linked Image]
The plates were wire brushed.

[Linked Image]
The bonded plates were cleaned in gasoline.

[Linked Image]
The push rods were inspected for defects and wire brushed, guite grungy they were.





66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #578286
12/27/14 9:03 pm
12/27/14 9:03 pm
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
Fitting the rollers to the clutch hub.

[Linked Image]

The hub is in the clutch basket.

[Linked Image]

Fitting the drive side.

[Linked Image]

Stator and rotor

[Linked Image]


66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
Re: 1967 Triumph Bonneville Restoration [Re: Dave M] #578339
12/28/14 9:47 am
12/28/14 9:47 am
Joined: Aug 2001
Posts: 765
USA
Dave M Offline OP
BritBike Forum member
Dave M  Offline OP
BritBike Forum member

Joined: Aug 2001
Posts: 765
USA
Stator and rotor are in, fitting the locking tool.

[Linked Image]

Tightened to the torque figures given in the Triumph workshop manual

[Linked Image]

[Linked Image]


Installing clutch plates

[Linked Image]



[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]





66 TR6R Trophy
67 T120R Bonneville
68 BMW R60/US
69 T100R Daytona
91 Honda ST1100
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