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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: 1,156
Winona, MN
Swan Offline

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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: 6,971
Laredo (South) Texas, USA
GrandPaul Offline
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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.



(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: 758
USA
Dave M Offline OP
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Dave M  Offline OP
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I made two mounts for the oil filter and Boyer box.



Needs paint and final adjustment.



Many things to do prior to joining the engine cases:


New hollow locating dowels, one was missing.


Oil plugs tightened.


Breather hose attached.


Through stud holes sealed.


Parts for the high gear.


High gear seal being installed.


High gear in and nut being tightened.


Secured.


The sludge tube cleaned, was about half full.


Sludge tube installed, securing bolt torqued.


New bearings and bolts.











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

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: 758
USA
Dave M Offline OP
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Dave M  Offline OP
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Shells installed.


Assembly lube.


Big ends being joined.


Big ends torqued.


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

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: 758
USA
Dave M Offline OP
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Drive side roller bearing to be installed on the crankshaft.


Cams lubed and in case.


Cam wheels being installed.




Cases to be joined.


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

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: 758
USA
Dave M Offline OP
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Cases being joined.


Engine in the frame, a small victory!


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

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: 2,584
Illinois, USA
TR6Ray Offline

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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: 758
USA
Dave M Offline OP
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Dave M  Offline OP
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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.


Time to install the barrels, a few things to take care of first.


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.


The guide blocks went in fine and I was careful to get them square.


Tappets are in with assembly lube.


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

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: 758
USA
Dave M Offline OP
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Following John Healys' method I washed the bores with hot soapy water.


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




Gaps were slightly large. I'm not going to worry about it.


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!


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

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: 758
USA
Dave M Offline OP
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Both pistons are on the rods, circlips fitted.


Base gasket is wrong way around in this pic. It was corrected.


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.


Rings covered, none broken.


Barrels home, cylinder base nuts finger tight.


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

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: 758
USA
Dave M Offline OP
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Dave M  Offline OP
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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?


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


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

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: 328
Irene, South Africa
robcurrie Online content
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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: 2,584
Illinois, USA
TR6Ray Offline

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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: 758
USA
Dave M Offline OP
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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

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: 758
USA
Dave M Offline OP
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A useful tip RE the ring compressor, thanks for weighing in Rob.


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.




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


Layshaft being inserted.


The selector forks and splindle are in.


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

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: 758
USA
Dave M Offline OP
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A miracle of precision, the Triumph 650cc gear cluster. It's a beautiful thing!


Both the inner and outer gearbox covers were readied for installation.










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

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: 4,478
U.S.
Magnetoman Offline

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U.S.
Originally Posted By: Dave M
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: 10,147
Boston, Massachusetts
J
John Healy Offline
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J
Joined: Mar 2005
Posts: 10,147
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: 4,478
U.S.
Magnetoman Offline

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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: 758
USA
Dave M Offline OP
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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

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: 758
USA
Dave M Offline OP
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While waiting for the transmission oil seal and other parts to arrive some areas were given attention.


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.






The rocker box bolt holes in the head were also cleared.


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.


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


Rocker box components, it's time for assembly.


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

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: 758
USA
Dave M Offline OP
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The rocker box surface of the cylinder head had been leveled by machinist Lee Young and I linished the boxes. It's all flat!


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


Encouragement of the ring with a dental tool.


The spindles are home. Preparing to fit the 6 rocker box studs.


This milder form of Locktite will hold the studs in place.



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

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: 758
USA
Dave M Offline OP
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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.


Filing ridge areas of the plain plate tangs. The plates are nice and flat.


The plates were wire brushed.


The bonded plates were cleaned in gasoline.


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

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: 758
USA
Dave M Offline OP
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Fitting the rollers to the clutch hub.



The hub is in the clutch basket.



Fitting the drive side.



Stator and rotor



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

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: 758
USA
Dave M Offline OP
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Stator and rotor are in, fitting the locking tool.



Tightened to the torque figures given in the Triumph workshop manual






Installing clutch plates















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

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