DO THE TON

Blood Sweat Tears and Grease => Projects => Restorations => Topic started by: swan on Nov 15, 2015, 13:41:59

Title: 1966 Triumph Bonneville restoration
Post by: swan on Nov 15, 2015, 13:41:59
Finally! After several months of searching I have finally found and bought a 1966 Triumph 650 motorcycle. It is a twin carburetor T120R Bonneville, the fastest stock production motorcycle in its day. 
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/Triumph-T120-Bonneville-1966.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/Triumph-T120-Bonneville-1966.jpg.html)
Stock 1966 Triumph Bonneville (export or US model)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0265_zpshqr1uxfa.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0265_zpshqr1uxfa.jpg.html)
(my new project)

My first motorcycle as an adult was a 1966 Triumph TR6 Trophy, which I sold after a brief summer fling with it and travelled to Europe with the money.  I always regretted selling that bike and I do not even have a photo of it nor do any of my friends. A few years ago I picked up a basket case 66 Bonneville with intentions of restoring it but my fate changed when I found my BSA Gold Star and sold the basket case to fund the Goldie’s restoration.

Earlier this year I aggressively searched for a 66 Triumph, not a restored version, but a basket case, bobber, chopper, barn find etc. so I could restore it myself. A decent 66 Triumph popped up on Indiana Craigslist and I spoke with a very nice man named Dan and I bought it for $1100. It just so happened I was going to central Illinois with a large truck the following week so I drove over to Indiana to pick up my bike in person. Dan is in his early 60’s and has had a lifelong love of motorcycles. He rides a Triumph T160, is restoring a 1967 TR6 along with an Indian chief. He sold this bike to help fund his Indian restoration. It is exactly what I wanted at a great price. It has been sitting unused since 1977.

The good news is it is a matching frame and motor serial number 1966 Bonneville with a title.  I have seen a lot less go for much more on Ebay recently. The motor and gear box turn freely, nearly all the black bits are included along with the correct original stainless fenders (mud guards), the one year only oil tank and front drum brake. Included, but not pictured, are the original tank badges, rear fender loop and exhaust pipes. The bad news is the seat and tank are incorrect for a 66 Bonneville, the center stand, headlight and ring, tail light, engine stays, carbs, pistons, push rod tubes and tachometer are missing. The wheel rims are crusty, one foot rest and the front fender stay are bent, the left side cover and oil tank have been chromed. Ugly handlebars, missing controls etc but to my eye it is the perfect start to my next winter project. I plan to have it ready to ride in the spring for her and my 50th birthdays.

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0304_zps3oecyrkt.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0304_zps3oecyrkt.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0264_zpskhrrdba0.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0264_zpskhrrdba0.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0309_zpsypv6vq7t.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0309_zpsypv6vq7t.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0289_zps4hee49ni.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0289_zps4hee49ni.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0271_zpsdyi9rt4a.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0271_zpsdyi9rt4a.jpg.html)

On my long, windy drive back to Minnesota I thought about how I want to build this bike and decided to keep everything in factory stock US style condition with two exceptions which can easily be reversed. First, I’ll use the 3 ½ gallon tank and paint it as a 1966 TR6 Trophy with Pacific blue and white with a gold pinstripe complete with a parcel grid on top and secondly install a UK (home) market lower handlebar.  I do not like Triumph slimline tanks, which were introduced in 66, and believe the TR6 blue and white color combination is Triumph most beautiful bike of all time. However, I do not want the white and blue fenders of a TR6 because white is very difficult to keep clean, so I’ll polish the stainless steel fenders that came with my bike. So basically this will be a bone stock 66 Bonneville with a TR6 tank and lower UK handlebars. I’ll keep my eye out for a decent original slimline tank, paint with the correct white and grenedier red stripes, and store it if I ever chose to sell this bike (unlikely).
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/66tr6tank.jpg)[/URL]
(1966 TR6 tank, beautiful)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/Swans%20Triumph%201966%20copy_zpsqfsnonzc.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/Swans%20Triumph%201966%20copy_zpsqfsnonzc.jpg.html)
My goal.
I spent most of Friday and Saturday, examining the bike and breaking down the motor. I took my time, made notes, took many photographs, cleaned and examined everything, labeled and bagged all the parts and made a list of things to buy. I have the correct Triumph service tools, a hydraulic press, and an impact driver with Pozidrive bits so everything came apart easily.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0358_zpsez9cny2p.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0358_zpsez9cny2p.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0357_zps9pguueoi.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0357_zps9pguueoi.jpg.html)
I was pleasantly surprised to discover nobody has been in the lower end of this motor. The gear box and components are pristine!
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0353_zpsrfqjjxni.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0353_zpsrfqjjxni.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0354_zpszkayc0xh.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0354_zpszkayc0xh.jpg.html)

The crankshaft, conrods, camshafts, tappets and main bearings are perfect. I will pull and clean the sludge trap this week and measure the conrod tolerences and replace what ever is suspect or out of factory specification. The primary is good except for the clutch basket which is on order. This is a low mileage bike that has been sitting for 40 years. The motor cases, cylinder head and rocker boxes were washed in my parts washer, rinsed with hot soapy water, scrubbed with Simple Green and a red 3M scrub pad for metal and then blasted with a combination of walnut shell and glass beads. The parts were then washed several times with hot soapy water and dried with compressed air, making sure to remove any leftover blast media. All will be sent to Green Tree Scooters tomorrow for vapor blasting.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0123_zpsplyuiasm.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0123_zpsplyuiasm.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0141_zpsuo4dofog.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0141_zpsuo4dofog.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0372_zpsu8zepoc6.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0372_zpsu8zepoc6.jpg.html)
clean and ready for vapor blasting

All the hardware will be cleaned, bead blasted and sent out to be cadmium plated as it was originally. All the black bits will be stripped, primered and repainted with catalyzed black paint. My friend Skip will install new valves, guides and seats. Once all of this is done, I’ll start going clockwise, enjoy the ride and stay tuned…
Title: Re: 1966 Triumph Bonneville restoration
Post by: unclerob on Nov 15, 2015, 14:17:31
Pleased to see you've started a new project! I read (and admired) your Gold Star build and looking forward to this one too....
Title: Re: 1966 Triumph Bonneville restoration
Post by: Rider52 on Nov 15, 2015, 16:04:39
Great project. 1966 bikes are my favorites, I read somewhere they were the fastest most reliable of all the 60s models. I had a 66 Bonny when I was flirting with British bikes. It belonged to a Sailor who rode it between San Diego and Southern Missouri several times visiting his girlfriend. Well, the love interest faded, but he kept the bike for several years after getting out of the service. The oil tank and side cover were chromed in Mexico, but the rest was mostly stock. He took it apart, stored all the parts in cosmoline and kept it until 1980 when I bought it from him for $150. I put it together, rode it for a few months and sold it to a guy specifically looking for a 66 Bonny. Interesting enough, when I bought it the original owner had two tanks both painted dark metallic blue. One was the slimline and the other was a TR6 with the package tray. I also opted for the TR6 tank as I thought it had a classic look. Mine also had apehangers, which I changed to XS650 bars which I thought were close to the home market bends.   
Title: Re: 1966 Triumph Bonneville restoration
Post by: o1marc on Nov 15, 2015, 16:24:58
Even with the missing parts you did quite well for $1100, I'd have jumped on that myself. Looking forward to your build as I just  acquired a 70 Tiger. Unfortunately I paid nothing for it but it came with an ultimate price, the loss of my brother to a heart attack. I inherited 4 bikes, but the Tiger will get restored and be my DD till I die. I believe everything on mine is year correct with the exception of the drag bars. 1st bike I ever bought was a 67 500 Daytona in that blue and white paint scheme that I gave $400 for in 1972. Should have them here by the end of the year.

(http://i253.photobucket.com/albums/hh79/o1racing03/Creative%20Candy%20Album%20II/Creative%20Candy%203/a%201.jpg) (http://s253.photobucket.com/user/o1racing03/media/Creative%20Candy%20Album%20II/Creative%20Candy%203/a%201.jpg.html)

I'm seriously thinking about restoring everything to factory stock, but I will pull the wheels and front end and set it up with a Ceriani and Kimtabs with disc brakes.
Title: Re: 1966 Triumph Bonneville restoration
Post by: yorkie350 on Nov 15, 2015, 16:26:32
Great bit of British heritage there so jealous  :P  you got a real bargain too you would pay 3 times that here in UK look forward to ya progress n thread
Title: Re: 1966 Triumph Bonneville restoration
Post by: o1marc on Nov 15, 2015, 16:38:11
Just looking at the pic of the white bike reminds me that the early Triumph 650's are one of the best looking bikes ever.
Title: Re: 1966 Triumph Bonneville restoration
Post by: VonYinzer on Nov 15, 2015, 19:40:48
Signing on. Not a huge Brit bike lover, but the quality of work you turn out is too good to miss. Keep the updates coming :)
Title: Re: 1966 Triumph Bonneville restoration
Post by: goldy on Nov 15, 2015, 19:58:50
I'm sure it's going to be great! Keep us posted!
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Nov 17, 2015, 10:45:33
Thanks all! I am very excited about this project, I've waiting a long time for this and it feels great to start a new motorcycle restoration just as the riding season here is ending.

Quick update: The crankshaft cases, cylinder head, rocker boxes etc were shipped to Green Tree Scooters for vapor blasting, new gasket set, seals, tab washers, bearings and more have arrived. I spent several hours yesterday literally going through every part in the factory parts manual and ordered every piece of hardware that was either missing or in poor condition. Once the hardware arrives, I’ll send everything (old and new) out to be cadmium plated so everything looks as it did when it left the factory.

I cleaned the crankshaft last night, removed the con rods and bearings. I was very pleasantly surprised to find the journals to be in standard spec, look really good and will need a simple light polish. The rods are good and within spec and although the main ball and roller bearings look, sound, and feel pretty good, I am going to replace them along with new, standard sized con rod shell bearings and con rod nuts. The sludge trap cap looked untouched and came off with heat, beeswax, Kroil, impact driver and a BF Hammer. The tube was surprisingly clean, further suggesting this is a low mileage bike. I pulled the tube via John Healy’s tap and bolt method and then scrubbed the crank inside and out in the parts washer. I will install a new sludge trap and hex cap, new bearings etc and wait for my cases to come back next week or so to start going clockwise on the motor. Meanwhile, I am ordering more parts including new pistons, rings, UK made grey top seat, seat hinges, UK handlebar, grips, cables, Lucas head light and rim, rubber foot pegs etc.  I did well on Ebay this week too and bought the missing cast alloy tail light shell, engine stays and bolt set all for much lower then they usually sell. I still need to find a steering damper and the correct 1966 center stand for US models using 4.0 tires. Onwards….
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0145_zpsegubowfv.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0145_zpsegubowfv.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0149_zpsmzcwztnd.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0149_zpsmzcwztnd.jpg.html)
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Nov 22, 2015, 13:22:23
Thanks all! I’m still going counterclockwise… Had a good day in the shop yesterday and broke down my rolling chassis to the frame. I photographed, documented, cleaned and inspected all the hardware and parts. Some good news, some bad news, but overall I am pleased with what I have found.

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0463_zpswghabmsv.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0463_zpswghabmsv.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0473_zps9kmiqfki.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0473_zps9kmiqfki.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0477_zpsz6gsbrlq.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0477_zpsz6gsbrlq.jpg.html)
Filthy…

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0526_zpsjakfkmsv.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0526_zpsjakfkmsv.jpg.html)


All the the hardware, with the exception of two fork pinch bolts, is original and in good shape, despite the rust and dirt. No mutilated bolt heads or screws from the wrong tools.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0576_zpsymkaccg8.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0576_zpsymkaccg8.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0594_zpsb1vd5gyf.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0594_zpsb1vd5gyf.jpg.html)
Once I finish cleaning the frame and swing arm, I’ll put it a frame jig and test it for straightness, tweek if necessary, then finish breaking it down.

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0585_zpsk5emxtfx.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0585_zpsk5emxtfx.jpg.html)
The front forks slide well, contained clean oil and should clean up well and the stations appear straight and can be re-used.

The back shocks are rough, but I’ll clean and break them down and then decide if I am going reuse them, replace the covers or replace them completely.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0583_zpsdu8ri9pk.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0583_zpsdu8ri9pk.jpg.html)


The hubs, brake pads, spokes, nipples are very good but it looks like I’ll need to replace the rims. They are straight and true, but too much chrome has flaked off in spots. It is cheaper to replace them then it is to have them rechromed. The wheel bearings looked great and the grease was very clean, indicating low miles and/or proper maintenance. The speedometer drive was empty, so I’ll need to buy a replacement.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0600_zpsxoyooubq.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0600_zpsxoyooubq.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0606_zpsqbu26yvy.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0606_zpsqbu26yvy.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0618_zpsptygz9vo.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0618_zpsptygz9vo.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0625_zpscr8vqnw3.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0625_zpscr8vqnw3.jpg.html)


I started the long process of cleaning, photographing and blasting all the hardware and black bits. I plan to burn a vacation day this week and spend it in the shop, drinking beer, listening to music and finish blasting the hardware and frame, remove the axles, tires, rims and spokes and to finish ordering missing and replacement parts. My kind of vacation.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0629_zpsddfmgagt.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0629_zpsddfmgagt.jpg.html)

My luck on eBay has continued and some of the missing parts have begun to arrive, including the cast alloy tail light holder.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0534_zpspwykqj1l.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0534_zpspwykqj1l.jpg.html)

A BritBike forum member has offered to sell me the correct tail light, steering damper and center stand at very reasonable prices. Once I finish cleaning and blasting all the hardware, I’ll do another hardware order to get the last of what I need then send it all out to be replated with cadmium. While that is out, I’ll have my crankshaft balanced to my new pistons and rings, paint the black bits and polish the covers.  My parts sent out for vapor blasting should be back this week as well so I can have Skip install new valve guides, seats and valves. Despite the fact winter is just starting, I am motivated to build this bike rather quickly and have it ready for the first day of riding this spring. Onwards...


 
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Nov 24, 2015, 13:54:49
Yikes, I just spent nearly $2k yesterday on new main bearings, con rod bearings, more hardware, rear shocks, wiring harness, switches, fork parts, complete exhaust system, and much more.

Look what just arrived from Green Tree Scooters, freshly vapor blasting motor parts! This motivates me finish blasting my hardware, send it out for cad plating, and once plated, I can start going clockwise. My friend Skip will install new valve guides, valves and seats now that the head is clean. Onward!
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0651_zpsgvqmhi6u.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0651_zpsgvqmhi6u.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0652_zpssen7duwg.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0652_zpssen7duwg.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0659_zps8ippcxvg.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0659_zps8ippcxvg.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0662_zps7ohax6m5.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0662_zps7ohax6m5.jpg.html)
Title: Re: 1966 Triumph Bonneville restoration
Post by: yorkie350 on Nov 24, 2015, 14:52:23
looking good so far mate :P yup wont be long before going clockwise maybe a few more $$ first tho  :o but see it as a investment when she's complete she gonna command her own price  ;) $$$$
Title: Re: 1966 Triumph Bonneville restoration
Post by: Tune-A-Fish© on Nov 24, 2015, 18:16:44
Even with the missing parts you did quite well for $1100, I'd have jumped on that myself. Looking forward to your build as I just  acquired a 70 Tiger. Unfortunately I paid nothing for it but it came with an ultimate price, the loss of my brother to a heart attack. I inherited 4 bikes, but the Tiger will get restored and be my DD till I die. I believe everything on mine is year correct with the exception of the drag bars. 1st bike I ever bought was a 67 500 Daytona in that blue and white paint scheme that I gave $400 for in 1972. Should have them here by the end of the year.

(http://i253.photobucket.com/albums/hh79/o1racing03/Creative%20Candy%20Album%20II/Creative%20Candy%203/a%201.jpg) (http://s253.photobucket.com/user/o1racing03/media/Creative%20Candy%20Album%20II/Creative%20Candy%203/a%201.jpg.html)


I'm seriously thinking about restoring everything to factory stock, but I will pull the wheels and front end and set it up with a Ceriani and Kimtabs with disc brakes.

Is that leaned against a Daytona :-\
Title: Re: 1966 Triumph Bonneville restoration
Post by: DohcBikes on Nov 24, 2015, 18:27:40
Is that leaned against a Daytona :-\
Relax fish, the bike is tethered and standing up. :P
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Dec 02, 2015, 11:54:42
Whew ...

The snow is here and it was a very busy week for me in the shop, spent mostly over the parts washer and blasting cabinet. All the hardware old and new has been photographed, degreased, bead blasted and ready to be cadmium plated. This is a long process but worth the time and effort.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0270%201_zpsu4xqwngj.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0270%201_zpsu4xqwngj.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0271%201_zpsla26wxkm.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0271%201_zpsla26wxkm.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0272_zpsnqw604co.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0272_zpsnqw604co.jpg.html)

Parts, old and new, are flooding in and I have bought nearly everything I need except for a new pair of Amal 389/95 monobloc carbs. Burlen/ Amal is out of stock for several months, so the hunt is on for a new pair. Britbike forum member BikeVice sold to me, at very reasonable prices, a correct centre stand, 679 Lucas tail light, Amal single pull throttle, and steering dampener. Thanks!
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0363_zpsicbiumyz.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0363_zpsicbiumyz.jpg.html)


When my last hardware order to arrives on Friday I’ll blast the new zinc plated bits so they can be cad plated with the original hardware and everything will have the same and correct appearance.

Most of the black bits have been blasted to bare metal as well. No surprises yet and everything is in very good condition. I checked the frame and tail section in Skip’s framing jig and I am pleasantly surprised to find it straight and true to factory specs. We ran it through the jet washer at the local auto machine shop to remove 1/2” thick, 40 year old hardened grease, oil and grime. I’ll bead blast it tonight and blow out all the moisture and media before primer.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0301_zps20tnul7x.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0301_zps20tnul7x.jpg.html)


All the wheel bearings are original Swedish made SKF, show little to no wear with very new looking grease, more indication this is a low mileage bike. To be safe, I ordered new rubber sealed SKF wheel bearings.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0261_zps63ueonqq.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0261_zps63ueonqq.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0670_zpslrgeahb3.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0670_zpslrgeahb3.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0678_zpsfw1bdysu.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0678_zpsfw1bdysu.jpg.html)

I plan to prep, prime and paint all the black bits this weekend with catalyzed gloss black automotive paint. While I wait for my hardware to return from cad, I’ll clean and prepare the gas tank for paint and polish all the motor covers. Skip is on the road for a week or so and when he returns we can hone the con rods, install new small end bushes and he will install new Kibblewhite guides, valves and springs as well as new valve seats. The project is coming along well, and at a good pace. I will be going clockwise in a couple of weeks!


Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Dec 06, 2015, 11:55:25
Parts, old and new, are still arriving and I still need to order a few more things like decals, lights and wiring for the gauges and new fork tubes. I thought I could clean up and use my original fork tubes, but after I dissembled the fork lowers, the left hand tube was completed rusted on the lower portion. Sigh, there goes another $100…
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0390_zpsnieukwcp.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0390_zpsnieukwcp.jpg.html)

I shipped out 35 lbs of parts of hardware to Colorado Plating to be cadmium plated and hope to have it back before Christmas.  In addition to all the parts from this bike, I included bits from two pre-unit motors, a unit motor and several pounds of spare CEI nuts, bolts and washers.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0739_zpsrvqvpdmf.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0739_zpsrvqvpdmf.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0724_zpsqyzavr0p.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0724_zpsqyzavr0p.jpg.html)


The original oil tank was heavily chromed and will need to be sent out to have the chrome electrochemically removed, but I discovered it was cheaper to buy a replacement.  I picked up an ugly 66/67 oil tank on Ebay for $50 and immediately stripped off the ugly hippy paint job.  It is solid with a few areas of Bondo but will be easy to refill the dents and prep for paint.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0697_zps5cms7qcx.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0697_zps5cms7qcx.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0701_zpskq2fthjh.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0701_zpskq2fthjh.jpg.html)

I have a busy week and will be back in the shop next week to get the last of the black bits primed and painted, repair and polish the fenders and to polish the side covers. Paint from Don Hutchinson should be here this week so I’ll to prep the tank as well. Onwards…
Title: Re: 1966 Triumph Bonneville restoration
Post by: o1marc on Dec 06, 2015, 12:21:10
Is that leaned against a Daytona :-\
it's actually an 82 Mondial.
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Dec 13, 2015, 13:59:52
Another busy week, I finished blasting, primering and painting nearly all the black bits with a single stage catalyzed urethane. I am happy with the results and need to do just a little bit of rubbing and polishing on a few pieces to make them perfect.  I am still working on the side cover and oil bag and will paint them both once my decals arrive.

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0776_zpsjjbvguv5.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0776_zpsjjbvguv5.jpg.html)
The front drum was painted with Duplicolor wheel silver, baked in the shop oven and it looks great.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0779_zpsawluny5j.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0779_zpsawluny5j.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0781_zpsxafrb2jg.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0781_zpsxafrb2jg.jpg.html)

I bought a correct pair of restored Smith clocks from Ebay seller aprivatepiece aka Bobby Carter and sent him my original speedo as a core. The are beautiful (but not as beautiful as Chronometrics) and I cannot wait to see them spinning clockwise this spring.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0787_zpsvk1fhdij.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0787_zpsvk1fhdij.jpg.html)

Parts orders are coming in from the Bonneville Shop, British Only, Classic British Spares, Walrige, Tri-cor, Ebay and more sources. Paint form Don Hutchinson also arrived. Here are some of the latest arrivals: Lucas shell, rim, lamp, bulbs, wiring, ammeter, UK handlebars, black grips, wheel bearings, UK made seat, rear shocks, Lucas lighting switch, ignition and key and more. The rear rim is from Central Wheel Components via Walrige, the front rim is on back order and should be here before the end of the month. I still am looking for a pair of new Amal 389/95 (389/19) carbs Everything is here else except for decals, build holders for the clocks and a battery. Now I must wait patiently for my hardware to return from Colorado Platers so I can put this beast together. Hopefully, the hardware will arrive before Christmas.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0798_zpsofmlaqjk.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0798_zpsofmlaqjk.jpg.html)
Title: Re: 1966 Triumph Bonneville restoration
Post by: wworm27 on Dec 14, 2015, 13:24:51
easily my favorite builder on DTT. The nitpicking and thoroughness motivates me to be cleaner with my build
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Dec 29, 2015, 18:26:32
Hot off the truck (cold actually, Minnesota, it's winter...), my freshly cadmium plated hardware! I can start going clockwise on Friday. The final parts are trickling in and when I get a window of time, this bike will come together rather quickly.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0815_zpsseb9qk4f.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0815_zpsseb9qk4f.jpg.html)
Title: Re: 1966 Triumph Bonneville restoration
Post by: brt651 on Jan 03, 2016, 07:56:36
Hi Swan,
Another enjoyable read. Keep up the great work and when you run out of things to do let me know. I'll send you a truck load.
Cheers
brt651
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Jan 10, 2016, 12:45:32
brt651, what do you have?

As much I was want to start going clockwise, I am still waiting on a few things. I called Walrige to check on an order placed over a month ago. They sent my spoke kits and front rim, but never received another of my online orders for a bunch of other parts, so I reordered. I would like to have everything at hand before I can build a rolling chassis. In the interim, I sorted the hardware, and prepped the tank for paint. Skip from Apparatus MC (http://www.apparatusmc.com)  installed new valve guides and new seats, valves and springs arrived from Kibblewhite so he will finish my head soon.

For me, motorcycles are not investments and should be ridden, hard and often. But given the amount of time and money I put in to my bikes I am curious to see what they are selling for. There was a Mecum auction in Las Vegas this weekend with six 1966 Triumph T120R Bonnevilles and and two TT's models. Five of the six Bonnevilles sold for and average price of $11,150. My project should come in under half that amount for parts, machine, work, plating and vapor blasting, but I am not calculating my labor which will be around 200 hours when I'm done. Mind you, much of that time is researching and sourcing the cheapest parts and a fair amount of time drinking beer and staring at my bike, processing and thinking. This is a fun hobby and would not like to do this for a living.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/Mecum%201966%20Triumph_zpscfdardsz.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/Mecum%201966%20Triumph_zpscfdardsz.jpg.html)
Title: Re: 1966 Triumph Bonneville restoration
Post by: Tune-A-Fish© on Jan 10, 2016, 12:57:39
ROI is tough in the hobby game. I would love to do this for a living, but I think it would be at a net loss for both money and the love for all things greasy. Once it becomes work the fun is gone or mostly gone.

I only hope to get paid for the value of the project, labor is always free and as long as the next one is funded the hobby is free also.
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Jan 20, 2016, 15:56:44
A quick update: more of the final parts orders arrived from Walridge Motors and elsewhere. I now have both front and rear CWC rims and spoke kits so I can lace and true the rims, mount tubes and tires and turn my pile of parts in to a rolling chassis this weekend. Also, my Minnesota title just arrived so I am the legal owner, free and clear. Onwards and upwards…
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0876_zpsrof444f9.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0876_zpsrof444f9.jpg.html)
Title: Re: 1966 Triumph Bonneville restoration
Post by: Maritime on Jan 20, 2016, 16:40:27
Just found this one, sign me up to watch, I don't care what bike you are restoring or building the work is always amazing.
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Jan 26, 2016, 12:18:16
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0439%201_zpsiyhzv2na.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0439%201_zpsiyhzv2na.jpg.html)

Thanks Maritime!
3 steps forward, two steps back… After two days in the shop I have the wheels laced and trued and am doing the final alignment of the center of the rims.  It is is a long, slow and tedious process to get the center of the rims perfectly offset and aligned to one another, but worth the effort.  I trued both rims to .004" radial and axial runout. The front fork seals and fork sliders took a couple of hours to clean and chase the threads because there was old paint, thread sealer?, teflon? crud and the seal holders would not go on easily until perfectly clean.  I should be able to mount the tires, rebuild front and rear brake drums, and have a rolling chassis by Friday. Skip bored and honed my freshly painted cylinder barrel and I can start on the motor next week. The days are getting longer and looking forward to the first ride this spring. Onwards...
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Jan 27, 2016, 11:16:16
They grow up so quickly… I had a productive evening in Skip’s shop last night and finished aligning the rim centers, mounted new tubes and tires, assembled the brake hubs and now have a roller! Skip finished a perfect hone on my cylinder and the ring gaps were dead on. I have a little bit of time this evening to mount the centre stand, bars, brake stay, fender stays, and more. More good news, Amal/Burlen emailed me this morning to say the Monobloc carb set I need was back in stock so I ordered them. The carbs the final piece in the puzzle so the bike should come together fairly quickly (when I can eek out some free time).
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0441_zpsgknpq68b.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0441_zpsgknpq68b.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0443_zpsishp7zbw.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0443_zpsishp7zbw.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0444_zpsw3llagbt.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0444_zpsw3llagbt.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0453_zps8todfd5t.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0453_zps8todfd5t.jpg.html)
Rubber meets the road, err, the shop floor

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0451_zps9c9cypkt.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0451_zps9c9cypkt.jpg.html)
Skip, master at work, honing freshly bored cylinders.
Title: Re: 1966 Triumph Bonneville restoration
Post by: surffly on Jan 27, 2016, 14:25:22
Very cool project.
Love the detail.

I have delusions of doing something like this with my Featherbed.
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Feb 02, 2016, 18:37:46
With very little free time this week. I managed to place the decals, clear coat, sand, polish and wax the oil tank. It looks much better than when I started:
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0883_zpstjrazxih.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0883_zpstjrazxih.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0697_zps5cms7qcx.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0697_zps5cms7qcx.jpg.html)
Title: Re: 1966 Triumph Bonneville restoration
Post by: Duchat on Feb 02, 2016, 21:06:00
I liked the leaf paint scheme. Rust hater.
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Mar 06, 2016, 14:00:53
Thanks all! A quick update, I have made intermittent progress in the last 2 weeks.  Although it does not look like much, it took many hours. The fenders were repaired in the English wheel, sanded, polished, and mounted.  The tail light and seat were installed and I started on the oil tank I bought off E-bay only to realize it did not have mounted tags as my original chrome oil tank has, so I fabricated two tabs and had Skip weld them. I cleaned the interior of oil tank a few more times, fogged it with oil and then mounted it. We also welded up the crack on the side cover and I will finish prepping and painting it this week.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF2788_zpsdpj319m6.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF2788_zpsdpj319m6.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF2795_zpsicmbncor.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF2795_zpsicmbncor.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF2731_zpsmd76b3ut.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF2731_zpsmd76b3ut.jpg.html)

I started on the wiring yesterday and finished all the wiring, soldering new bullet ends, etc in the headlamp assembly. I still need to research and decide how I want to wire a kill switch. There is a lot of confusion on the kill button for this bike and I am not sure which to use.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF2838_zpsz0b4hdy1.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF2838_zpsz0b4hdy1.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3149_zpswxrenbat.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3149_zpswxrenbat.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3148_zps8hwuiivz.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3148_zps8hwuiivz.jpg.html)

I should be able to finish the wiring, mount the new Podtronics regulator and Boyer ignition this week and then hound Skip to finish cutting my new valve seats so I can build the motor. Spring is here and I should be able to get out on the Gold Star for the first ride of the year! Soon I will be riding this bike too.
Title: Re: 1966 Triumph Bonneville restoration
Post by: 3DogNate on Mar 10, 2016, 20:47:57
Looking good brother! I am about at the same point on my '69 restoration. I do wish that I had taken the time to send my hardware off for cad plating... I've done some zinc at home on mine but some did not take very well and I have to redo it.

Keep it up...
Title: Re: 1966 Triumph Bonneville restoration
Post by: jimmer on Mar 10, 2016, 20:54:19
Very nice build. 👌
Title: Re: 1966 Triumph Bonneville restoration
Post by: goldy on Mar 11, 2016, 08:26:01
Yes indeed ...coming along very nicely!  :D
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Mar 15, 2016, 15:30:39
Thanks all. 3Dog Nate, once you go with cad, you will never go back to zinc.

I eeked out a few hours of free time this week and continued to go clockwise.(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3149_zpswxrenbat.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3149_zpswxrenbat.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3601_zpsbmpn8qik.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3601_zpsbmpn8qik.jpg.html)
Heated in the shop oven
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3599_zpss0wudjo9.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3599_zpss0wudjo9.jpg.html)
Bearings in the freezer
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3603_zps6pydrrkc.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3603_zps6pydrrkc.jpg.html)
Here we go…
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3604_zpspgdwsbzo.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3604_zpspgdwsbzo.jpg.html)
Clean and reground crankshaft, new sludge trap and cap
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3686_zpsvnb88eps.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3686_zpsvnb88eps.jpg.html)
Machined con rods, new small bushes, new shell bearings, and con rod nuts.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3600_zpsam4ubgwj.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3600_zpsam4ubgwj.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3687_zpsycwir3zb.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3687_zpsycwir3zb.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3905_zpso8jclgdd.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3905_zpso8jclgdd.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF3697_zpsv5zslshp.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF3697_zpsv5zslshp.jpg.html)

The lower end is in the frame, timing side is done, and I’ll try to find the time to install the gearbox, primary components, pistons and barrel this week. Skip will machine my head’s valve seats this week too, so the motor can be finished soon. Onwards…
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Mar 20, 2016, 18:45:44
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF4267_zpsgb0z8jjf.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF4267_zpsgb0z8jjf.jpg.html)

More clockwise.

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF4219_zpsify4cwui.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF4219_zpsify4cwui.jpg.html)
Skip removing the old valve seats. In with the new!
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Mar 23, 2016, 14:43:24
Slow and steady...
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF4521_zpsbo0krqck.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF4521_zpsbo0krqck.jpg.html)
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Jun 19, 2016, 15:58:14
Slow and steady indeed, life tends to get in the way of motorcycle projects sometimes, but I have made some more progress. Skip finished my cylinder head with new valve seats, guides, springs, valves and Time Serts for spark plug holes and rocker covers. It is beautiful with perfect machining and the valve lift was dead on.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF9445_zps2dttmxfm.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF9445_zps2dttmxfm.jpg.html)

After buying, stripping, prepping, painting and polishing a used oil tank, I realized it was not the correct one for a 66 so I sold it on the forum and put in way too much time restoring the original chrome covered oil tank and side cover. After running it through the parts jet at the local auto parts store, I sanding off the the chrome and began the long process of filling pits, sanding, prepping, priming, painting and polishing another tank for this bike. I am please with results and am glad I bought the expensive two part catalyzed primer.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF9939_zps4hp5psok.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF9939_zps4hp5psok.jpg.html)

The tank took forever to clean, prep, paint and polish and though I am pleased with it, there are two minor issues with my paint job, but it will get me down the road. The badges are the high quality, made in the UK versions, but the holes are just a bit off, so I may try to fix them or re-chrome and repaint the original badges. New petcocks, grid rack, cap, knee pads and style strip.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF9988_zpswxibl8yb.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF9988_zpswxibl8yb.jpg.html)

Getting down to the wire and I still need to polish the primary cover, finish wiring the bike, install the chain and chain guard, exhaust system, cables, and the carbs. I am going to try to burn a vacation day this week to install the last bits, set the tappets and electronic ignition timing, add fluids, and hope to have her running by the weekend. Onwards...
Title: Re: 1966 Triumph Bonneville restoration
Post by: grandpaul on Jun 20, 2016, 11:31:44
Wow. Nice.
Title: Re: 1966 Triumph Bonneville restoration
Post by: Tune-A-Fish© on Jun 20, 2016, 11:35:04
That's one of the nicest Triumph tanks I've ever seen.
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Jun 26, 2016, 12:05:40
 (http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF0084_zpsqr1spvaz.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF0084_zpsqr1spvaz.jpg.html)
Thanks guys, she is looking good. So close... I spent a quiet day in the shop last week and most of yesterday working on my Bonnie. Cleaned and installed the oil tank, polished and install the gearbox cover, cables, chain, chain guard (what a PITA), battery, exhaust system, foot pegs, inspected and synchronized the carbs, and started on the electrical. There was a massive annual car show yesterday in downtown Winona and I entered my Gold Star just so I could park it in front of the shop while I worked. Dozens of people stopped in Skip’s shop while I tried to work, so I lost a lot of time chatting, but had a great time. I’ve got a busy week but will try to finish as soon as possible so I can start her up.

Here’s what’s left to do: finish wiring, install Boyer ignition, set timing, install air cleaners, swap the temporary carb cables for correct ones, polish and install primary cover, add fluids, clean the tank one last time, add gas, and then fire her up. I cannot wait to ride this bike.
Title: Re: 1966 Triumph Bonneville restoration
Post by: goldy on Jun 26, 2016, 16:46:16
Beautiful! Love that paint scheme.
Title: Re: 1966 Triumph Bonneville restoration
Post by: Maritime on Jun 27, 2016, 08:42:11
Beautiful as always sir!
Title: Re: 1966 Triumph Bonneville restoration
Post by: edhaeuser on Jun 27, 2016, 17:22:34
Looking great Jon!  I stopped by Skips yesterday and had a look.

Ed
Title: Re: 1966 Triumph Bonneville restoration
Post by: Bootsey on Jun 27, 2016, 21:56:41
Stunning work as always.
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Jun 30, 2016, 10:53:47
Thanks Bootsey.
I am getting closer! I set the tappets, installed and timed the Boyer ignition and installed new bulbs for the idiot lights. She has spark.  Tomorrow I should be able to finish wiring, clean the tank, add fluids and fire her up.

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF0159_zpsiexhm0jx.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF0159_zpsiexhm0jx.jpg.html)
Title: Re: 1966 Triumph Bonneville restoration
Post by: grandpaul on Jun 30, 2016, 13:02:43
Tomorrow I should be able to finish wiring, clean the tank, add fluids and fire her up.

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF0159_zpsiexhm0jx.jpg)
My self-esteem just got a HUGE boost.

I've been criticized no end for using automotive type crimp-connectors on some of my builds; I was U.S.Navy trained on PROPER crimping techniques, so I KNOW they are secure.

Now that I see some in one of YOUR builds, I feel much better.
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Jun 30, 2016, 13:42:28
GP, these are the connectors which came with my Boyer ignition. The rest of my wiring harness I soldered Lucas bullet connectors.
Title: Re: 1966 Triumph Bonneville restoration
Post by: grandpaul on Jun 30, 2016, 14:01:48
S'okay, I recognized them immediately.
Title: Re: 1966 Triumph Bonneville restoration
Post by: Rider52 on Jul 04, 2016, 14:08:26
Beautiful job!
Title: Re: 1966 Triumph Bonneville restoration
Post by: 3DogNate on Jul 04, 2016, 15:21:10
F'n -A dude looks awesome! My tank and fenders are going off for paint this week. I hope my bike ends up looking as good as yours....

Be sure to video the first start up... if you'd checked all the boxes it should fire right up. That's a great feeling when a build starts first couple of kicks.

Did you stick with stock carbs? Mine are pretty nasty and the slides don't look especially great... I'm likely to just go with a new set of Amal Premier carbs and be done.
Title: Re: 1966 Triumph Bonneville restoration
Post by: grandpaul on Jul 04, 2016, 16:34:36
Did you stick with stock carbs? Mine are pretty nasty and the slides don't look especially great... I'm likely to just go with a new set of Amal Premier carbs and be done.
I'm always in the market for reasonably priced donor/core Amals, when the time comes.
Title: Re: 1966 Triumph Bonneville restoration
Post by: 3DogNate on Jul 04, 2016, 19:27:15
I'm always in the market for reasonably priced donor/core Amals, when the time comes.

I probably take them apart in the next couple of weeks and give them an ultrasonic cleaning and make a real assessment of them more than the initial glance I gave em a few months back.
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Jul 05, 2016, 11:01:44
Thanks guys, after messing around with used Amal carbs with unknown histories on several bike projects, I simply bite the bullet and buy new ones, they are much better than they were made originally.

She’s alive!!!!
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF0439_zpsbyiedhtj.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF0439_zpsbyiedhtj.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF0443_zps4vcsdlfv.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF0443_zps4vcsdlfv.jpg.html)

Fired her up for the first time two nights ago and rode her for the first time yesterday. Wow, all that time, hard work, and money was worth it. She now starts on first or second kick, idles well and really pulls hard. What a joy to ride and I rode her to work this beautiful morning.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF0323_zps7qbdfydd.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF0323_zps7qbdfydd.jpg.html)

She fought me hard on the final details. After much frustration with the battery carrier and side cover, Skip and I realized it was too low and had been modified. I folded the tops of the carrier back to how it was originally, and everything fit the way it was designed. Skip loves wiring and went over my loom a few times, soldering, crimping and testing all the connections and all the electrical works as it should. Thanks man.  The 2 into one cable system is frustrating to say the least and so is the cable bend in to the top  of the carbs. The throttle cable routing took quite awhile to get right, so as not to raise the idle. There is not a lot of room under the tank. At times like this, I am glad I bought new Amal carbs, fuel line, and petcocks. They all work well. The motor, primary and gearbox are drip free (so far) but the left fork is weeping oil at the bottom.  The clutch cable (new) is sticking and needs to be lubed.

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF0338_zps2acubqil.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF0338_zps2acubqil.jpg.html) First ride.
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF0333_zpsocablut4.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF0333_zpsocablut4.jpg.html)
 Skip (right) and I setting the air mixture on the carbs.


I am going to put on more break-in miles, fettle, go over all the nuts and bolts, recheck the tappet clearances, timing the ignition again, retorque the cylinder head, change the oil, etc.  I have been riding clip-on handlebars for 15 years straight and it is a very strange sensation to be sitting upright on a motorcycle. I am still getting used to the upright European bars and have not quite found where I want the bars and control levers. The blade levers may not last too long on my bike and I may switch to the solid cast Amal type.

 Anyways, thanks all for the encouragement and support during this build, it really helps. This motorcycle has special and personal meaning to me so I am keeping it for life. Time to put on some more miles….

Title: Re: 1966 Triumph Bonneville restoration
Post by: Maritime on Jul 05, 2016, 11:07:12
Ride, ride, ride, then ride some more. She's a keeper for sure.
Title: Re: 1966 Triumph Bonneville restoration
Post by: datadavid on Jul 05, 2016, 11:17:36
Perfect, just perfect 👌
Title: Re: 1966 Triumph Bonneville restoration
Post by: grandpaul on Jul 05, 2016, 12:17:38
"That'll do till something else comes along"

Actually, it'll do rather well!
Title: Re: 1966 Triumph Bonneville restoration
Post by: goldy on Jul 05, 2016, 18:08:13
The more you ride it, the better it'll get. Excellent work..paid off for sure, the bike is stunning!
Title: Re: 1966 Triumph Bonneville restoration
Post by: yorkie350 on Jul 06, 2016, 06:08:51
Beautiful bike mate great thread. When you end up with a keeper you know you hit the jackpot , enjoy the miles and the attention you gonna get with the old trumper ,look forward to ya next project.
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Jul 07, 2016, 10:50:45
Awww, thanks guys...
I hit my first 50 miles last night with no issues other than a blown fuse. I had a 15 amp fuse when the books say 30 amp fuse. I plan to change the oil, rinse the oil tank, check the tappet clearances, retorque bolts, etc tomorrow. She is running really well, the gearbox 'snicks' cleanly up and down through all the gears, and is an absolute pleasure to ride. I have a couple days off with great weather this weekend so I will be out as much as possible. Here are a couple of before and after shots:

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0304_zps3oecyrkt.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0304_zps3oecyrkt.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF0528_zpso36mtgn6.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF0528_zpso36mtgn6.jpg.html)

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/IMG_0270_zpsssk7fk9q.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/IMG_0270_zpsssk7fk9q.jpg.html)
(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF0522_zpshkfradfa.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF0522_zpshkfradfa.jpg.html)
Title: Re: 1966 Triumph Bonneville restoration
Post by: grandpaul on Jul 07, 2016, 10:57:55
I love a good "before and after" photo shoot!

Man, that's a beauty.
Title: Re: 1966 Triumph Bonneville restoration
Post by: Kamn on Jul 07, 2016, 11:40:31
Nice work, damn man thats a good looking bike
Title: Re: 1966 Triumph Bonneville restoration
Post by: swan on Jul 18, 2016, 10:32:29
225 miles and all is good, almost. My bike starts, runs, and rides beautifully. Had a group ride this weekend with old friends, we bombed the back roads, and my bike ran perfectly. The only issue so far is that the odometer stopped working but the trip odometer is still recording mileage. The UK made speedo cable is tight and properly lubricated so it must be the internal parts of the speedo. I emailed the person who restored my gauges about the problem and I'll wait for his response.

Initially, I had intermittent noise around the top end and I finally discovered the source. One of the exhaust pipes was rubbing on the exhaust stub after it warmed up. It only happened at certain rpms so it was not the tappets, rocker spindles, etc. Of course I broke another cooling fin by tightening it too much. I used lock wire from the head to a new cooling fin and the noise is gone but I would like to find a better solution than lock wire.

I plan to change the primary oil tonight and tighten up the clutch springs because it slips a little when I really hit the throttle. The weather is perfect and I want to ride her as much as possible.

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF1338_zps53v3xvie.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF1338_zps53v3xvie.jpg.html)

(http://i170.photobucket.com/albums/u272/66triton/1966%20Triumph%20Bonneville%20restoration/DSCF0514_zpscwbxd56q.jpg) (http://s170.photobucket.com/user/66triton/media/1966%20Triumph%20Bonneville%20restoration/DSCF0514_zpscwbxd56q.jpg.html)
Title: Re: 1966 Triumph Bonneville restoration
Post by: amitharp on Dec 01, 2016, 16:47:07
Beautiful project, I've started now to restore 1968 tr6, do you know any sorece for the no' + size of the nuts + bolts needed for the conclusion of this project?
Title: Re: 1966 Triumph Bonneville restoration
Post by: grandpaul on Dec 01, 2016, 17:46:29
...do you know any sorece for the no' + size of the nuts + bolts needed for the conclusion of this project?

The parts books are available online in several places. I don't know of anyone that has itemized a list of fastener hardware for ANY particular BritBike...
Title: Re: 1966 Triumph Bonneville restoration
Post by: grandpaul on Dec 01, 2016, 17:47:57
Awww, thanks guys...

Are you going to enter this in the TriumphRat classics & vintage section "Most Improved 2016" contest?
Title: Re: 1966 Triumph Bonneville restoration
Post by: amitharp on Dec 07, 2016, 17:11:39
Thanks
I don't think it's going to be a project to be proud of I'm voluntarily restoring it for a friend who is not going to put the necessary founding. The project started some years ago and was neglected when the restorer had a cardiac arrest, so now it's a case of lets jest finish it.   
Title: Re: 1966 Triumph Bonneville restoration
Post by: grandpaul on Dec 07, 2016, 20:57:39
I think it would be a great addition to the contest. Let the owner know about it and see if he'd like you to enter it for him. I would appreciate it.

The more, the merrier.
Title: Re: 1966 Triumph Bonneville restoration
Post by: amitharp on Dec 08, 2016, 17:40:44
I'll talk to him, but I think it will be relevant only for the 2017 contest.