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Author Topic: 1966 Triumph Bonneville restoration  (Read 19649 times)

Offline swan

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Re: 1966 Triumph Bonneville restoration
« Reply #30 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.




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.




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.
« Last Edit: Mar 06, 2016, 14:32:54 by swan »
1966 Triton cafe, 1962 BSA Gold Star DBD34, and 1966 T120 Triumph Bonneville.
BSA Gold Star barn find restoration
1975 CB400F Cafe Racer build
1966 Triumph Bonnevile restoration

Offline 3DogNate

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Re: 1966 Triumph Bonneville restoration
« Reply #31 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...

Offline jimmer

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Re: 1966 Triumph Bonneville restoration
« Reply #32 on: Mar 10, 2016, 20:54:19 »
Very nice build. 👌
Yamaha Blaster Bike                                                                  Suzuki T500 Titan Twingle Yamaha XT 225

Offline goldy

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Re: 1966 Triumph Bonneville restoration
« Reply #33 on: Mar 11, 2016, 08:26:01 »
Yes indeed ...coming along very nicely!  :D
1948 Norton ES2
1955 AJS 20B
1956 Triumph TRW
1968 Triumph T100 special
1969 Norton Commando
1975 XS650 Yamaha

Offline swan

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Re: 1966 Triumph Bonneville restoration
« Reply #34 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.

Heated in the shop oven

Bearings in the freezer

Here we go…

Clean and reground crankshaft, new sludge trap and cap

Machined con rods, new small bushes, new shell bearings, and con rod nuts.





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…
1966 Triton cafe, 1962 BSA Gold Star DBD34, and 1966 T120 Triumph Bonneville.
BSA Gold Star barn find restoration
1975 CB400F Cafe Racer build
1966 Triumph Bonnevile restoration

Offline swan

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Re: 1966 Triumph Bonneville restoration
« Reply #35 on: Mar 20, 2016, 18:45:44 »


More clockwise.


Skip removing the old valve seats. In with the new!
1966 Triton cafe, 1962 BSA Gold Star DBD34, and 1966 T120 Triumph Bonneville.
BSA Gold Star barn find restoration
1975 CB400F Cafe Racer build
1966 Triumph Bonnevile restoration

Offline swan

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Re: 1966 Triumph Bonneville restoration
« Reply #36 on: Mar 23, 2016, 14:43:24 »
Slow and steady...
1966 Triton cafe, 1962 BSA Gold Star DBD34, and 1966 T120 Triumph Bonneville.
BSA Gold Star barn find restoration
1975 CB400F Cafe Racer build
1966 Triumph Bonnevile restoration

Offline swan

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    • 1962 BSA Gold Star barn find restoration
Re: 1966 Triumph Bonneville restoration
« Reply #37 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.


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.


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.


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...
1966 Triton cafe, 1962 BSA Gold Star DBD34, and 1966 T120 Triumph Bonneville.
BSA Gold Star barn find restoration
1975 CB400F Cafe Racer build
1966 Triumph Bonnevile restoration

Offline grandpaul

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Re: 1966 Triumph Bonneville restoration
« Reply #38 on: Jun 20, 2016, 11:31:44 »
Wow. Nice.
It ain't braggin' if ya done it.

Offline Tune-A-Fish©

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Re: 1966 Triumph Bonneville restoration
« Reply #39 on: Jun 20, 2016, 11:35:04 »
That's one of the nicest Triumph tanks I've ever seen.
"I didn't come here and I ain't leavin"  Willie Nelson

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