The Bonneville Project

Total bike inventory

I'm midway through cataloguing the whole bike - listing what I have and what's missing.

It's a laborious but eye-opening job.

I'm pleased, for instance, that the forks I have are virtually complete and salvagable.

Had I needed to do so, replacing the top covers or headlamp brackets (parts 97-2161/2) would cost me an arm and a leg (£50 to be precise or almost $100 if purchased in the UK).

That said, I would dearly love to get my hands on an original Lucas SS700P headlight shell, properly engraved on the underside (99-0608).

Or a pair of original horns (60-1900/1).

Anyway, everything I have - and everything I need - is listed in this Microsoft Excel file right here.

Brake torque stay

It's always good to rescue a part that initially appears beyond repair.

At first glance, the brake torque stay looked rather battered.

It was covered in grease and grime. But a closer inspection revealed that it was at least straight.

An initial clean-up soon revealed that it needed repainting, but it was also evident that I would be able to make it look good as new.

Having stripped all the old paint and cleaned the oil pipe, the torque stay is now waiting to be resprayed.

If only fixing the whole bike was this easy...

Speedo gearbox repair hitch

I've had a reply from Speedograph Richfield, whom I had asked to restore my original speedometer gearbox.

I had sent two speedometer gearboxes: one original (and not working), the other a replica (missing the original Smiths writing on the casing).

In my quest to make the bike as original as possible, I was hoping they would be able to restore the original using parts from the replica.

But they wrote back informing me that they don't have supplies of spare parts and that using parts from the replica box would involve destroying the sealing ring.

This is a minor setback - but at least I have a working gearbox until I find someone who can restore the original.

Workshop manual dissected

Are workshop manuals and parts catalogues tools?

Not in the conventional sense I guess, but strictly speaking they are just as vital as a decent set of spanners, which is why I'm posting this under the workshop and tools category.

Yesterday I split the workshop manual into 11 separate A4 folders - one for each of its sections.

The sections are: general data; lubrication system; engine; transmission; gearbox; frame and attachment details; wheels, brakes and tyres; telescopic fork; electrical system; service tools; and conversion charts.

Having these sections in their own folder makes it easier to access the relevant chapter for whichever part of the bike I am working on.

There's an added benefit too: it makes the whole project seem much more manageable because the workshop manual is now in bitesize chunks, rather than a weighty doorstop.

Frame fasteners - nearly there

I've located most of the remaining fasteners and washers for the frame and swinging arm from Grin Triumph.

I emailed them this morning and they replied within an hour. The parts they are sending are as follows:

Part No.	Description	Price	Quant.	Total
NW100	Grease nipple	2.00	1	2.00
WE170	Fibre washer	0.25	1	0.25
PCW73A	Washer	2.15	2	0.16
GS303	Washer	0.10	3	0.30
14-0702	Self-locking nut	0.50	1	0.50
14-0703	Self-locking nut	0.65	1	0.65
14-0304	Nut	0.35	1	0.35
S25-2	Plain washer	0.10	2	0.20
S26-1	Spring washer	0.10	2	0.20
S25-13	Plain washer	0.09	1	0.09
	Split pin brake rod	0.25	1	0.25
57-1076	Screw (3/8 in. U.H.)	0.25	3	0.75
82-4717	Self-locking nut	0.25	5	1.25
82-8090	"O" ring	0.75	2	1.50
			Subtotal	8.59
	All prices in GBP		P&P	2.50
			VAT	0.33
			TOTAL	11.42

 

Frame fasteners arrive

I'm really pleased with the delivery that arrived today from Tricor.

Everything is high quality and everything has been part-numbered so I can tell each nut and bolt from the next.

This is probably the best experience I've had from ordering anything over the internet.

The only downside is that Tricor didn't have everything I needed in stock.

But that is the same with every supplier and hardly surprising as I was ordering obscure fasteners rather than major components.

Frame & swingarm fasteners

All the suppliers I can find seem to have most of the parts I need, but no supplier seems to have all of them.

This is especially the case when it comes to fasteners - in this case for the frame and swinging arm.

I can salvage most of the nuts and bolts, but some of them need replacing. This is because they are either non-standard and don't match or have been damaged.

Compared to larger parts, fasteners come cheap. But there are so many of them that the cost soon mounts up - especially when you add on tax and postage.

I've just ordered a bundle of bits from Tricor England. I chose them as a supplier because their website has photographs of every last nut and bolt they sell.

This should help me identify what I've ordered once it arrives.

The order below cost me a hefty £91.59 - but it does include a brake light switch (£15), two swing arm bushes (£3.50 each), two bearing cups (£6.00 each) and a cone (£6.50).

Part No.	Description	Price	Quant.	Total
14-0113	Bolt	0.16	1	0.16
14-0235	Shock absorber bolt	0.50	4	2.00
14-0302	Nut 5/16	0.16	1	0.16
14-0303	Nut 3/8	0.18	4	0.72
82-3158	Spring	1.20	1	1.20
82-4671S	Spring	4.00	1	4.00
82-5412	Switch clip	2.00	1	2.00
82-5413	'D' washer	0.20	1	0.20
82-6042	Swingarm bush	3.50	2	7.00
82-7021	Bolt	1.40	1	1.40
82-7155	Steering stop	1.20	2	2.40
82-7386	Brake Rod	5.60	1	5.60
82-7387	Brake adjuster	2.50	1	2.50
82-8382S	Stainless sidestand spring	4.00	1	4.00
82-9387	Bolt	1.80	1	1.80
97-0111	Cup	6.00	1	6.00
97-0439	Cone	6.50	1	6.50
97-1001	Dust cover	2.50	1	2.50
SPX017	Brake light switch	15.00	1	15.00
			Subtotal	71.14
	All prices in GBP		P&P	8.00
			VAT	12.45
			TOTAL	91.59

To repair or replace?

This bike is never going to be as original as it was when it first came into my posession.

True, it had been mildly customised to satisfy the whim of its previous owner, but nothing was less than 35-years-old.

It still dripped oil and even smelled authentic.

Now, in putting the bike back on the road, some of that authenticity is going to be lost. Although I'm creating a rideable machine, I'm also in danger of destroying some of its spirit.

The speedometer gearbox is a case in point. Rather than refurbish the old gearbox, I discovered it was cheaper to buy a replacement.

So I ordered one - and very nice it looks too (click on photo (right) for a larger picture).

Except that the original bears the proud words "Smiths Motor Accessories Ltd, England." And then "Brit Pat 529397".

Smiths started as clock and watch business in mid-19th century London*.

The replacement gearbox has no words. There's nothing wrong with it - in fact, nobody would probably notice the lack of writing once it's on the bike.

But it has no history or pedigree. It's just not the real thing and was probably made in the Far East.

So, I've decided after all that I will have the old gearbox refurbished. It will take a little longer and cost a little more money but I believe it will be worth it.

The same goes for the numbers on the faded instrument dials. It's possible these days to have them reprinted with computer-aided accuracy.

But I prefer the originals and I'm keeping them.

*Smiths eventually became an aerospace-to-medical equipment maker. In January 2007, it agreed to sell its aerospace division to US giant General Electric (GE) for £2.5bn - see BBC online story.

Money spent so far

Below is a running total of the amount I have spent so far on this project.

This is a labour of love, so I am not costing my time. Nor am I including money spent on travel or phonecalls.

But everything else should be here - unless I decide the project is costing an inordinate amount of money that my other half doesn't need to know about... 

          The Bike

1. THE BIKE ITSELF: 1969 T120 Bonneville  £2,200
2. Carburetter: replacement parts  £33.94
3. Mudguards and stays etc  £281.40
4. Shock absorbers Free
5. Control cables  £81.50
6. Replacement cylinder head  £141.00
7. Powder coating hub (a mistake)  £29.38
8. Removing powder coat  £10.00
9. Hammerite No.1 Rust Beater  £3.99
10. Hub parts order: Part 1  £168.59
11. Frame & swing arm fasteners  £91.59
12. More frame & swing arm fasteners  £11.42
13. Engine rebuild £1,383.87
14. Speedo & tachometer refurbishment £237.30
15. Stanchions (pair) - web post and details to come
16. Fork Sliders plus bushes 189.12 - web post to come
17. Wheel rims, spokes, tyres - £620
18. Frame straightening - £217.38

          Subtotal  £5,700.48

Manuals, books and research

1. Book: How to restore your motorcycle £12.53
2. DVD: A bike is born - 1970 Triumph Bonneville T120R  £14.99
3. Admission to Battlesbridge Autojumble (2 July 2006)  £5.00
4. Book: Haynes Triumph 650 & 750 Twins Owners Workshop Manual  £5.00
5. Book: Instruction Manual No 17 for Triumph Twin Cylinder Models  £15.00
6. CD-ROM: Kim the CD Man's Triumph CD (4th ed.) purchased via Triumph Spares  £29.95
7. CD-ROM: Bonneville T120 1969 Parts List, purchased via Ebay  £5.99
8. Book: How to Set Up Your Motorcycle Workshop  £20.25

          Subtotal:  £108.71

 Workshop

1. 10 Shelf brackets £4.70
2. Two packs 20 x 1.5 inch screws £2.73
3. 25 x 150 saw wood for shelves £6.98
4. White masonry paint for walls £23.49
5. Paint rollers £5.17
6. 6 x MDF boards (1220 x 610 x 12mm) £27.78
7. Floor sealer plus rollers £76.96
8. Installation of strip lighting and plug sockets £100
9. Workmate £23.39
10. Protection goggles £10.79
11. Fork service tools £39.96

          Subtotal £321.95

          Consumables

1. De-greaser (and swarfega) £25.00
2. Polishing Kit (purchased from Ebay) £20.45

          Subtotal: £45.45

Total so far: £5,176.59

Speedo and tachometer

Today I'm sending the speedometer and tachometer away to be repaired.

Both instruments are damaged externally – the glass in each is smashed and missing and the bezels and casings have certainly seen better days.

I am unsure of the internal condition of either instrument but both contain shards of glass.

They are being sent to Speedograph Richfield in Nottingham - experts in repairing Smiths instruments.

Prior to wrapping in bubble wrap, I covered the face of each instrument with cardboard to protect the dial and pointers and then wrapped it in newspaper.

I've asked Speedograph Richfield to quote me for a full repair on both instruments, using the original dials, pointers and internal workings if possible.

I've also asked them to return the casings to the original black - at the moment they look like they've been either chrome plated or painted silver.

The speedometer is an SSM5001/06 100 model, with a maximum speed of 150mph on the dial. Once repaired, it will be set at 05704.3 miles - the mileage shown now.

The tachometer is an RSM 3003/01 A 4-1 model, showing RPM x 100 with a maximum RPM of 100 (ie. 10,000 revs).