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Glutton for punishment - 1998 TBS restoration

5K views 56 replies 12 participants last post by  CharlieS 
#1 ·
So, in addition to my TBS engine rebuild and repaint, helping a buddy with a full on custom bonnie build, and prepping the Daytona for light track duty, I've now taken on a 1st year TBS restoration. The opportunity arose to pick up a low mileage TBS (5100) with a clean title, and I couldn't resist adding it to the stable. The allure of having both the first year and last year of the TBS was too strong and now I have another project. It's been repainted poorly in the past and sat outside, so some of the shoddy bodywork has begun to rust. Additionally, the previous owner was blindly trying to track down the cause of the bike shutting off after 10 min (likely pickup coil), and in the process completely buggered the wiring harness. Other than that, it's had a recent carb rebuild and balancing and is mostly stock. Unlike my '04, I am planning on restoring this back to mostly stock, the only exception being the paint. I have the original tins off my '04 and most of the 1998 tbird parts bike, so this should be a relatively straightforward process of swapping parts over, cleaning, polishing, and painting.

As for paint, the bike was originally Yellow/Black. As a personal preference thing, I really do not like yellow so I'm thinking of taking a bit of a liberty with the paint scheme and doing a Tuxedo tank in Jet Black with a fusion white scallop.

Going to start tearing in to it next week and will post updates as I progress.

Cheers,
Jason
 
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#2 ·
Sounds like fun. Glad you found a TBS to play with.
I was never big on yellow, but after I had mine for a while, it grew on me.
 
#3 ·
you know, I used to watch shows like American Pickers and wonder, "how do these guys become hoarders like that? Does someone need 100 bikes just rusting away in a barn?" Now I understand...

I think I've reached junior hoarder status with Triumph Triples. Current lot:

2004 TBS
2008 Daytona 675
1998 TBS
1998 Thunderbird (80% complete parts bike)
2002 955i engine
3 Tbird tanks, 3 rear fenders, 2 sets of side covers, etc etc

I was never big on yellow, but after I had mine for a while, it grew on me.
my 04 tbs was black/yellow and I never cared for it. The 98 has been painted by what looks like to be a 5 year old, so new tins are going on anyway. My original '04 tins are in great shape, but since the paint scheme wouldn't be original anyhow, I might as well do something different. I've always loved the Tuxedo tank since my 2010 T100 build and think it'll look very classy on this bike with the original chrome exhaust cans and polished aluminum rims.
 
#4 ·
@simplyj - have you figured out how to get the swoosh exact on either side. I wanna copperleaf the swoosh on my tank but can't figure out how to get the swoosh perfect. Any suggestions.

This is what happens when you move into a gorgeous house with a garage (or do you guys have a double garage now)


Zee

2000 Triumph Thunderbird Sport
2015 BMW F700GS
 
#5 ·
@simplyj - have you figured out how to get the swoosh exact on either side. I wanna copperleaf the swoosh on my tank but can't figure out how to get the swoosh perfect. Any suggestions.

This is what happens when you move into a gorgeous house with a garage (or do you guys have a double garage now)


Zee
I'm going to attempt to scuff and paint just the scallop then re-clear, but first I'm going to make a template just in case.
 
#8 ·
To trace the swoosh (?)

cover the swoosh and surrounding area with cling film
trace the outline on the clingfilm with magic marker.
cover cling film with duct tape (must have white backing) Poke holes through the tape where the tank badge holes are.
Remove cling film and tape, you will then have the outline marked, cut out around the magic marker pen line.
The template is flexible enough that you can invert it and use it on the other side of the tank, just use the two holes to align it properly.
 
#9 ·
To trace the swoosh (?)



cover the swoosh and surrounding area with cling film

trace the outline on the clingfilm with magic marker.

cover cling film with duct tape (must have white backing) Poke holes through the tape where the tank badge holes are.

Remove cling film and tape, you will then have the outline marked, cut out around the magic marker pen line.

The template is flexible enough that you can invert it and use it on the other side of the tank, just use the two holes to align it properly.


Why duct tape with white backing if I may ask? The cling film is a superb idea as I was gonna use painters white tape instead and go over the whole tank. The badge holes as reference points are also perfect (that was another worry for me)


Zee

2000 Triumph Thunderbird Sport
2015 BMW F700GS
 
#10 ·
If you just use cling film it will not keep its shape when you remove it. The duct tape is thick enough to keep its shape and thin enough to be inverted to use on the other side. It also is strong enough to make the holes so it can be accurately located on either side of the tank.
Using this method you can design any simple pattern and replicate it accurately on both sides of the tank.
 
#11 ·
If you just use cling film it will not keep its shape when you remove it. The duct tape is thick enough to keep its shape and thin enough to be inverted to use on the other side. It also is strong enough to make the holes so it can be accurately located on either side of the tank.

Using this method you can design any simple pattern and replicate it accurately on both sides of the tank.


I was curious about the white back duct tape. But I guess there is no special reason for the "white" part. :)


Zee

2000 Triumph Thunderbird Sport
2015 BMW F700GS
 
#13 ·
"Back in the day" when my wife's brother and I painted and customized cars, we would lay everything out on one side, cover it with masking paper, and use a Ponce wheel and trace over all the lines. A ponce wheel puts tiny holes in the paper. We would then pull the paper, flip it over, tape it to the other side, then take a small bag filled with chalk dust and pat down all the lines made by the ponce wheel. The chalk would penetrate the holes and land on the paint. Remove the paper, and we'd have a chalk outline of where to tape the lines. It worked well for flames and graphics.

https://www.amazon.com/s/ref=nb_sb_noss_2?url=search-alias=arts-crafts&field-keywords=ponce+wheel
 
#14 ·
Just got home from a weekend in the mountains and was able to steal a few hours to start tearing down the TBS and see where I'm at.

Overall the bike is pretty solid, although the wiring is completely buggered. 5100 miles but the bike has definitely sat outside or in a barn as a good number of bolts are corroded. From what I can assess right now, the major parts that will need attention or replacing will be:

- Main Wiring Harness
- Airbox
- Coils/leads
- Pickup coil
- coolant expansion tank
- Caliper rebuild
- service (oil/filter, plugs, chain cleaned/lubed, fork oil)

Subframe will need to be repainted, wheels polished, a number of rubber bits replaced, right side switchgear replaced, rear tail light harness, and the seat recovered.

5141 miles but you'd never know it looking at it


To say it needs some bodywork is an understatement. Aside from a crappy paint job, the guy's father took a bat to it in a dispute. Good thing I have a spare tank sitting around.


Wiring harness is equally as messed up, with black duct tape and ancient electrical tape holding most of it together. And yes, that is a coat hanger holding the tank on. :-/


pickup coil wiring has been hacked. No wonder the seller said it was shutting off after 10 min of riding.


Similar hack job for the right control


Duct tape was holding on the rear coil


some sort of epoxy was also holding together the expansion tank


Corrosion on the rims as well (bike also still has its original Avon tires!)


but it looks like they will clean up nicely:


Sans the bodywork, airboxes, carbs, main harness, and coils


I have a matching jet black rear fender and side covers that are in great shape, so I'll be sticking with my stock"ish" restoration with a tuxedo style tank and all the other tins Jet Black. Honestly, I couldn't even attempt this restoration without the 1998 Tbird parts bike I have in the garage. That bike also has around 4-5k on it but aside from the front end collision has led a very pampered life. Wiring harness is complete, new looking, and uncut. Both airboxes were replaced with NOS ones by the previous owner as were the coils and leads.

Aside from paint, upholstery, tires, brake pads, fluids, and the gasket for the engine cover housing the pickup coil, I don't think I'll need to buy any other parts. I'm hoping to get the bike fully restored for around $500-750. Without the parts bike, the bill would be well into the thousands and probably not worth it.

Cheers,
Jason
 
#15 · (Edited)
Spare tank and seat sitting in place just to see how things look. I'm hoping I can find the stock seat cover from my TBS as this one has a tear on the top as well as some rub marks. If not, I'm thinking of sourcing some vintage style basketweave vinyl and getting my upholsterer to use it to replace the top panel.


dug around in the spare parts bins and found the seat cover for my 2004 TBS. It's in better shape but still not perfect, so I might stick with the idea of incorporating vintage style pleated basket weave.

current seat:


replacement seat cover:


right now my bikebandit order stands at:
1 GASKET,RH CRANK COVER,T309RT

Thinking about going full out stock style resto and replacing the worn or missing stickers as well, but haven't decided if I'm going to go down that rabbit hole yet.
 
#16 ·
#17 ·
I saw that poor bike on Craigslist. It looks like you have it well on it's way.



http://www.ebay.com/itm/1998-Triump...ash=item463c427214:g:G6gAAOSwEeFVJXnA&vxp=mtr



A new harness might be worthwhile.



Have fun!

Yeah, took weeks of pestering the guy before he returned my call (via text). I think it'll be worth it in the end.

My parts bike has a very clean wiring harness and NOS replacement parts. Looks like its going to pay for itself several times over on this one.
 
#18 ·
Oh, that's right. You have a harness sitting right there. Heck, you'll be done in no time.
 
#22 ·
Had a few hours to myself last night so spent them in the garage. Cleaned and mounted the rear fender, touched up some chips on the subframe and cleaned/degreased the engine. Also, started tearing into the parts bike removing the airbox, battery tray, igniters/plug wires, and carbs to prepare to remove the harness for transplanting.



The subframe has some scratches and wear on the top rails. I'm debating whether it's worth fully removing and sending out for blasting and powder. None of the wear will be visible with the seat and tank installed, but I'll know it's there. Powder isn't cheap though.

Engine is looking pretty clean. Also removed all the duct and packing tape residue from the frame backbone. Things are looking pretty spiffy.


Spare parts pile is growing

 
#23 ·
You're right. Powder isn't cheap. It's also not as tough as its reputation.
For spots on the subframe or the engine covers, get some semi gloss rustoleum hi heat barbeque paint and apply it with a sponge to match the texture. It's about as perfect a match as I have found.
 
#26 ·
Oddly enough, the frame is smooth semi gloss black and not textured like my 2004. I always thought all TBS had the textured frame. Waiting on a powder quote but also might just order some 2k semi gloss eastwood chassis black and shoot it myself. Turnaround time is also important as I want to get this one done and move on to all my other projects.

I have a gun and toaster oven in the garage for powder coating small parts such as brackets, bolts, etc. and am planning on making a makeshift booth for shooting the clear on the tank, so I can likely fit the subframe in that.
 
#27 ·
Took the wiring harness off the parts bike, rewrapped the main portion with cloth loom tape (same used on vintage german cars) just to clean things up a bit and got it and the coils/plugs installed on the TBS



also installed the replacement overflow tank


Then the carbs and airbox


Also, when rummaging around in the service manual I got with the 1998 Thunderbird parts bike, I came across this Akront sticker... putting to rest my other inquiry. This particular Akront decal is not reproduced and this one is in good enough shape that I can likely have a buddy who is in the vinyl decal business copy it for me.



That's all for the next few days as I'm flying out to Illinois early tomorrow morning for my firm holiday party.
 
#29 ·
Put some duct tape or something similar on the overflow tank where the patch was. I've seen a lot of them that are worn in the same spot. Must rub on the fuel tank...



Have your buddy make a couple hundred of those Akront stickers...

Oddly, I never experienced any problems on my 04 with the overflow tank. Plenty of other cooling system related issues, but not that...

As for the stickers, doubt there is that much of a demand for reproduction decals but I'll see about doing a run of some
 
#30 ·
my buddy is going to do a run of digitally printed decals which was significantly cheaper than the flexo/offset option. He's going to do as many as will fit on a 1'x1' sheet so I'll have a good amount should anyone need. He says it'll be about a 90% match which is good enough for a non concours resto in my opinion. If anyone needs any, let me know
 
#31 ·
Haven't been on here for a while. Had one of those years and have only ridden one bike, the TBS, twice all year. :(

Interesting thread to come back on though. I've had the odd flight of fancy of getting an early example but doubt that I will though.

Also had thoughts on repainting my black and yellow TBS as I prefer the more classic colour schemes of the Thunderbirds but again doubt I will do it.

Had to smile at the hoarding as I've got rather a lot of parts and accessories for the TBS including the four different seats!

Great refurbishment and looking forward to seeing the completed project.

Chris
 
#33 ·
started working on the pickup coil and it took all of 5 min to remove the spare off the parts bike, but then I go to remove the side cover on the TBS and it's not budging. Looking around, I see this bullsh*t:

instead of getting a $3 gasket from triumph, the PO slobbed on some sort of epoxy sealer and painted over it.


finally got the cover off and am greeted with this:


after an hour of careful scraping I have about 50% of this crap removed, but my garage heater ran out of propane. I was running out of patience anyhow, so I decided to move on to something else. Being a couple of beers in and my girlfriend being out with her friends until at least 10pm, I decided this was my moment to set up a paint booth in the basement and tackle the tank.

a roll of plastic sheeting and some duct tape and I have a spray booth/kill room


after thoroughly washing the tank and scuffing it with a grey scotchbrite, I taped off the scallop




painted the scallop with 2 thin coats of adhesion promoter followed by duplicolor Ford performance white

the stuff dries ultra fast and is ready for topcoat in only 30 min so unmasked to see how it looks:


despite my nifty spray booth, I still got some crap in the paint and a little lifting of the pinstripe, but overall I'm pretty happy with it as it sits wet

and I think Neil would approve as well...
 
#34 ·
The work you're doing is really nice.
But I can't believe what the previous owner did with the crank pickup. Unbelievable.
 
#35 ·
The work you're doing is really nice.

But I can't believe what the previous owner did with the crank pickup. Unbelievable.

Yeah, no wonder it was shutting off after 10 min. Also, due to his buggering about, I now have to powdercoat the spare chrome cover and try to match it or source a new side cover on eBay and then touch up the engine paint. Ridiculous
 
#36 ·
tank is dry and i'm very happy with it. Not bad for approx. $30



Bike looks 10x better already (at least in my opinion)


got the fender and side covers in the booth as well.


Things left to do:
- pickup coil & repair/replace engine cover
- clean calipers
- swap triples and fork ear rubbers (parts bike triples are in better shape)
- clean/lube chain & replace chrome chainguard with stock black one
- new tires
- oil/fluids

money spent this far:
66 Autocolor: $53.88
Eastwood: $31.89
Bikebandit: $27.10
Pep Boys: $27.78
------------------------
total: $140.65
 
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