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Old 05-11-2009, 04:37 AM   #1 (permalink)
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1971 T120R Matching Numbers Basket Case

Ive been meaning to give a little bit of insight into a young mans quest!!!!.....

A 1971 T120R Purchased November 2007 Matching Numbers basket case.




Originally purchased as a project to give me some time with my old man with our mutual love for classic bikes. Has Now progressed to give us something to argue and fight over.

I’m still to this day frequently shown (at least weekly) all past photos of his bikes. He still finds tremendous joy in telling me that my mother has been on more triumphs and been to more race meets than me. Those old photos of my dad sporting a porno mustache wearing flares with my mum (pregnant with me) in the pits also still haunt me. Hearing how your dad raced 40 Weekends a year gets to you after a while. I wish I could say he was lying but he still races and regularly kicks my arse. I put it down to having too much to lose.

Back to the topic!!!


First thing was the strip down and noting what things were ok and what things will need replacing of fixing. I was quite good at stripping the bike down without any methodology and mixing up parts i.e. putting gearbox bits in with top end bits, apparently a real no-no for seasoned bike restorers. It took me about a weekend to strip down and maybe 4 weeks to for the old fella to reorganize all the parts into the correct used ice cream containers. This was when i was called alot of names which i wont post.

Frame/Wheels/Body



Frame was de-powdercoated using a chemical bath (preferred un-powder coated for easy touch ups and welds). Hubs were chromed and had to get de-chromed (don’t know why you would chrome them in the first place??) and engine cases were sent to get a blast.



Rusty rims were sold on Ebay and I got some undrilled Akront Morad mud-catcher rims and stainless spokes. I went through a lot of drill bits but finally managed to lace em’ up and true up wheels. All got new bearings etc. Brakes surfaces were ok but slightly worn. I did have to get some thicker brake shoes made up at the brake joint. Trouble was that even with new brake shoes I wasn’t getting much contact. The thicker shoes did the trick and were quite cheap. The hubs and fork legs were then polished. It was a bit of a nightmare polishing the hubs with all the fins etc and nooks in the conical hubs.

Original tank had way to much rust to convert so I found a later OIF tank Ebay and was also kindly donated a breadbox tank by Ozbloke (what a champ!!!!). Sealed both tanks and painted.

Original shocks and seat had to be replaced with new ones as they were too far gone!!!
Some light welding of the seat swivel lugs was carried to make new seat fit.
I had to also get a new wiring harness which I haven’t put on yet (I’m leaving the wiring till last as I reckon its going to be a bit of a pain in the arse). The old man has commented on how good the bike is going to look as a centre piece in my lounge room or as a large paper weight when I can’t get the wiring!

Frame was painted in back yard (all my paint had been done in back yard…insects and all) and swing arm was assembled (new bushes). The wheels went on and I noticed that this was a lot easy to push in and out of the garage for the next 2 years while the project slowly progressed.



That’s all for this episode. Stay tuned for next installment……

Last edited by valiantbultaco : 05-11-2009 at 07:47 AM.
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Old 05-11-2009, 09:20 AM   #2 (permalink)
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Hey! I recognize that last photo, I know I've seen it before...

I'll add your thread to the sticky list.
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Old 05-13-2009, 05:01 AM   #3 (permalink)
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Engine

The Engine was completely stripped and cleaned out. All oil routes were cleaned out and rough bits of the cases were cleaned up with a bit of help from a dremel that was probably about as old as the bike.



The barrel was bored and got new pistons. Crank got a grind from a guru out in Sydney’s west who does a lot of work on speedway and V8 supercars. The old guru pretty much lived in his factory surrounded by hundreds of cranks. I was positive that i was going to get the wrong one back but he came through with the goods.

Here is a pic before the guru got to it



The head got new valves and guides and seat work along with new springs etc.
I decided to use install a plunger for more positive gear selection. The 71’ came with a crappy detent spring which is a nightmare to line up when the inner gearbox cover goes on. A Bultaco plunger fits really nice the in boss with some minor drilling and tap work. All engine seals were replaced along with a new oil pump and main bearings. New 14 plate clutch kit and the list go’s on and on!!






So thats pretty much the condensed version of the engine without going into too much detail.

Stay Tuned for the next installment,.......there's plenty more to come!!!
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Old 05-13-2009, 05:10 AM   #4 (permalink)
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Extra Engine pics

Thought i may as well add some extra engine pics as your limited to 4 a post!!!

Primary Side




Timing Side





Front On





Rear On




Stay Tuned for the next installment!!!
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Old 05-13-2009, 08:54 AM   #5 (permalink)
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That's a might clean engine! You didn't post a shot of the crank after it got turned...

Excellent work.
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Old 05-13-2009, 05:05 PM   #6 (permalink)
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thats real clean!
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Old 05-14-2009, 10:20 PM   #7 (permalink)
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Crank

Due to extreme popular demand i have decided to post some pics of the crank after it came back from a grind. Can you tell the difference??

Before



After





Obviously new big end bearings and undersize seal were installed.
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Old 05-14-2009, 10:32 PM   #8 (permalink)
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Wheels/Hubs

I mentioned before the hubs had been chromed by a previous owner. I had to reverse the chroming process to remove flaky chrome and then started polishing.....and polishing some more.

Here is the state of the hubs when they came back from decrhoming. Again i had another mission out to Sydney's Western Suburbs!!



I decided to drop the 19" front to a 18" to make front & back 18" rims (i'm going for a pig street tracker/motard type look) and got some bridgestone Battalax's.

To Run a 520 Regina speeday chain i got hold of a 520 back sprocket and grinded away at a standard size front sprocket so it would take the 520 Chain. I think the 520 chain is a heap less bulky than the overkilled standard???


Back





Front





Back again




In this pick youu can see the pillion frame mounts which i have now chopped off and made a single fixing point to attached my home made upswept exhuast pipes. (which i will be wrapping this weekend).

Stay tuned.......
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Old 05-15-2009, 08:39 PM   #9 (permalink)
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Pillion Frame mounts

As i spoked about earlier, here are some pics of the new pillion frame mounts/exhuast fixing point that i made outta steel. I have kept the originals that were chopped off and can reweld them back on when im feeling sentimental. I dont plan on destroying too much originality on the bike as i want to keep it looking like a bonnieville.




Otherside




I have finished painting the battery tray & coil brackets and im getting closer to the dreded wiring phase!!





The back guard came up good considering the state of how it was it. Its amazing what you can do with a super cheap auto hammer & dolly (rrp $14.95) and some undercoat.

Still using the orignal lucas lens which was one of the only few things on the basket case that didnt require fixing!!



Stay Tuned for next installment
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Old 05-18-2009, 03:41 PM   #10 (permalink)
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Holy guacamole! Those hubs look fantaastic.
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