Today the plan was to install the front forks and hopefully the rear shocks. Day did not go as planned.
First, things started out well. I had to machine the special tool required to pull the fork tubes up into the taper in the top yoke. I had made one for my BSA last year and hoped it would fit. Not sure who I thought I was fooling. BSA thread is the same diameter, but a different pitch. BSA is 20 TPI and the Triumph is 26 TPI.
So I chucked up a piece of aluminum in the lathe and machined the piece. Here's the finished product. So far, so good. Although that's without a doubt the worst knurl I've ever put on a piece.
This is the tool assembled prior to using it. The poly cup is to draw the tube up into the yoke and provide clearance for the piece that threads into the tube. I made the cup from poly so it will not mar the paint on the top yoke.
Here is the tool after I'd pulled the tube up into the taper in the top yoke. I'm holding the poly cup up so you can see the piece that threads into the fork tube.
This is how it looks when you are drawing the tube up into the taper with the nut on the bolt. Also note the space between the fork cover and the bottom of the yoke. You can see the fork tube. I suspect this is due to the tapered bearings in the steering head. I'll probaby fit an o-ring in there to take up the space and keep the water and crud out.
So, as you see, I got one tube installed. That's when I noticed a small, but annoying issue. When I ordered my parts, the fork gaitors were from EMGO. I never really thought much about it and figured they'd be as good as any. WRONG! The gaitors have a few issues. First, they are shorter than the OEM gaitors. Second and third are the top and bottom are uniformly molded. The OEM gaitors are not. Top of the gaitor has a rib molded in that engages the spring seat and the bottom of the gaitor has a groove molded in to engage the lip on the dust preventer (seal holder). EMGO gaiters had neither of those features.
Here's a comparison between an EMGO and OEM gaitor.
EMGO gaitor on top. Too short. It would reach, but would not stay in place without band clamps. STRIKE 1.
Here is the top of the OEM gaitor showing the rib that engages the groove in the top spring seat.
Here is the bottom end of the OEM gaitor showing the groove that engages the lip on the slider dust excluder.
Here is the end of the EMGO gaitor. Both ends are identical STRIKE 2 and STRIKE 3. EMGO is OUT!
So, I removed the tube and put the gaitors back in the packaging and will order a correct set tomorrow. I need some other stuff so I'll just order it all now and pay one shipping price.
So, looks like I won't be working on the bike for the next week or so. But that is actually a good thing. I really need to prep my bikes for their winter sleep and have been putting it off to work on the Bonnie. Now I have no excuse. I'll probably paint that fork stop and let it dry for a week.