TBS winter project checklist and questions - Page 13 - Triumph Forum: Triumph Rat Motorcycle Forums
Hinckley Classic Triples 885cc Classic Styled T3's: Legend, Thunderbird, Thunderbird Sport & Adventurer.

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post #121 of 228 (permalink) Old 02-19-2017, 10:16 AM Thread Starter
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dog woke me up at 6am on Saturday, so got an early start on messing on the bike. Decided to break out the carbon fiber and try my hand at a front fender. I'm really digging the hexagonal (wasp) carbon fiber I got a yard of, so tried that first. Came out ok for my first part but had some problems with the vacuum system as well as getting the hexagonal carbon fiber to conform to the curves. I'm planning on painting it with just some CF showing through, so it'll do.

Shop dog Whisky checking out my vacuum bag job once I finally got it going (vacuum saver system, not a true vacuum pump)


out of the mold (excuse the dried pva)


Also, worked on re-racking the carbs. The 2-3 carb spacing is slightly bigger than the 1-2 carb spacing so still have to mess with that a bit, but getting closer.



also, messed around with some tape to test out an idea for a paint scheme. Definitely painting the bike Audi Nardo Grey but thinking of doing a two tone with black and a gold pinstripe separating the two.
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post #122 of 228 (permalink) Old 02-19-2017, 04:55 PM Thread Starter
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Mostly did house work today, but in between projects had some time to work on the bike. Tackled the seat today using the old cover I had made a few years back. Dimensions weren't exactly on point but I got it to work with the thruxton seat.

As someone recently asked about fitting a thruxton seat, I took a few pics of the underside to show the necessary modifications. The expanding foam was just to repair some damage to the seat foam.










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post #123 of 228 (permalink) Old 02-25-2017, 08:51 AM Thread Starter
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Friday I got the call that my bearing and connecting rod bolt order came in, so in anticipation of building the engine, the cases got the full degreasing treatment and scotcbriting... and then i started the very tedious process of masking it in preparation for paint. Sadly after 33k, overheating several times, and having coolant spilled all over it while hot, the factory engine powdercoat was too far gone and repainting would be necessary.

Hours in the garage armed with a roll of painters tape, a razor blade, and a growler of beer and I made it this far:




i got about 1/2 way through the lower case before running out of tape (and patience) for the evening. Being half a growler in I decided to move forward with another project I'd been mulling over for a while and out came the grinder to shave the rear subframe!

Passenger pegs, side cover mounting brackets, and rear fender brackets all came off. Passenger pegs will be replaced with a set of bolt on ones for when the gf wants to go riding. Threaded bungs will be welded flush into the subframe tubing and a set of bolt on peg mounts from a newer sportbike will be utilized.

All this was done to the parts bike subframe, so no rare TBS parts were harmed in this picture:

Have a plan formulating for the rear master cylinder to really open up the triangle and get rid of that unsightly reservoir and hose.
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post #124 of 228 (permalink) Old 02-25-2017, 09:08 AM
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Quote:
Originally Posted by simplyj View Post

Have a plan formulating for the rear master cylinder to really open up the triangle and get rid of that unsightly reservoir and hose.
Newer dirtbikes have the rear master cylinder and reservoir in one assembly. My 2003 KX250 does for example and friends CRF450 has it also. The service manual for my KX250 does not list the bore size of it. Might be something to look into.

edit: found pics and it appears to be a 1/2 size on the casting.

http://www.ebay.com/itm/2004-Kawasak...9SKMBC&vxp=mtr
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post #125 of 228 (permalink) Old 02-25-2017, 06:02 PM Thread Starter
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Yeah, I was planning on using the KTM brembo rear master which is 13mm. Slightly smaller than the stock 14mm, but close to the popular 1/2" (12.7mm) upgrade on the t595.

Mount spacing is 40mm which is way off from the stock bracket, but that's what welders are for.
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post #126 of 228 (permalink) Old 02-26-2017, 08:03 PM Thread Starter
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After hours of tedious masking, I finally painted the cases. 13 years and 33k hard miles had taken its toll on the stock finish and the HD texture black looks 100x better. The paint is a bit pricey at $23.50 a can but after seeing the results, it was well worth the cost. Laid down very evenly and was dry to the touch within 15 min. Masking tape pulled clean and everything was cured at 180 degrees for an hour.




close up of finish


Also cut the rest of the brackets (except the master cylinder bracket) off the subframe and got it mocked up and the new shock installed.

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post #127 of 228 (permalink) Old 02-27-2017, 02:48 PM
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Unbelievable paint job...and effort. In times like this I am thankful to have very clean chrome that only requires some polishing here and there. Seriously, excellent job! I'm going to be hacking the rear peg loops off the frame too and will need to match the black wrinkle paint. What are you using for that? Cheers!


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post #128 of 228 (permalink) Old 02-27-2017, 03:07 PM Thread Starter
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Unbelievable paint job...and effort. In times like this I am thankful to have very clean chrome that only requires some polishing here and there. Seriously, excellent job! I'm going to be hacking the rear peg loops off the frame too and will need to match the black wrinkle paint. What are you using for that? Cheers!


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I was going to experiment shooting rustoleum satin from a gun with low air pressure for a texture effect or try a foam roller. I've achieved a similar texture with high build primer and foam roller so might try that route and just spray rustoleum satin directly over that.

I've heard the satin matches well for spot repairs with a sponge but that's not really feasible for an entire subframe.
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post #129 of 228 (permalink) Old 02-27-2017, 03:09 PM
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Sounds good, let us know. I was thinking similar, Rustoleum satin with foam brush and dab it. Then satin clear coat.


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post #130 of 228 (permalink) Old 03-06-2017, 10:11 AM Thread Starter
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Didn't get too much done on the bike this weekend and starting to get very nervous about getting this thing rideable by the time the warm weather comes to stay.

What I did get done:

Found a used nissin rear master with a billet reservoir on ebay. The ad was short on details and the seller wasn't too knowledgeable but I took the risk and snagged it for $30 shipped. Turned out to be a great deal as the master was almost identical to the stock TBS nissin and the billet reservoir bolted right up. I have no idea what the brand is, but it appears to be well built.



much cleaner compared to the stock hose and piss cup. should tuck behind the heel guard nicely.



started to work on the battery/electronics tray. Had some sheets of 22 ga mild steel sitting around so cut out a pattern, but once I got it mocked up and tacked in, I realized that it'll be a little tight getting everything in there and well situated. As I'm no longer using the fender, I think I'm going to cut out that middle brace and use a thicker gauge steel for the tray to maintain rigidity.


What ate up most of my time was laying out the engine components and starting with the reassembly. Got as far as getting the main bearings in and double checking clearances before my gf yelled down that the clothes dryer was on fire! Turned out the control panel burnt out... oh the joys of home ownership. Add the cost of a new gas dryer to the list, meh.

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