[nschiller]

Well, I have started in earnest in a restoration project of an early 1964 Bonneville (SN DU6063) that was willed to me from my Brother. The bike was open garage stored for better than 20 years and was frozen up bad. I disassembled it about a year and a half ago and now I am starting to rebuild. The bike was built with 11:1 pistons, full race cams and the painted with a Candy Apple Red that was probably something in its time. My plan is to put it back to stock. The start of the rebuild was to obtain a new lower unit from Britishonly.com to scavenge the Crank, cams, timing gears, Oil Pump, etc.
I will have lots of questions and need lots of help.
I will try to update as I go along. My goal is to ride this bike to Mad Dogs and Englishmen in Richland, Michigan when done.

 

[jnamohn]

Looks like a lot of work and lots of fun!

Keep us updated on the progress.


Jeff

 

[nschiller]

Bottom End stripped down and ready to start engine rebuild

Well, the bottom end that I bought from BritishOnly is stripped down. Crank, Cams, Bearing, Timing Gears, Rods are all good. Cleaned out the sludge tube and have now ordered new plug and Big End Bearings, Oil Seals, etc. to start lower end rebuild.

 

[gbc]

Good Luck

Nice to see another 64 coming back to life. One of the best years in my opinion, but of course I am somewhat biased. Mine is no where near 100% correct but I enjoyed bringing the "Old Girl" back from the dead. Enjoy the experience, it is the greatest stress reliever out there................................

Before


Now

 

[Tobydog61]

Congrats on getting the bike. I love the fact that it has family history tied to it. I have an all original '64, number DU6009 and can take pics if you want to see exactly how certain details were from the factory. I'm on the West side of Michigan so maybe I'll see you at a show. I just completed a resto on a '67 and I can tell you that you are in for a wild ride. Prepare the check book for a real beating.

 

[GrandPaulZ]

What was wrong with the original bottom end? I would have done everything possible to keep the original matching numbers.

 

[nschiller]

Tobydog61,

Thanks for the reply. I certainly followed your description of finding your '64 (and was quite envious). I may take you up on some pictures and other information. I am not far from you in Bloomingdale, Michigan (half way between Kalamazoo and South Haven).

 

[nschiller]

The bottom end was severally damaged from the time of neglect. The cams were shot, the crank had some pretty severe corrosion (as in missing metal). I was able to salvage the cases so I have preserved the Serial Number. I needed a crank, cams, timing gears, oil pump, etc. to rebuild. A good lower unit seemed to be the lowest cost avenue to get there.

I just put the plug in the slug tube of the crank today, installed the big end bearings and mated the crank and cams to the cases today. One of the many mistakes that I made in tearing the bike down was not bagging all of the parts with identification as to what goes where. It gives me a good reason to replace nuts and bolts with new.

More to come!

 

[nschiller]

Tobydog61,

Just re-read your response. The serial number of my project is DU 6063. We are close.

I am a retired Mechanical Engineer from the Aerospace and Defense business. I expect the costs and look forward to the challenges of rebuilding this machine. Growing up there were two kinds of riders, Harley and Triumph. I was always in the Triumph clan. I worked with one of the premier engine guys for Harley and always tried to get my brother to let me bring this engine to him. He has retired as well and I may still need him.

Do you know a good source to strip chrome? Several parts were chromed that should be black (and the chrome has peeled).

 

[Tobydog61]

The '67 I did had extra chrome on it as well. Must have been the thing to do. Rear swing arm and oil tank was chromed. The guy I used for powder coat said no issue going over the chrome as long as he prepped it correctly and the swing arm turned out great. Beyond that I know it can be stripped but not sure who could do it short of someone who actually does chrome plating.

The oil tank was toast so I needed a new one anyway before paint.

I found that the cost of re chroming most parts was more than buying new re pop pars so you have to balance that out on a part by part basis.

Let me know if there is anything I can do to help. There is an excellent mechanic in my area if you need help.

 

[nschiller]

Bottom End is ready

Well, the Bottom End is done. Put together with the covers on temporarily while doing more.
I have also been working on frame parts, getting them painted and clear coated. Started on the rocker covers. I have parts to take to the sand blaster (foot pegs, rocker covers). My brother had the rocker covers painted flat black, I need to sand blast them to get the paint out of the fins.
Here are a couple of pictures of the progress.

 

[GrandPaulZ]

So you rebuilt the bottom end using the MISMATCHED cases?

I still don't see the reasoning behind that. I would have put all those internals into the matched cases.

Still worth it to do so before the top end goes on...

 

[nschiller]

GrandPaulZ,

I did use the original cases to preserve the serial number match to the frame. There was nothing wrong with the cases, only the internals. I harvested the crank, bearings, cams, oil pump, and timing gears from the '63 bottom end. There is still a lot of work to be done but I am pretty pleased with how the bottom end has gone together. The cylinders and head are in good shape. I have the rocker arms out for sand blast right now (they were painted flat black). I haven't even started on the carbs yet. They worry me more than anything else.

Neil

 

[GrandPaulZ]

Okay, I misunderstood. I thought you built a new bottom end, but kept the original matching cases "preserved" (like, in a box).

If it's not too late, DO NOT sandblast the rocker arms. Soda blast or hydroblast.

Excellent.

 

[nschiller]

Grand PaulZ,

It's not too late. Thanks for the heads up. Thinking about it soda would be a much gentler media. I'll pull them back. May let them sand blast the chromed pieces as the chrome was pretty thick on the pieces that I have mechanically abraded.

Neil

 

[Wally]

Tobydog61,

Just re-read your response. The serial number of my project is DU 6063. We are close.

Do you know a good source to strip chrome? Several parts were chromed that should be black (and the chrome has peeled).

And I am DU6108. DU6106 recently turned up on eBay and tempted me to no end. Nice to see a couple of bikes closer to mine.

The best source to strip chrome is a plating shop. They simply reverse the process. Unfortunately Brown's went under at the first of the year. They actually saved my cylinder head from the evil chrome that had been applied.

 

[Tobydog61]

nschiller - Will you be going to Battle of the Brits in September? If so, look me and my '64 up.

 

[Wally]

Never mind....

 

[nschiller]

nschiller - Will you be going to Battle of the Brits in September? If so, look me and my '64 up.

No. I have a three week trip planned in the 5th Wheel out to the west coast. I would like to get together sometime to meet you and see your '64. We aren't that far away from each other.

 

[nschiller]

This is the first I've ever heard of it. Looks like a great event, but I don't think I can make it this year. Thanks for the tip, though.

Wally,
I spent 11 years in the DFW area. Live in Dallas on Forest Lane for the first year then moved out to The Colony. Worked for TI in Dallas and then Lewisville. Bought my '77 650 Yamaha in Richardson (still have it in the barn).