When I'm over at the Castle working on Bonnie, I take tons of photos. Reference photos are a great way to recall so many details that we might either have forgotten or just failed to notice. For things like parts orientation they are invaluable.
Here are some of the thousands of Bonnie photos I've taken over the years, as well as some useful tips and info that I've accumulated. Still a work in progress.
Top-End Tear Down
"Taking it all off" for you yet another time! Always something new to see. Always something interesting to learn. Always some new anxiety to keep me awake at night.
Recessed Valve Seats. What to do?
At 88,000+ miles, the valve seats in Bonnie's cylinder head were quite recessed. There's no easy solution to this problem, one simply cannot buy a new 1969 Triumph T120R cylinder head. They ceased being made long ago! So I explore the alternatives.
Complete Cylinder Head Restoration
New valve seats, guides, valves, springs, the works! Amazing boost in performance! This is like a brand-new cylinder head!
Comparing Triumph Crankshafts with Heavy and Light Flywheels
The end of Bonnie's crankshaft keyed for the rotor suffered irreparable damage somwhere along the way and had to be replaced by a used, reground crank. The original had a light flywheel and the replacement's is heavy. Compare the two in these photos.
Engine Sprocket Shims
Is it normal for engine sprocket shims to become "crinkled" by the engine sprocket splines? Apparently.
Assembling Shell Bearings and Rods to Crankshaft
Using Plastiguage to check main bearing clearance and assembling rods to crankshaft journals.
Assembling the Cases, Camshafts, and Crankshaft
Practice makes perfect and the first time is a success.
Gold Discovery in Bonnie's Gearbox!
This winter Bonnie will receive new oil lines, fuel lines, primary chain,
throttle cables, etc. as well as all the regular routine maintenance and
lubrication.January 2018
Transmission and Gearbox Disassembly
Dismantling the transmission and gearbox using special tools. Includes photos showing range of motion of the gearshift quadrant using a degree wheel. February 2018
Better Way to Remove Engine from Frame (12 photos)
A few times previously I'd used rope and chain hoist to remove Bonnie's engine. A hydraulic jack and a bunch of shims made the job way easier! Removing the engine provides a rare opportunity to shine the bottom side as well as the top. But how will I know which side to keep up? February 27, 2018
Fabricating a Plywood Engine Base (7 photos)
To facilitate the installation of two gearbox bearings in the casing I fabricated this engine base for use on a hydraulic press.
Podtronics Installation (8 photos)
I used a couple of tie-wraps to install a Podtronics regulator/rectifier
completely out of sight beneath Bonnie's battery carrier.
Gear Oil Compatibility with Yellow Metals
Some background info on yellow metals and GL5 gear oil products and
some sinetific research.
Assembling the Triumph Unit 650 Gearbox: Hancox Method
A photo-illustrated, step-by-step description of Hughie Hancox's method of assembling the gearbox components.
Camplate & Quadrant Indexing.
A photo-illustrated description of indexing the gearbox camplate and quadrant in
first gear, fourth gear, and neutral between 2nd & 3rd.
Removing Cylinder Head, Cylinders, and Pistons
Removing the top end of a 1969 Triumph T120R. Shows use of a home-made grudgeon pin removal tool. January 2016
DS Mainshaft Bearing Replacement Made Easy
Bearing on a stick! Here's a clever trick for replacement of the hard-to-get-at DS gearbox ball bearing. April 2016
Replacing Cylinder Head and Rocker Boxes
Too many photos of Bonnie's 1969 Triumph T120R top end reassembly. May 2016
Engine Tear-Down
Electrical gremlins, gearbox still popping out of gear, and a broken mainshaft key were all part of the mix for Winter 2015. Triumph owners in northern latitudes at least have plenty of time on our hands for wrenching.
4-Speed Triumph Gearbox Components Reference Photos
Reference photos of Bonnie's 4-speed gearbox components. Includes photo comparison between older and newer type gearbox parts. Winter 2015
Making a Custom Wiring Harness from Scratch
How to make a custom Wiring harness for the 1969 Triumph Bonneville. Includes complete list of supplies and tools obtained from British Wiring. 2015
Top End Disassembly
Disassembly of Bonnie's Top End. Winter 2006
Powder Coating Everything!
Bonnie's newly powder coated parts. Winter 2006
Engine Reinstalled in Powder coated Frame
Putting Bonnie back together from the ground up after powder-coating the entire frame and tinwork and doing the top end.
Installing a Reproduction Wiring Harness
Photos of reproduction wiring harness replacement on on a 1969 T120R. Showing harness routing and connections. Winter 2006
Original Wiring Harness of a 1969 T120R: Photos
Photos of an orginal 1969 T120R wiring harness showing harness routing and wiring connections. 2005
(2018) Forget that macrame stuff, here's a way easier, probably safer way to remove the engine.
Reconstituting Bonnie After Complete Disassembly
Putting it all back together after complete disassembly to paint cylinder block, frame,
and tinware. Very shiny! Winter 2004
Back on the Road Again
Back on the road after being painted, painted, painted black and sporting stainless steel fenders and new exhaust headers. June/August 2004
Bonnie's Maintenance Log
All the embarrassing shit.
