My TR6 build starts here! - NOW FINISHED

[Dan Boy]

Fantastic, the new front wheel bearings turned up today. I finally found a set that I would work with. It took a lot of hunting down. I can't believe that the stock bearings for this wheel only had capacity for a 12mm wheel spindle, that seems way too small for any application.

Cheers Dan.

[Dan Boy]

So this evening I figured I would take a look at getting the new head bearings in and getting the new front end on. I never install bearings without using some copper slip. This stuff is great and lasts forever. I have never had a bearing seize in using this stuff.



I always have some large enough lumps of timber laying around the shop to use as a drift while I use a mallet to knock them in.



As the new front end has steering stops built in, I didn't need the stock setup and seeing that they would look pretty ugly just sitting there, I decided to cut them off and grind the radius down.

Before:-



After:-



These tapered roller bearings are a much better setup than the stock ball bearing arrangement. Front ends in, so now I can strip the frame and take it to the powdercoaters.

Cheers Dan.

[Dan Boy]

So that's it then, there is no more fabrication to do on this build. I have just finished off the small amount of welding I had to do and that's it. I will take this lot to the powdercoaters on Monday and sit back and wait.

Trouble is I'm not really all the patient!

Cheers Dan.

[Dan Boy]

Well, I'm bored already and I've only had one day with nothing to do. I decided that a good job would be to clean up my lift. Its amazing how much crap builds up during the build process, it was covered:-

Before:



After:



Cheers Dan.

[Bodyworx]

That lift probably wont work for your next build. Just send it to me and i will dispose of it for you. Ill PM you my address.

[Dan Boy]

Great, the frame is now at the powder coaters and I have just had an email telling me that my seat has been done. I should get it through the post tomorrow or Wednesday and I'll be sure to post pictures on here when I get it back.

Cheers Dan.

[MeanMike]

Hang in there Dan. The worst part of the build for is the "wait". I'm really looking forward to seeing your bike come together.

[Dan Boy]

Cool, I collected the seat from the Post Office this morning and it looks amazing, a real class job. I'll post some pics of it later after I get off work.

Cheers Dan.

[Nick32vic]

Great build thread! Love your bike.

[Dan Boy]

So here it is, remember this is what I wanted out of a seat but I can totally recommend Adrienne at Ghillie dhu Leather, she did a great job and I am totally happy with it.

http://www.ghilliedhuleather.co.uk

Cheers Dan.

[Jenks]

Dan - the seat looks great, nice coloring and good thick material - I didn't think of getting the underneath done too, nice touch mate..

[Dan Boy]

The trouble is with builds, as I am sure all you guys have found, is that you are missing small items, a stud, nut or in my case a gasket or two. There are many places in the UK that will sell small parts like this but they often want a minimum order value to process any order. As these gaskets are £0.51 each, I was never going to get to the minimum order value and after waiting a couple of days trying to find other items I could order to increase the value of my order, I could not think of much but I did find some gasket paper so I thought I would make a set.

First off, I was lucky enough to have one of these gaskets so I could use it as a pattern. So, after drawing it up on the computer I printed it out on normal paper to check I had it exactly the right size.



I then cut my gasket paper to a size where it would fit through the printer, drew the second gasket on the computer and then printed it straight onto the paper. It didn't print brilliantly but I could see where the lines where.



Next, with a new blade in my knife I carefully cut around the outside and then cut out the holes. I think if I was to do this again I would cut the holes first and then cut the outside. It would have given me more to hold steady as cutting the holes was a little fiddly.



Then I tested them for a fit and it was perfect, they fit just as well as the original.

Cheers Dan.

[that_stupid_kydd]

sweet zombie jesus!, if i would have known you were looking for a springer i would have traded mine for that girder

[Dan Boy]

For those guys thinking of or already have a zinc plating kit, I found an old phone charger that puts out 5v and this seems to be a great voltage for plating, not only does the finished plating come out smoother than with higher voltage plating but it can be buffed to a chrome finish. Check out this rocker spindle that was rusty.

Cheers Dan.

Before:-



After:-

[supercrouton]

Dan, you are the man! You inspired me to get a zinc plating outfit, I should have done it long ago. Btw the saddle looks great too.

[Dan Boy]

Great news, I got a call from the powder coaters today to say that the frame etc was ready for collection. I went straight over there after work and I've got to say I was not disapointed, this stuff is so good I just want to lick it!!



If I was going to be critical of anything it would be my own welds. Some of my first welds still don't look too great even after powder coating and especially next to the David Bird ART welds but that just makes me want to become a better welder.

All the male threads were kept clean by the powder coater and I had already put bolts in all of the female threads to keep them clean. I am glad I took the precaution to cut a couple of tapered bungs for the head bearing cups so they will be nice and clean and the front end can go straight on.

Cheers Dan.

[supercrouton]

^^nice idea^^ I would have thought wood would burn or at least ash a bit, but it looks like it worked brilliantly. That looks much easier/faster than masking the inside.
Cheers, Dan.

[Dan Boy]

Originally Posted by supercrouton

^^nice idea^^ I would have thought wood would burn or at least ash a bit, but it looks like it worked brilliantly. That looks much easier/faster than masking the inside.
Cheers, Dan.

Yes, it worked really well. I used 22mm plywood to make up the bungs and there seemed to be no burning at all and no damage that I could see from the blasting. When I took them off, the bearing cup faces were as clean as they were when I put them in so I can get the front end straight on.

Cheers Dan.

[S.G]

The build is coming together nicely, you should hav that roliing this weekend

[Dan Boy]

I took a tip from a JJ member and mounted the frame to the engine rather than the engine to the frame. This method works a treat and I got the engine and frame back together with no chips, dents or scratches on that beautiful powder coat.

Once that was done it was a short step to getting the David Bird hartail and the seat hinge bolted in place.

Tomorrow, I hope to get the rockers bolted on and the head steadies installed, also the front end and the seat so that I can make a start on the wiring. I can't get the rear wheel in yet until I get my stuff back from chrome.

Cheers Dan.