# 1966 triumph chopper rebuild **URL:** \ **Category:** Builds\ **Created:** [May 6, 2009, 10:30pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409 "2009-05-06T22:30:25Z")\ **Posts on this page:** 20\ **Page:** 1
**Author:** ![blackout](https://avatars.discourse-cdn.com/v4/letter/b/439d5e/32.png) [@blackout](https://forums.speedlife.net/u/blackout)\ **Post date:** [May 6, 2009, 10:30pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/1 "2009-05-06T22:30:25Z")
I’m starting with a vintage chopper. It is a 1966 triumph 6T “Thunderbird”. The 6T was a dumbed down version of the T120 Bonneville. The T120 put out about 47HP. The Thunderbird was 37HP. Each was the same 649cc displacement engine, but the Thunderbird had lower compression, different timing, and smaller carbs. The plan is to tear down the entire bike. Next I’m going to tear the engine down to the crank, and rebuild with every performance part I can access. New engine parts All bearings 750cc big bore kit- alloy pistons performance oil pump alloy push rods upgraded valves/springs/guides aftermarket oil filter performance cams(if I can find them) After I tear down the engine- - The cases and covers are all getting polished. Then I plan to order any misc. parts and rebuild the engine After I rebuild the engine- - The pipes are getting wrapped. - 2005 sportster front wheel and brake system for it. - Flat black frame and tins - 1" handlebars - Recovered/shortened seat - Misc black powdercoating on everything chrome THIS IS HOW THE BIKE LOOKED IN 1966 ![http://physiology.usouthal.edu/restore/66bnvl.jpg](http://physiology.usouthal.edu/restore/66bnvl.jpg) THIS IS BASICALLY HOW I BOUGHT IT. The bike has a hex springer front end, Paucho frame, spool front wheel, stock sprocket/drum brake rear wheel, “sporster” tank, drag specialties seat, dual mikuni carbs, and 7/8" drag bars ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1271.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1271.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1272.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1272.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1269.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1269.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1270.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1270.jpg) ---
**Author:** ![EvilJay](https://avatars.discourse-cdn.com/v4/letter/e/a5b964/32.png) [@EvilJay](https://forums.speedlife.net/u/EvilJay)\ **Post date:** [May 6, 2009, 10:38pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/2 "2009-05-06T22:38:19Z")
potential ---
**Author:** ![blackout](https://avatars.discourse-cdn.com/v4/letter/b/439d5e/32.png) [@blackout](https://forums.speedlife.net/u/blackout)\ **Post date:** [May 6, 2009, 10:40pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/3 "2009-05-06T22:40:16Z")
Teardown to rolling chassis. This wasn’t too complex. The bike is basically a frame and engine. It took three hours to tear it down and bag up parts. ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1273.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1273.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1273.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1273.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1308.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1308.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1304.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1304.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1274.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1274.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1279.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1279.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1280.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1280.jpg) Motor on stand ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1275.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1275.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1277.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1277.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1278.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/101_1278.jpg) ---
**Author:** ![Quattro\_Krant](https://avatars.discourse-cdn.com/v4/letter/q/ac91a4/32.png) [@Quattro\_Krant](https://forums.speedlife.net/u/Quattro_Krant)\ **Post date:** [May 7, 2009, 1:32am UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/4 "2009-05-07T01:32:58Z")
My dad had a 69 Daytona, nice bike. Then he sold it for a 71 Norton Commando 750 which was really really nice. He said that the Daytona was much more rough, the most he could ride it for was about 2 hours. Cool looking project. I’d love to pick up a Moto Guzzi in the future. ---
**Author:** ![blackout](https://avatars.discourse-cdn.com/v4/letter/b/439d5e/32.png) [@blackout](https://forums.speedlife.net/u/blackout)\ **Post date:** [May 7, 2009, 12:28pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/5 "2009-05-07T12:28:59Z")
TOP END TEARDOWN- Rocker covers off ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0484.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0484.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0486.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0486.jpg) Head removed- ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0488.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0488.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0489.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0489.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0487.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0487.jpg) Jugs removed- ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0490.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0490.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0491.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/HPIM0491.jpg) ---
**Author:** ![Paulo](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/paulo/32/7328_2.png) [@Paulo](https://forums.speedlife.net/u/Paulo)\ **Post date:** [May 7, 2009, 12:35pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/6 "2009-05-07T12:35:27Z")
Cool project. :tup: Paging Turbociv. He’ll like this. ---
**Author:** ![blackout](https://avatars.discourse-cdn.com/v4/letter/b/439d5e/32.png) [@blackout](https://forums.speedlife.net/u/blackout)\ **Post date:** [May 7, 2009, 12:42pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/7 "2009-05-07T12:42:38Z")
Rocker covers- ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1400.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1400.jpg) Old & New head. I was going to fix and rebuild my old one, but I found this new one, already rebuilt and blasted. So, I’m throwing the new head parts I purchased on Ebay to recoup most of what I paid for the rebuilt one. ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1387.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1387.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1392.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1392.jpg) Old Head- ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1389.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1389.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1393.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1393.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1394.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1394.jpg) New head- ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1391.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1391.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1316.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1316.jpg) ---
**Author:** ![blackout](https://avatars.discourse-cdn.com/v4/letter/b/439d5e/32.png) [@blackout](https://forums.speedlife.net/u/blackout)\ **Post date:** [May 7, 2009, 12:49pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/8 "2009-05-07T12:49:47Z")
Old 650 jugs vs. New 750 Big Bore Kit ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1395.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1395.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1396.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1396.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1397.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1397.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1398.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1398.jpg) ---
**Author:** ![blackout](https://avatars.discourse-cdn.com/v4/letter/b/439d5e/32.png) [@blackout](https://forums.speedlife.net/u/blackout)\ **Post date:** [May 7, 2009, 1:04pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/9 "2009-05-07T13:04:38Z")
So far I’ve tore off the top end. I started the primary side but had to stop because I had to order a couple triumph specialty tools from England. The only “major” issues I’ve found so far are… - Two out of four broken pushrod cups(valve side) - Shorted alternator wire in engine(now I know why it wasn’t charging all the time) This is the brake system I picked up to go with the Sportster front wheel. The connecting rod and bracket are custom made to adapt a late model Harley brake to a springer front end. If all goes well there should be only one hole to drill in the springer. ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1403.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1403.jpg) This is the only tail light I will be running. It will mount to the right side axle after some modifications. ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1402.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1402.jpg) ---
**Author:** ![blackout](https://avatars.discourse-cdn.com/v4/letter/b/439d5e/32.png) [@blackout](https://forums.speedlife.net/u/blackout)\ **Post date:** [May 7, 2009, 1:12pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/10 "2009-05-07T13:12:22Z")
My first question for you guys is gas tank preference… I have a “Sporster” style and a mustang tank to choose from. Mustang- ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1290.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1290.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1292.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1292.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1291.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1291.jpg) Sporster- ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1304.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1304.jpg) ![http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1305.jpg](http://i4.photobucket.com/albums/y129/BlackoutYJ/triumph/100_1305.jpg) ---
**Author:** ![TrueBlue](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/trueblue/32/7245_2.png) [@TrueBlue](https://forums.speedlife.net/u/TrueBlue)\ **Post date:** [May 7, 2009, 1:13pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/11 "2009-05-07T13:13:14Z")
Way cool. My old man used to hack up Harleys and Triumphs in the 70’s, all he’d wrench on. Keep it coming. ---
**Author:** ![King](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/king/32/7329_2.png) [@King](https://forums.speedlife.net/u/King)\ **Post date:** [May 7, 2009, 1:33pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/12 "2009-05-07T13:33:15Z")
less flames…more chopping the frame to allow for a fatter tire :tup: project is really cool though ---
**Author:** ![blackout](https://avatars.discourse-cdn.com/v4/letter/b/439d5e/32.png) [@blackout](https://forums.speedlife.net/u/blackout)\ **Post date:** [May 7, 2009, 2:49pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/13 "2009-05-07T14:49:54Z")
> [@King](#): > > less flames…more chopping the frame to allow for a fatter tire :tup: > > project is really cool though Thanks. It’s not going to have any flames. Going flat black to match my truck. Frame is not getting any work done to it. I like the old school stance just the way it is… ---
**Author:** ![Carnut](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/carnut/32/7590_2.png) [@Carnut](https://forums.speedlife.net/u/Carnut)\ **Post date:** [May 7, 2009, 3:14pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/14 "2009-05-07T15:14:32Z")
Holy 1970s ---
**Author:** ![King](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/king/32/7329_2.png) [@King](https://forums.speedlife.net/u/King)\ **Post date:** [May 7, 2009, 3:17pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/15 "2009-05-07T15:17:04Z")
fltblk everything would be hottt ---
**Author:** ![blackout](https://avatars.discourse-cdn.com/v4/letter/b/439d5e/32.png) [@blackout](https://forums.speedlife.net/u/blackout)\ **Post date:** [May 7, 2009, 3:21pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/16 "2009-05-07T15:21:18Z")
> [@Carnut](#): > > Holy 1970s exactly ---
**Author:** ![stmotorsports](https://avatars.discourse-cdn.com/v4/letter/s/bb73d2/32.png) [@stmotorsports](https://forums.speedlife.net/u/stmotorsports)\ **Post date:** [May 7, 2009, 4:04pm UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/17 "2009-05-07T16:04:31Z")
awesome project :tup: I wanna say I like how the mustang tank looks on there but would almost have to see the bike put back together to get a better idea ---
**Author:** ![Quattro\_Krant](https://avatars.discourse-cdn.com/v4/letter/q/ac91a4/32.png) [@Quattro\_Krant](https://forums.speedlife.net/u/Quattro_Krant)\ **Post date:** [May 8, 2009, 2:12am UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/18 "2009-05-08T02:12:42Z")
> [@King](#): > > less flames…more chopping the frame to allow for a fatter tire :tup: > > project is really cool though That is COMPLETLY going against what the overall theme of this bike is, or will be, the fat rear tire. ---
**Author:** ![turbociv](https://avatars.discourse-cdn.com/v4/letter/t/dfb087/32.png) [@turbociv](https://forums.speedlife.net/u/turbociv)\ **Post date:** [May 8, 2009, 6:17am UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/19 "2009-05-08T06:17:14Z")
god i hate fat tire bikes.☹ I love the fact that its a triumph and someone already chopped it but im not liking the huge rake and the seat which you said was coming off anyway. solo spring seat and a shorter less rake would make this project titties. oh, and mustang tank FTW on this bike.:tup: ---
**Author:** ![JDMSIR](https://yyz2.discourse-cdn.com/flex034/user_avatar/forums.speedlife.net/jdmsir/32/7376_2.png) [@JDMSIR](https://forums.speedlife.net/u/JDMSIR)\ **Post date:** [May 8, 2009, 6:29am UTC](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409/20 "2009-05-08T06:29:11Z")
I agree, the rake is way to much, if it was a touch shorter it would look a lot better. Still awesome project. You may need to grow a mustache though. [Next page](https://forums.speedlife.net/t/1966-triumph-chopper-rebuild/67409.md?page=2)