Trojan Classic Motorcycles: Full Metal Jacket

Customer Filip has been heavily modifying a Triumph T100sc. This is his first bike and we can't stress how enthusiastic and determined this guy is. No matter what problems arrise, he refuses to give up.
Some hard lessons learnt along the way (trusted a dodgey mechanic and the first engine re-build stung him hard), also a few people claiming to be able to tackle jobs they are not capable of - welding for one...
But that's all in the past as this beast is now coming along nicely!
We have been offering advise and supplying parts for this build from it's humble begginings and it's good to see it in it's finishing stages.

The following is basically how the machine arrived to us, but i will get the early stage pics because the amount of work involved to get it to a roller was quite amazing - especially for the fact that Filip built 90% of it in his flat living room!!

Filip was right to be suspicious about the previous "engine builder".

When we started to strip down this abused 500cc, we were astounded to say the least!

The head was painted gloss black, but they didn't remove or mask the valves, springs etc. The exhaust valves were burnt and the guides worn.

Removing the paint was very painstaking as they painted the head without removing tar, grit and the usual contaminents.
In a nutshell, they pulled the head off, quick degrease and painted everything as it is.

The barrels now off and we found new piston rings installed on standard old, worn and damaged pistons. The bore also had scores and was not honed.

With the timing cover off we have come to the conclusion that the cases have never been split...Hope at last! I say hope because if no
one has touched the bottom end then the chances are that the damage stops here.

Just when we had our hopes up we removed the inner and outer g/box cover and we were shocked beyond belief...The picture tells the story.

The gear cluster looks like it's been in a sewer, no wonder Filip was worried that his gears were not shifting by hand and k/starter won't work!

I'm amazed at the fact that the bloke who "re-built" this engine ever thought that he would fool anyone into attempting to fire it up!
SHAME!!!

The Re-build:

We Hydro Tech blast alloy parts and polish covers, it's the best way to go, if you want details, please contact us for more details regarding this process.

This is how a Triumph alloy head should look.
It wasn't easy to get all the crap off it but well
worth the effort.

Chemical cleaning and balancing is imperative to any engine re-build.

Crank, rods, cams and pinions installed and cases now ready to marry.

If your engine is not this clean during the re-build, then you're not doing it right.
Take your time, have plenty of white cloth rags
hanging about and keep wiping!

Next - Rings gapped, pistons to conrods to take bored, honed and painted barrels!
Don't forget to cover the cases when installing the piston circlips. That's the last thing you need. Dropping a circlip down the cases...

At this stage we like to triple check everything... And everything is perfect!

Getting close, we have re-built the head, rocker assys completely and torqued it down to the barrels.

The gearbox and clutch assy are also assembled.

The engine is now ready to fit onto the motorcycle.

It does help to have someone help guide or lift to avoid any damage to the frame or other components - not to mention personal injury.
Time now to align the engine, tighten bolts and double check everything.

We are very pleased with the result so far and Filip is preparing a headlight bracket and other odds and ends.
The next stage is the exhaust and elecrical system. Carby and Dizzy are also ready to install.

Carb, plumbing, headers now mounted and Filip seen here wrapping the pipes with heat tape - Dirty job but someone has to do it.

Today is Filips' day!

Wiring all done, oiled up and ready to go.
God only knows the last time this bike was ridden, but one thing i can say is that Filip didn't want to stop riding!