TR6 work log

copied from the ongoing google spreadsheet:

Project Status Date Description Notes
Headlights done 8/20/2018 got halogen light kit on sale at TRF Installed halogen lights, much brighter now. Added backing plate for passenger side where hole too large for screw.
radiator shroud done 8/1/2018 missing fiberboard version from TRF installed
Door panels done 7/22/2018 shrunken, warped New panels from John Skinner, ordered at the same time as the seat covers. Installed with velcro instead of metal clips.
Reuphoster seats done 7/17/2018 Both seats need a complete rebuild: foam is crumbling, covers need to be replaced Winter-spring 2018 project, finished both and reinstalled July 2018. Foam and covers from John Skinner, new dunlop straps from TRF, all new stainless fasteners.
convertible top done 7/1/2018 needs patching or replacement, some snaps pulled out, missing some sealing pieces, straps gone. It's not the original top, and not as bad as expected; leaky, but no huge holes. Patched and reinforced holes where snaps pulled out, polished windows, replaced edge velcro strips.
Bent pushrod done 5/6/2018 Adjusting valves because of extra tapping noise and found #11 pushrod bent. This is on the same valve where the rocker broke a while back. Assuming a persistently sticky valve. Replaced pushrod with new, readjusted valves. Will recheck after some miles.
new tires done 10/1/2017 after suspension work and alignment done Yokohama Avid Ascend 205/70-15 from Discount Tire.
repaint wheels done 9/20/2017 wheels are a little ratty, clean and repaint in prep for new tires Used standard silver wheel paint from parts store, pretty close match to original
check, repack front hubs done 10/1/2017 Front hubs are quiet, but a little loose - check bearings and axle, replace or repack. Maybe get spacer kit to get rid of flex. Checked bearings, look good, plenty of grease, only reassembled and adjusted.
Headlights and side lights done 10/1/2017 Check side light wiring for good grounds and replace bulbs as needed. General running lights working fine. Added headlight relay kit from Moss, headlights seem a bit brighter.
replace water return tube done 9/1/2017 part of manifold project, pipe seems to be seeping coolant replace with stainless version
replace manifold gasket done 9/1/2017 exhaust side definitely leaking, maybe also intake side? Used 2 standard manifold gaskets. Had intake vapor blasted, used slip plate on exhaust. Installed all new manifold studs, new lock washers and brass nuts. Much quieter, better idle at all temperatures now.
steering wheel cover done 9/1/2017 Wheel rim is partially wrapped in electrical tape, original foam is splitting and missing a chunk Installed wheelskins custom cover, 15"x2.5", with strip of foam bike bar tap on the inside for a little extra cushion and size
replace turn signal switch done 9/1/2017 End of lever broken off. new Lucas replacement
steering column bushings done 9/2/2017 wheel is sloppy, turns hard Installed standard bushing kit, adjusted steering column location for proper fit. Much smoother.
horn done 9/3/2017 doesn't work Horns were corroded beyond fixing, replaced with new ones. Installed new steering wheel contacts, horn operation is still somewhat sporadic.
engine hesitation done 8/1/2017 Engine periodically hesitates when cruising at 3500 rpm or above. Fuel pump? Distributor? Coil? Vacuum lines? Try blowing out fuel line between tank and pump. Carbs rebuilt by Mike winter of 2017, Bill rebuilt distributor. Idle and power much better.
heater control switch done 10/1/2016 started leaking replace with upgrated Everco valve
Headlight wiring done 9/1/2016 Only works when high beams are on, bad switches? Maybe install relay kit and/or halogen bulbs for better light. new headlight adjusters 9/2016, high/low beams working after cleaning contacts
u-joints done 5/1/2016 clunk when shifting forward/back is diff bushings, but u-joint should be replaces as we do other rear-end work replaced 4 u-joints in axles as part of rear suspension project
door seals done 9/1/2016 doors rattle even though latches adjusted tight, especially passenger side installed new furflex seal around doors
differential leak done 5/1/2016 front pinion seal Mike replaced seal, cleaned out disgusting goo from diff, painted, new cover gasket
front suspension done 5/1/2016 shimmy at highway speeds, metallic clunking over bumps, vague steering New bushings, new front shocks and springs, tie rod ends, sway bar mounts. Lower a-arms done 9/2015, remaining front done 5/2016
Rear suspension done 4/1/2016 Rear tires rub shocks with 2-people in the car. Check swingarm bushings, replace springs and find a replacement for the shocks; either original levers or new tube shock kit. New springs, swing arm bushings, adjustable brackets, new shock mount kit and new tube shocks
rear hubs done 4/1/2016 rear hubs have play. Larry Berg with MN Triumphs rebuilt them, part of rear suspension project
Front brakes done 3/1/2016 car pulling to one side, left caliper dragging rebuilt calipers, new pistons and seals, painted black, new hoses for installation
Door waist seals done 3/1/2016 To help with rattling windows, reduce rattling Made installation tool, a little hard on the hands, but 1 less rattle.
Brakes done 8/1/2015 check and replace as needed, left rear adjuster frozen Has new right rear wheel cylinder, new rear adjusters, replaced all fluid with DOT5 silicone. Master cylinder rebuilt and new servo installed.
change oil & all filters done 6/1/2015 change to spin-on oil filter installed spin-on filter kit (Fram PH3600)
clutch done 5/1/2015 Pedal drops to the floor, either hydraulic failure or broken fork pin. Assume at least rebuilds on both master & slave units, hydraulic flush & bleed. Evaluate for clutch disc after initial connection fixed. All new hydraulics & hoses, used DOT 5 silicone fluid. Plate seems fine, just a little chatter, needs a firm foot.
radiator hoses done 5/1/2015 lower hose leaking all new black hoses & clamp kit, new thermostat + gasket
check for frame rust/cracks done 5/1/2015   Frame looks solid, diff mounts already reinforced, no bubbling around t-shirt area or trailing arms. Trailing arm mounts seem solid.
engine tune up done 5/1/2015 test and record cylinder compression, crank thrust bearing clearance new plugs, wires, cap, rotor, condenser, points, fan belt, new breather hoses, new vacuum line for brake booster
thrust washer done 6/1/2015 excessive clearance Washer had dropped in to pan. Installed .015 washer, slightly reduced to .013, had .004 clearance at installation. Some deformation on crank journal face, should do 360° bearing and cap in the future for better fix.
door latches done 8/1/2015 a little sticky, doesn't close very tightly Both sides cleaned and lubed. Latches adjusted so the doors close tighter
passenger seat done 8/1/2015 doesn't latch in position, clean & grease. Both seats a little loose on the rails. Cleaned and re-greased passenger rails, latch a little sloppy but holds fine
seat belts done 8/1/2015 belts way too long new lap belts installed (belts dad had bought)
keys done   check that doors & trunk lock, extra keys as needed 2 sets made; ignition and trunk
Fuel system done 7/1/2015 check system for issues relating to old gas, fuel gauge unreliable Cleaned and patched fuel tank, replaced fuel pump, new sending unit, flushed remaining lines, new filter, cleaned carbs
Diff mount bushings done 9/1/2015 slight clunk when switching between forward and reverse Rear diff bushings replaced with poly, greatly reduced clunk from rear-end. Will replace front when diff is dropped for other service.
brake light switch done 10/1/2015 brake lights always on cleaned and greased switch, reinstalled. Have a new switch if needed.
engine tuning done 9/1/2015   Valves adjusted, carbs cleaned up after stuck needle valve, rebalanced, timing adjusted by vacuum. Vacuum reading good, but a little bouncy, added seafoam to clean up potential valve buildup.
fix rattling door windows done 10/1/2015 Original felt is shot, missing outer door seals relined window channels with velcro, oiled mechanisms
change gearbox and diff oil done 10/1/2015 used Valvoline GL4/GL5 80W-90 Old gearbox oil looked hazy and green. Diff oil just topped up. 9/2017, changed gearbox to Redline MT90, and it's shifting much smoother.
front suspension done 10/1/2015 bad shimmy at highway speed, upper control arm bushings totally shot, rattling over bumps New upper control arm poly bushings, new ball joints, new front shocks with poly bushings. Other bushings purchased, not yet installed; knocks are much better, but still shimmies around 55-65.