How to Restore the Triumph : TR5/250 and TR6

by Williams, Roger

• ISBN13: 9781901295924
• ISBN10: 1901295923
• Format: Paperback
• Copyright: 2001-10-21
• Publisher: Motorbooks Intl

Summary

This book, which covers all Triumph TR5/250 and TR6 models, explains the characteristics of the different models, what to look out for when purchasing one, and how to restore a TR cost effectively. The author uses his restoration experience and the help of various TR specialists and professional restorers to provide truly detailed coverage of a complete restoration and good advice on how to overcome common problems.

Table of Contents

Acknowledgements and about the Author	6	(1)
Foreword	7	(1)
Introduction and using this book	8	(2)
Which TR to choose?	10	(9)
Selecting your first TR and buying tips	10	(1)
A review of the TR range	11	(1)
Origins	11	(1)
Sidescreen TRs	11	(2)
Non-sidescreen TRs	13	(3)
The ``Wedgies''	16	(1)
Conclusion	17	(1)
Buying - some golden rules	17	(2)
Body, paintwork and trim	19	(9)
What to check when buying	19	(6)
Mechanical matters	25	(1)
Inspecting the IRS TR chassis	26	(2)
Preparing your restoration plan	28	(7)
Stripping the car	28	(1)
Do you have the contacts?	29	(1)
Chassis or body first?	29	(1)
What and where To paint?	30	(1)
A typical home restoration plan	30	(4)
Spare parts	34	(1)
Body restoration	35	(19)
The Michelotti - Karmann differences	35	(1)
Minimising body repair difficulties	36	(1)
IRS car body repairs	36	(1)
General body restoration	37	(1)
The doors	37	(3)
One-piece body repairs	40	(2)
Two-piece body sequence	42	(2)
Ongoing matters	44	(3)
Additional details	47	(5)
New TR5 and TR6 bodyshells	52	(1)
Sand blasting	52	(2)
Chassis restoration	54	(13)
Main areas of corrosion	56	(4)
Modifications and improvements	60	(1)
Lower wishbone mountings	61	(2)
Strengthening the lower mountings	63	(2)
A replacement chassis	65	(2)
Painting, plating and rust prevention	67	(8)
Galvanising	67	(1)
Painting your chassis	68	(1)
Powder coating	69	(1)
Painting body tub and panels	69	(1)
Step 1: zinc primer	70	(1)
Steps 2 and 3: etch priming and final gloss finish	71	(1)
Doing your bit	72	(1)
Other painting detail	72	(1)
Stone-chip protection	73	(1)
Bright metal finishing	73	(1)
Chrome plating	73	(1)
Component preparation	74	(1)
Rust prevention	74	(1)
Restoring engine and clutch	75	(19)
Introducing the `six-pot'	75	(1)
Rebuilding the bottom end	76	(1)
Crank thrust washer refitting	77	(2)
Lubrication matters	79	(2)
Additional bottom end details	81	(1)
The top end	81	(1)
Removing the head	81	(1)
USA cylinder heads	82	(2)
Other top end detail	84	(1)
The clutch	85	(3)
Assembling and fitting the engine	88	(6)
Modern oils and fuels	94	(5)
Running-in/breaking-in and engine oils	94	(1)
Oil thermostats	94	(1)
Using unleaded fuel	95	(1)
`Unleaded' cylinder head	96	(2)
Anti-run-on valves	98	(1)
Gearbox (Transmission) and overdrive	99	(8)
Overdrive matters	101	(1)
Problems and solutions common to 'A' and 'J' types	101	(1)
The 'A' type overdrive	102	(3)
The `J' type overdrive	105	(2)
Petrol injection (PI) system	107	(11)
Petrol injection reputation	107	(1)
Faults mistakenly attributed to PI	107	(3)
PI system problems and solutions	110	(1)
The PI system in outline	111	(1)
Throttle mechanism	112	(1)
Checking and correcting fuel pressure	113	(2)
The original CAV fuel filter	115	(1)
The fuel pump and motor	115	(1)
The metering unit	116	(2)
Carburettors	118	(5)
Identifying your carburettor	118	(1)
Preliminary operational checks	119	(2)
Adjusting idle speed	121	(1)
Balancing twin carburettors	121	(1)
Replacing the throttle spindle	122	(1)
Front suspension and steering	123	(8)
Reasons for a suspension rebuild	123	(1)
Improving handling	124	(1)
The TR2, 3, 3A and 4	124	(1)
The TR4A/TR250/TR6	125	(1)
The upper fulcrum pin	126	(1)
Improving the steering	127	(2)
Additional tips and suggestions	129	(1)
Front coil spring compressor	130	(1)
Rear suspension and differential	131	(10)
Triumph IRS system	131	(1)
Trailing arms	132	(2)
Differential alternatives	134	(3)
Driveshaft details	137	(1)
Universal joint longevity	138	(1)
Rear hubs and bearings	139	(1)
Spring compressors	139	(1)
Summary of upgrades	139	(2)
Brakes	141	(5)
Background	141	(1)
Brake lines	141	(1)
Identifying brake calipers	142	(1)
Brake servo performance	143	(1)
General brake tips	143	(3)
Miscellaneous matters	146	(5)
Electrical suggestions	146	(2)
Improving security	148	(1)
Bonnet release cables	149	(2)
Interior trim	151	(14)
Restoring the wood veneer	151	(1)
Sound deadening felt and carpet fitting	151	(6)
Internal trim panels	157	(2)
Seat belts	159	(1)
Rebuilding the seats	160	(4)
Boot/trunk panels	164	(1)
Hood/Soft top	165	(8)
Rebuilding the hood frame	165	(2)
Fitting the hood	167	(4)
Hood maintenance	171	(2)
Lefthand drive to righthand drive conversion	173	(7)
Predominance of LHD cars	173	(1)
Preparation/stripping	173	(1)
Steering	174	(1)
Pedals	175	(2)
Hydraulics	177	(1)
The wiper change	178	(1)
Electrics, dashboard and instruments	178	(2)
Conclusions	180	(1)
Appendix 1: Clubs, suppliers and specialists	181	(2)
Clubs	181	(1)
UK specialist TR restorers, repairers, dealers and spares suppliers	181	(1)
Overdrive repair specialists	181	(1)
Gearbox rebuilding	181	(1)
Chassis repair and manufacture	182	(1)
Paint manufacturers/specialists	182	(1)
Hood renovation products	182	(1)
Chrome restoration	182	(1)
Electrical	182	(1)
PI specialists	182	(1)
Cylinder head refurbishment/unleaded compatibility	182	(1)
Body repair tools and equipment	182	(1)
US spares suppliers	182	(1)
Paint manufacturers/specialists	182	(1)
Appendix 2: Welding, tools and techniques	183	(7)
Welding	183	(1)
The alternative methods	183	(1)
Welding equipment	184	(1)
Additional equipment	184	(1)
Safety	185	(1)
Learning to weld	185	(1)
Types of welds	185	(1)
Seam/stitch welding	186	(1)
Basic metal forming and adjustment	186	(4)
Index	190