The 1957 Triumph Freebird returns from Bornfree 11

Just back from Bornfree 11, the 1957 Triumph Freebird is getting some further tweaks like a brass air filter. There was a minor engine fubar (push rod slipped off the rocker arm) that was fixed a couple days after I got back, and we are running strong!

There are points from the front and back where the levers and cables all but disappear. Getting the bars to look clean was one of the goals on this build. The Honda internal cable throttle and bar-end levers with strategic exit points on the bars keep everything tidy.

After coming back from the show, some tweaks were done like the bars angled a little lower, kickstand re-bent, left header pipe lengthened slightly on the muffler end, and a new yoke style lever on the rear brake panel (the one that was on there is a side-pull style opposed to the yoke style that does not torque the lever or bend the pull-rod as much.)

Once the engine was running right, an air filter had to be made before the final carb tuning could take place. Made from .050 and .032 brass sheet, the Amal velocity stack is inside and the threads are used to mount it to the carb. Everything was done by hand and eye, not using even a ruler or compass. There are ways of pressing or spinning metal to get a similar result, or even CNC, but the hand-made individuality of the pieces was what I wanted for not just this part, but the whole bike.

It would be hard to not make it out of brass at this point. Also noticing once again how artfully Jason Small made the paint line on the tank.

The brass hardware from the original Amal 389 carb fit the new carb perfectly. It does not bother me to see the scratches and nicks on it.

Salt shaker muffler grills.

The amber capped kill switch works fine.

Some ground-level details. There is a pipe that runs between the oil tank and battery box, connecting with the oil tank vent on one end and the engine crankcase vent on the other. An upside-down “Y” comes off the tube just above the sump level and drains to the catch-can/chain oiler. The primary cover vent also drains into it via a separate tube. The voltage regulator can be seen below.

Once again, the levers disappear. The seat cover design by Paisley of Penny Goods Leather echoes the tank package rack. I was just going for the ribs down the seat in the traditional form, but she came up with this design and it looks so much better because of it! The Small Time Motors paint job by Jason Small continues to blow me away as well. It was definitely the sleeper strategy to bring such subtle colors to a chopper show. The response was about what you would expect…about one person out of a hundred dug on it.

I do not mind the signs of use as long as it is honest. The appearance of leather grips after some use warms up and humanizes the bike. The Wade Oliver Wilson engraving on the levers and kick start pedal was a big hit at the show.

Just a little lowering of the bar ends makes for a better profile and fit.

Another example of hiding a cable in the silhouette of the bike on the front brake cable. making it a little longer or shorter makes it more noticeable.

Detail of the pannier inside. Once again, I did not ask for some of the detail like the inner canvas pocket, but was stoked with the outcome!

I always want the tail end of a bike to have a certain look. Tidy and sexy is the only way to describe it. Sometimes it works, sometimes not. Happy with this one.

The 1957 Triumph Freebird inches toward completion.

Getting the last of the puzzle pieces together to complete this build. The engine is now back together, the cables and controls are completed, everything on the electrical system is done except the battery hook-up and kill switch, wheels are completely built, all just waiting on the final pieces. The seat is being upholstered and the panniers are starting to get the hardware applied. As soon as the battery arrives, the battery box can be completed and the oil bag and hoses put on. With all that done, the wheels will go on and we will have a roller!

A new Lucas magneto advance unit was sourced from England. After seeing what happens to fiber gears, I went for the alloy drive gear option.

A little of the red accent color was used in the script on the primary cover.

A new backing plate , pivot and spring arrangement for the choke inverter has it working well. The brass rocker tubing was routed and just needs to be hooked up at the oil bag.

Really happy with the blends of color and texture. Between the brass, leather color, cadmium and chrome plate, and the paint, there is a softness that I was hoping to achieve.

The Amal 389 carb will probably get a polish and an air filter may get made, but the engine is otherwise done. As soon as it is on the ground, the exhaust will be put on, and by all appearances it will be a complete bike.

A lot of effort went into keeping the bars clean and the cables tidy

There will be some leather-wrapped grips that match the rest of the upholstered parts.

This is the first time to see the footpegs on the bike with the new brass treads.

With the magneto advance unit in place and the engine timed, the side covers can finally be put on. The original brass emblem was reapplied with some new mounting pins.

The panniers are going together. Penny Goods Leather made the flaps and covered the inside and outside of the boxes, adding the canvas pocket. The hardware is being riveted to the front side of the boxes while the rear portions are still getting some finishing at the leather shop.

A little rough still, but the basic form can be seen.

Last minute details before the 1957 Triumph Freebird goes to Bornfree 11.

A mechanism to invert the choke lever. The carb being used is an Amal brand. Their chokes require a cable pull to turn them off, backwards from most choke actuators. Because the vintage Doherty choke lever that I am using would end up with the lever sticking straight up on the handlebar to turn the choke off, a fix was needed. It is made of brass and will be completed when the new carb gets here.

Here is the Doherty choke lever. The natural patina on this piece and the steering damper knob seen just behind it were the inspiration for the brass patina given to the hand-built parts.

Some vintage alloy exhaust collars. I have been warned about their tendency to expand and loose grip when heated, but just going to have to make sure the exhaust is well tethered. They were sanded and shaped a little, buffed smooth then bead blasted.

Bright and satin finishes together. I love this look and have used it on a lot of my bikes. There is always a question as to when to go to one finish or the other, trying to keep it balanced.

Alien mini-drone or voltage regulator? A brass cover was made for the Podtronics brand voltage regulator. The unit was shaped a little to contour it and make it a little smaller. This picture was while it was being worked on. The final version is finished with the same patina as the rest of the pieces.

The regulator has a brass tube that comes out the back and allows the wires to pass cleanly to the battery box.

Inching along. The colors were chosen to soften the look of the bike and be a backdrop for the more blingy parts.

Test fitting parts. Some of these parts have been on and off the bike a couple of times as the final tweaks on electrical and plumbing are worked out.

At this point, the wheels and covers could be slapped on and it would look finished, but still more to go to get it right. This needs to be a fully functioning and ridable bike when it gets to California.

Cam timing. The head-steady mount makes a great mount for the feeler gauge, but long ramp quieting cams are a little odd to deal with.

An alloy spacer made for the footpeg mount.