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DIY forward controls for Triumph Bonneville & how to bleed the brakes – ep 33 p2 – Roma Custom Bike


Hey folks, I’m Custom Cez for Roma Custom
Bike and we are back for part 2 of the installation of custom forward controls on a Triumph Bonneville. By the end of this project we’ll have made
this… A custom support made from scratch that we’ll
use to install the forward controls… While we are at it we’ll move the original
brake pump… And we’ll bleed and re-set the brake hydraulic
system. In part one we fabricated the support bracket
and took care of relocating the brake pump and reservoir, if you missed it you can check
the link on the description so you can get up to speed with the project. Now we need to tackle the shifter side. I mark the center of the plate and we proceed
with drilling the support hole. Then I can remove the original shift lever. We’ll mount it pointing down so to connect
with the extension bar we got with the kit. The extension will connect to the forward
control lever effectively transferring motion to the shifter box. The universal kit is definitely not a bolt
on kit, everything needs to be modified and adjusted, starting from the extension bar. First I cut to size the external cylinder… Then, after measuring how much the threaded
bar needs to stick out, I cut that too. Now I’ll ether improve or ruin a perfectly
fine shift lever… I need to drill the hole that will allow the
extension to be hocked up to it. Everything is ready, all I need to do is screw
in the threaded bar to the new shifter… then insert the outer sleeve… and screw
in the connector that will screw onto the drilled out original lever. This way every movement of the new shifter
can be mechanically transferred to the gear box. We cut out the excess material from the original
lever and it all looks pretty clean… Awesome! It’s coming out cool. After a night of well-deserved rest I’m
right back at it! A quick curing cycle in the oven and we got
ourselves some nicely powder coated parts. I’ve done so many videos on the subject
that I decided not to document the process this time. But if you are interested, check the description
for a link to my powder coating playlist and your curiosity will be satisfied, I guarantee
it! If you are in Europe you can check the site
www.verniceapolvere.it to find powder coating equipment and powders even in small quantities. Once all the parts have cooled off I put them
back on the bike for the 743 time… Hopefully Is the last one!!! This additional support was added after hours
last night. It’s for the tension regulator so that we
can get it off the front fork, we didn’t like it there. Every piece finds its place back on the bike
and I’ve got to tell you, I like what I see,
To get the brake pump to work in its new location I have to extend the hydraulic hose that connects
it to the brake caliper. I tried to rout it the most discrete way possible
all the way to the pump… then I install the fitting. The pump and the right peg are also installed
for what I hope to be the final time. I think I can start to see the end of the
tunnel!!! Just like for the hydraulic hose, the stop
light switch cable has to be extended. Before continuing with the work I have some
pretty amazing news to tell you. Starting in September we will launch the new
DIY web series called “Roland Master Maker”. With the valuable support of Roland DG Mid
Europe that have given me free access to their equipment, from the printers to the mills,
and to their knowledge and support base, in each episode I’ll explore DIY manufacturing
projects that span outside of the motorcycle realm. This will allow me to document projects of
larger interest bat that retain that “Roma Custom Bike” spirit. So don’t forget to subscribe and click the
little bell so that you’ll receive a notification as soon as I’ll post a new video. Thank you Roland for this great opportunity
and a special thank s goes to you guys for helping me get to this point! Now, let’s get back to work. Now that everything is in place I can bleed
the brake system. It’s not a difficult process, but if it’s
not done properly it can take all day and it can compromise the quality of the braking. First of all I need to loosen the purging
fitting on the brake caliper and connect it to a length of clear plastic hose. The hose needs to be routed upward and then
looped around a couple of times so that the oil that will come out from the caliper will
form a sort of a one way valve that won’t allow the air to flow back into the system. Then everything is secured with a zip tie. Now I can open the reservoir tank… And fill it up with DOT 5 brake oil trying
not to make a mess like I’m doing right now. To bleed the system and flush out the air
I start pumping the lever and when the system is full, oil starts pouring out of the bleeding
valve on the caliper. As you can see a mixture of oil and air bubbles
are coming out of the valve. Those air bubbles have to go, because being
air a compressible gas, it would compromise the quality of the braking. After quite a lot of pumping and a few oil
refills of the reservoir, we can see that the air bubbles are diminishing until they
disappear. At this point I can tighten the bleeding valve
and then remove the plastic hose. The reservoir can also be closed at this time
and the braking system is ready to go… well, actually is ready to stop… anyway… It’s time to remove the center stand and
glance at the result of our hard work! I’m very happy with what we did; the different
elements of design are well implemented with the functionality of this project. The parts we made from scratch come out really
nice and blend in with the existing pieces like if they were conceived at the same time. The powder coating come out very nice and,
although I do like the rough metal look, the paint makes everything look more professional. Now all is left to do is try the bike out
and see if everything works. The test drive went very well. Thanks to Polsky Rage’s incredible work,
and this time he really surpassed himself, we managed to complete yet another successful
project. I’d like to invite you to subscribe to the
channel, click the like button and to check out the other videos of the series. I’m Custom Cez for Roma Custom Bike and
I’ll see you next time.

7 thoughts on “DIY forward controls for Triumph Bonneville & how to bleed the brakes – ep 33 p2 – Roma Custom Bike

  1. I’ve been wanting to do this to my thruxton. Thanks for the motivation. I still don’t understand why no one makes a kit for this

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