Dedicated to providing information and resources for the Hinckley built Thunderbird Sport

 
  What you need.
  • Napoleon Bar End mirrors (2 each) (Old Britts #70-201002 Chrome or Black)
  • Velox rubber end plugs (optional - 2 each) (limited availability at bicycle shops)
  • Problem Solvers 10mm Brake Stud Plugs (available at bicycle shops)
  • Small round file
  • Vernier Caliper
  • Razor knife
  • M5 x 60 mm fastener, preferably stainless (2 each)
  • Split lock washer (2 each)
  • After acquiring the necessary items to complete the job remove both of the OE barend weights from the handlebar.

  • With the vernier caliper measure the distance from the end of the handlebar to the plug inside as shown. In case you didn't know, the metal bit that slides out the bottom of the caliper is for measuring depth.

  • Using the measurement from the caliper, cut the Velox plug down so that it's depth will allow it to fit flush against both the handlebar end and metal plug inside.

  • Using the round file, enlarge the hole in the Velox plug so that it will just fit over the section of the mirror that fits into the handlebar. You will need to make a notch in the plug to match the one on the mirror.

  • Insert the Velox plug into the handlebar to check that it stops against the plug inside yet does not have a gap between flanged end and the handlebar end. If it does, remove a little more of the plug end.

  • Put the split lock washer on the M5 x 60 fastener and insert the barend mirror into the Velox plug. Tighten. The flange on the Velox plug will compress filling the gap, aid in stabilizing the mirror and reduce some vibration. 

  • Install the bicycle brake boss plugs into the original mirror mounting points.

  • Job done! Now do the other side!

  • I found that the rearward vision is greatly improved and the classic look of Triumph's design work is preserved.

  • I'm not sure if there is any difference in distortion from vibration over the drill and tap method.

Footnote 1:
After a couple of years the Velox rubber plugs split. I feel that this failure was due to not enlarging the center of the plug enough to allow the mirror to pass through without overstressing the rubber.  I've since installed Speed Triple handlebars and Adventurer handlebar clamps. The Speed Triple handlebars allowed the use of the original Napoleon hardware. Distortion from vibration was about the same.
Footnote 2:
If you have access to a machine shop you can have spacers machined from stainless steel, aluminum or some high tech plastics instead of using the Velox plugs.
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The information, opinions, recommendations and experiments are that of Thunderbird Sport and Hinckley Triumph riders from around the world. Before performing any modifications to your Triumph motorcycle consult your warranty, local vehicle regulations and mechanical skill level.

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