Author Topic: 1978K Resto-mod "HaCkJoB"  (Read 23932 times)

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Offline Killer Canary

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #50 on: October 22, 2012, 12:46:24 PM »
I believe the damping adjusters on the bottom of the legs are supposed to be facing the rear of the bike.
If it's worth doing at all it's worth over-doing.
Honda MT250, CB400F, CB450K, CB550, GL500, CBR929
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Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #51 on: October 22, 2012, 08:03:15 PM »
You're probably right :) I've never messed with any of these forks before and was waiting on my calipers to come in to tell me which way they go. LOL
The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #52 on: October 22, 2012, 09:10:02 PM »
Mounted some old tires for a more accurate mock up. 110/90-19 front & 120/90-18 rear. The swing arm would easily hold a 130 , or maybe wider , rear tire. I don't know if I will go bigger or not. I also messed around with these pipes some more. I think I might stick with this setup. I kinda dig it. I'm also kinda digging the silver rims on the blacked out bike for now. It's growing on me....

PART_1350962283763 by Shiny Ribs, on Flickr

PART_1350961473630 by Shiny Ribs, on Flickr
The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #53 on: October 26, 2012, 10:10:24 PM »
I redid the turn out.Kicked it up a tad and made a muffler for it.Each side of exhaust weighs in at 8lbs .

SANY0078 by Shiny Ribs, on Flickr

SANY0074 by Shiny Ribs, on Flickr

SANY0075 by Shiny Ribs, on Flickr

I also shaved the sidecovers for a more modern look and kicked the side stand up out of the way.

SANY0089 by Shiny Ribs, on Flickr
Made some new pegs.

SANY0098 by Shiny Ribs, on Flickr
I have been contemplating making some sort of heat shields ,just for looks, but am completely undecided on the idea.Any thoughts?

SANY0095 by Shiny Ribs, on Flickr

SANY0093 by Shiny Ribs, on Flickr

SANY0092 by Shiny Ribs, on Flickr


The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline Mugen_Stumpo

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #54 on: October 27, 2012, 07:36:18 AM »
looks great imo :)

Offline Godffery

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #55 on: October 27, 2012, 11:30:47 AM »
I'm think'n that Suck'a is gun'a be LOUD.?!  8 O

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #56 on: October 27, 2012, 11:04:59 PM »
Haha. Nah,it wont be too bad.I built a similar muffler for my other bike and it sounds OK.Quite enough that you can ignore it on the highway. Speed holes suck to drill >:( Pegs and foot controls are done-126 holes in all. I gotta couple holes off on the brake stem. I dont care right now.I'm tired of holes....

SANY0106 by Shiny Ribs, on Flickr
I pulled the bike out to get to the other side and now I'm kinda diggin the silver s-arm. I dunno. But that rear rotor has to go. UGLY ! At the least,it will get severely drilled. No more holes,please! :'(

SANY0111 by Shiny Ribs, on Flickr
The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #57 on: November 18, 2012, 10:43:21 PM »
Update time.


Foot controls pc'ed. The drilled tubes I heated with the torch until I got the desire color then pc'ed them clear

SANY0138 by Shiny Ribs, on Flickr
Rear m/c tab made and mounted

SANY0135 by Shiny Ribs, on Flickr
Bars and hand controls all sorted. Switches gone through inside and then everything pc'ed to match

SANY0151 by Shiny Ribs, on Flickr

SANY0152 by Shiny Ribs, on Flickr

I made a set of mini-risers to mount the bars to the gixxer top yokes. Worked out easy enough,but still need to be final shaped

SANY0153 by Shiny Ribs, on Flickr

New steering stops. Stainless stops so no chipped PC

SANY0151 (2) by Shiny Ribs, on Flickr

Steering stabilizer mount tab

SANY0153 (2) by Shiny Ribs, on Flickr

Welded on the bike ,then torched and bent in to proper alignment


SANY0155 (2) by Shiny Ribs, on Flickr
Oil system is finally done. Main tank:

PART_1352593965064 by Shiny Ribs, on Flickr

Pretty tight fit. Chain notch and another notch for the shock body

PART_1352438359912 by Shiny Ribs, on Flickr

Tucked in the frame.Dipstick will hide nicely behind the side cover

PART_1352593935252 by Shiny Ribs, on Flickr

Oil return line making a hard u-turn past the s-arm!

SANY0159 by Shiny Ribs, on Flickr
Breather tank for the oil system. The main tank allows me to run at full stock oil capacity,but left little room for venting/breathing.

SANY0152 by Shiny Ribs, on Flickr
Unused axle nut off the GXSR front end turned oil fill tank

SANY0152 (2) by Shiny Ribs, on Flickr

It peeks out from behind the fuel tank  ;)


SANY0160 (2) by Shiny Ribs, on Flickr

Oil line adapter made


SANY0124 by Shiny Ribs, on Flickr

Stubs locate the o-rings just right  :)

SANY0131 by Shiny Ribs, on Flickr

Altogether,mounted and hoses run

SANY0154 by Shiny Ribs, on Flickr

I redid the electrics under the tank. Solid state R&R now.

SANY0166 by Shiny Ribs, on Flickr

Doctored up this points cover.


SANY0156 by Shiny Ribs, on Flickr

SANY0161 by Shiny Ribs, on Flickr

Pretty pleased with the results myself

SANY0156 (2) by Shiny Ribs, on Flickr

I have this whole next week off. Hope to make some good progress!   Later on!...


The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #58 on: November 19, 2012, 09:16:03 PM »
Windowed the clutch cover to match

PART_1353374225394 by Shiny Ribs, on Flickr

Alright,I know all you guys have better things to do,but opinions would be greatly appreciated on this side cover idea I have going on right now.

The idea was to mount the side cover behind the tubing to help preserve some of the open frame look,and to keep a more narrow look to the rear section. The little wing off the back is what it takes to hide the battery 100%. I'm not opposed to flat blacking the battery and losing the wing...or the whole shooting match for that matter.
good or bad,let me know what you think. If it really does look like poo just say so. I can take it :)  LOL


SANY0153 (2) by Shiny Ribs, on Flickr


SANY0152 by Shiny Ribs, on Flickr


SANY0150 by Shiny Ribs, on Flickr
The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #59 on: November 19, 2012, 09:17:55 PM »
Oh,and the idea (for now?) is to leave the side cover raw AL to contrast the dark frame.
The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #60 on: November 21, 2012, 10:22:02 PM »
Front axle sorted out :)


SANY0157 by Shiny Ribs, on Flickr

SANY0159 by Shiny Ribs, on Flickr
The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #61 on: November 23, 2012, 06:45:50 PM »
PO's suck. Replacing a plug before storing is not all that hard  :'(  Fingernail grabber under the arrow.


HJ-bore rust by Shiny Ribs, on Flickr

The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline lucky

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #62 on: November 26, 2012, 09:11:36 PM »
A lot of very good work!!

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #63 on: November 29, 2012, 08:52:03 PM »
Thanks for the compliment Lucky. And thanks for the interest as well :)
The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline Badluckhonda

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #64 on: May 06, 2015, 03:26:27 PM »
So you're gonna be running the stock wheel ?

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #65 on: May 06, 2015, 03:28:11 PM »
Actually. The whole bike pretty much changed directions. I'll update tonight.... it's gonna be a long update. lol

But, to answer your question, no. I dumped the Comstars and went with flanged alloy rims on stock hubs.
« Last Edit: May 06, 2015, 03:29:52 PM by shinyribs »
The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline Badluckhonda

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #66 on: May 06, 2015, 04:35:35 PM »
The comstar and spoked wheel run the same axle up front right ? I ask because I like the axle spacers you mad

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #67 on: May 06, 2015, 05:33:44 PM »
The axle diameter is the same, I don't recall if it is the exact same axle or not. But the GSXR front end didn't really work out. Tree offset brings the forks too close to the bike and using the stock 19'' tire up front created some serious tire-to-header clearance issues. Also, they are so short ( about 2.5-3'' shorter than stock) that ground clearance was also an issue.

I ended up just popping that front end on to my '76F right before I sold it. Those forks did ride beautifully, though. Extremely smooth and properly sprung for a bike of this weight.



I ended up with CBR1000 forks (Hurricane) on this bike. I thought conventional forks looked more like they belonged and they gave me really nice ground clearance. The forks go on with an extremely simple stem swap and tapered bearings. The trick was mounting the CB hub to retain a 19'' spoke rim.

Quick dump of the whole process. I can provide details if needed.


Had to make a new axle spacer for inside the hub since converting to a 20mm axle. Kept the wall thickness pretty thick since it's AL, so needed a way to be able to knock the bearings out on a later date if needed. So I went with notches.




It droops a tad, but the axle goes in easily anyway. Plenty of access there to remove the bearings.



I think I'm actually using this rim backwards on this bike due to making room to use the speedo drive that came with this front end. It was designed to run on the left side of the rim and I'm pretty sure stock on the SOHC bikes was opposite. I don't know...just make it all fit,right?

Anyway, here's what it started as:



The original lip on the SD kept it from being able to hit the bearing inner race so that had to be trimmed. Once on the axle, and in the forks, I just tapped the axle deeper and deeper until the rim was centered. That made it where I didn't have to shave the SD down any and only would have to make a spacer for the right side of the bike.



This left a gap between the hub and the SD,of course. Made a spacer for that. Looks like it's touching,but it has .010'' of room to float.





You probably noticed the machine screw on there. I tapped a hole in the hub to put that in there to drive the SD. Just gotta get a 10-32 set screw to replace that with that will sit flush and not interfere with the rotor.




You probably also noticed that the bearing retainer portion of this rim was pretty chewed up looking. Those bearing retainers aren't really needed. If you look at modern bikes they don't use them. Once both bearings are in and the spacers are clamped between the forks the rim can't move off the bearings. But since this thing was chewed I just decided to make a spacer to hide it. Was easier than unlacing the rim to turn that face down pretty again.



Just like the other spacer this one looks like it's touching but it floats. Its locked to the bearings,of course,but has .010'' gap away from the rim.

The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #68 on: May 06, 2015, 05:44:40 PM »
Made some adapters to fit up a single front rotor. Dual discs would have been too much on what eventually turned in to a tracker build. I can't remember what the rotor came from. A Ducati, but I'm not sure which. It's in my notes somewhere.




Caliper is a 6 pot from a Hayabusa.

I got my front caliper mount made,but it took me about 3 hours. I had never done this before and was kinda at a lost on how to measure everything. I finally came up with a way that worked pretty well for me, so I figured I'd post it here incase it may help someone down the road.

Pics will explain after I try to describe.

Chuck your bolt in the tailstock to align it.



Add a nut to give it extra stability. Pure luck that the diameter of my button head matched my nut. Using all hex's you'd be set anyway.



Turn down the tip of the bolt to have a perfectly centered locating pin.

Once I dod that just play around with washers and all until all of the fork leg caliper mounting bosses and the caliper itself has a bolt poking through it with those little locater pins (no pic,sorry). Hold everything in place and press a thin of cardboard in to the pins.

That should give you all of your holes plotted out and ready to be transferred to your material. Hope this helps someone save time.


I'm running real close to the disc on this setup. Everything is pushed way out towards the fork leg so that the caliper will clear the spokes. This is twice I've ran in to caliper-spoke clearance issues using modern calipers on old spoked rims. Probably best to use calipers with dead pads on the inner side.





The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #69 on: May 06, 2015, 05:54:34 PM »
While we are still talking front end...headlite mounts.






Then bent up some tubing to make the arms.


Drilled & tapped the headlite bucket bolts to accept signals. Hides the wires inside the bucket this way.


Ended up going to a pair of 1 1/8'' bars, but not seeing those pics atm.
The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #70 on: May 06, 2015, 06:01:07 PM »
Hydraulic clutch conversion. Slave cylinder is from a Cannondale, but not sure what model.

The wall in the center is for the bearings (for the push rod ) to press up against. The four holes drilled in that wall are to allow oil to flow through to lubricate the single-ball bearing on the end of the SC piston. Machined a groove for a snap ring so I know the bearings can never fall in to the engine.I never could source a nice, long single bearing for this. Kinda hate using double stacked bearings like this, but...you do what you gotta.




Of course, pop off the dust covers so the oil can actually get inside and around the bearings.


Here's what the pushrod ended up looking like. The small end fits inside the pressure plate, the hub is so it can't fall in to the engine,which it can't do anyway,but I still felt like doing it.



So it slides in like so. If you look in the four oiling holes you can see some of the balls in the bearing. It lined up nicely.



Then the slave just plops down right on top. Easy-peasy! I know two of those "bolts" are actually counter sunk fasteners,which don't belong here, but that counter sink come in handy. If you use that after tapping the first hole it centers the fastener in the hole of the part perfectly. I taught myself that trick...tonight...due to a lack of proper hardware. Still a neat trick,though...




Side view with the pushrod poking out...ready for bidness.



And on the bike.





« Last Edit: May 06, 2015, 06:09:15 PM by shinyribs »
The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #71 on: May 06, 2015, 06:03:07 PM »
Oh yeah, made up a little cover to give it a nice,finished look.

*EDIT: some of this is horribly out of synch with real time. lol. But it'll all come to  a common point soon.  :o
« Last Edit: May 06, 2015, 06:04:48 PM by shinyribs »
The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #72 on: May 06, 2015, 06:16:22 PM »
Traded in the big,fat XS tank for a nice,slim....well,XS tank. ;D

First thing, I cut off the factory rear mount (nowhere near working for me) and reinforced the area with some patches. Stress cracks on fuel tanks scare me.



I wanted to reinforce it since this ( I guess you'd call it a crossmember ) is kinda skinny. Just wanted to spread the load a little. The rubber isolaters are Sportster oil tank mounts. They're handy.





Split some exhaust tubing and made some cups for the front mounts. Exhaust tubing is awesome. Easy to cut, easy to weld, easy to bend and plenty sturdy when braced correctly.





Rear tank frame mounts




Sheer dumb luck that the petcock cleared the frame. I'll take it.



Mucho better!

The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #73 on: May 06, 2015, 06:22:58 PM »
Threw the old oil system away. Too complicated.

Played with coardboard.



Moved on to steel.



Lot's of baffling since it's such a shallow tank.



Robbed an oi fill neck and dipstick


Drilled a big ol' hole in my tail.  :'(









The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0

Offline shinyribs

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Re: 1978K Resto-mod "HaCkJoB"
« Reply #74 on: May 06, 2015, 06:28:26 PM »
Made some bobbins



And a chain guard.






Decided to run an early DOHC F front fender

The darn fool didn't know it couldn't be done...so he went ahead and did it anyway.

My Hackjob build- http://forums.sohc4.net/index.php?topic=106103.0