Author Topic: 82' CB650 Retro/Modern Cafe Racer Project (Read 3747 times)

adrianm1972 · « **on:** August 04, 2012, 06:02:14 PM »

I am moving my build thread from DTT to here as I am on this forum a lot more.

So...I am one of the many suckers that got into Cafe Racers due to the TV show. After looking at a few bikes I got this, a 1982 CB650 with a title, 1 1/2 extra engines and a pile of parts. It was running but had some front brake issue.

I didn't take long before I tore into it.

I found some galled cam followers and he cam as worn too. Luckily I had a good 650 cam in the pile o parts

I got a CB750 tank as i liked the looks of it better.

adrianm1972 · « **Reply #1 on:** August 04, 2012, 06:03:04 PM »

I am working on my CB650 as time and finances allow. This is my first project so I am buying a lot of tools as I go along.

This week I worked on my wheels. I learned a lot and I am very happy with how they came out. To save a few $$ i decided to try the epoxy paint instead of powder coating. Thanks to Do The Ton and the SOHC4 forums I knew exactly what to do.

Prep:

1.Disassemble the wheels
2. Paint stripper to remove the clear coat on the aluminum bits
3. Wash the spokes and scotch brite them to cleam them up.
4. 6" brass bristle wheel on my drill to remove oxidation (They looked so good almost didnt want to paint them after this)
5. Derust the rims with Naval Jelly (The front was rusted through and I had to but another wheel...thanks eBay $85 delivered. Ended up with a spare perfect condition CB750 brake rotor and hub)
6. Scuff the chrome with 120 grit paper on my orbital sander
7. Etching primer on the hubs spokes and rims (scotch brite the primer to get a smoother finish)
8. Black Rustoleum Epoxy on the rims and hubs
9. Silver Duplicolor on the spokes (Spoke nips were buffed with the brass wire wheel.

Here's what I ended up with!

The pics are crappy but the spokes look like fresh sliver Cad plating.

CB750 Donor wheel from eBay. I used the rim and the spokes. The brake rotor is spankin' new it may only have a couple hundred miles on it.

adrianm1972 · « **Reply #2 on:** August 04, 2012, 06:04:03 PM »

I spent a lot of time on these prepping the lowers and the trees. I had planned to polish the fork lowers but they had some pitting that was too deep to sand out. I ended up hand sanding the lowers with 120/220/320 paper. Then priming and filling the pitting with glazing putty. I lot more priming and sanding later they look better than show room new. The lower triple got stripped wire brushed, primed and painted with black epoxy.

I got new seals, wipers, crush washers and drain bolts from Service Honda.

adrianm1972 · « **Reply #3 on:** August 04, 2012, 06:05:16 PM »

I will be running clip ons and different gauges so I cut off and reshaped the upper triple tree. I made a heck of a pile of aluminum dust but the results were worth it.

Next up:

I need to order some gaskets, rings and parts to reassemble the engine...

Smooth!

adrianm1972 · « **Reply #4 on:** August 04, 2012, 06:06:26 PM »

I ordered a ton of parts from Service Honda (gaskets, orings, brake rebuild kits....) mainly for engine assembly so I cleaned up, flexhoned and painted my cylinders.

adrianm1972 · « **Reply #5 on:** August 04, 2012, 06:07:45 PM »

I got some fun stuff in the mail and got to work modding my frame today.

CNC Clipons from ebay. They were $79.99 shipped and they look great. I like that I can go to longer or shorter bars by spinning a few screws. They are light and very well made.

Here are the shorty lever master cylinder/clutch lever kit you guys have seen on ebay. I got them shipped for $115. Quality and finish look great.

I never liked the kinked seat rails on the 81 and 82 CB650 frames so I had a Ton'er make a long tail loop and went to town with an angle grinder. I used curved tubing from the old kinked seat rail to make new mitered frame adapters to fit the new rail. There are 7/8" schedule 40 steel tubing inserts that will be plug welded then the butt joints will be welded. I am confident this will be stronger than stock. The overhead shot looks crooked but I measured everything six ways to sunday and its all dead balls straight. Btw, all the tubing was hand mitered with a cut off wheel and a 36 grit flapper sanding wheel....yes it took forever. I messed up on the front right frame adapter but i think it will be ok.I plan on mig welding the crap out of all the plugs and joints...1 or two passes...then sanding them flush. My goal it to not see that there were any mods after painting.