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Author Topic: and so it begins, cb550k under the knife  (Read 39050 times)

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Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #50 on: February 12, 2015, 01:29:23 PM »
Spent a bit of time with the wire brush on the grinder.

Honda did not blow the budget on the welding!



removing the side and centre stand brackets is taking up a bit of time, seems to be a lot of rust and moisture underneath.



removed the id plate, it is not in great shape as the bike has been painted before, can a new one of these be obtained from Honda?

« Last Edit: February 18, 2015, 09:02:36 AM by DMcD »
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Offline SOHC4 Cafe Racer Fan

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Re: and so it begins, cb550k under the knife
« Reply #51 on: February 12, 2015, 06:00:34 PM »
There's a vendor that makes replicas but Honda will not provide a replacement.
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1975 CB550K1 "Blue" Stockish Restomod (http://forums.sohc4.net/index.php?topic=135005.0)
1975 CB550F1 frame/CB650 engine hybrid "The Hot Mess" (http://forums.sohc4.net/index.php/topic,150220.0.html)
2008 Triumph Thruxton (http://forums.sohc4.net/index.php/topic,190956.0.html)
2014 MV Agusta Brutale Dragster 800
2015 Yamaha FZ-09 (http://forums.sohc4.net/index.php/topic,186861.0.html)

"There are some things nobody needs in this world, and a bright-red, hunch-back, warp-speed 900cc cafe racer is one of them — but I want one anyway, and on some days I actually believe I need one.... Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba." Hunter S. Thompson, Song of the Sausage Creature, Cycle World, March 1995.  (http://www.latexnet.org/~csmith/sausage.html and https://magazine.cycleworld.com/article/1995/3/1/song-of-the-sausage-creature)

Sold/Emeritus
1973 CB750K2 "Bionic Mongrel" (http://forums.sohc4.net/index.php?topic=132734.0) - Sold
1977 CB750K7 "Nine Lives" Restomod (http://forums.sohc4.net/index.php?topic=50490.0) - Sold
2005 RVT1000RR RC51-SP2 "El Diablo" - Sold
2016+ Triumph Thruxton 1200 R (http://forums.sohc4.net/index.php/topic,170198.0.html) - Sold

Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #52 on: February 17, 2015, 03:04:30 PM »
Got the stand brackets completely removed today.  As mentioned before, there was a lot of rust underneath, but it ground off, leaving clean metal behind.



95% of the grinding finished.



I had been looking forward to doing some welding on the frame.  I have said already that I am only a hobby welder, and tidying up the welds with the tig proved more challenging than I had hoped.  Some of the welds were ok, but others proved quite difficult due to what I think was rust/dirt/moisture in the joints, which is a bit of a no no for tig.





Oh well, at least most of the crappy mig welds, are now masked by crappy tig welds  ???
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Offline calj737

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Re: and so it begins, cb550k under the knife
« Reply #53 on: February 18, 2015, 07:23:54 AM »
Some of that is impurities, some of those air bubbles is from tapped gas and heat. Slow down perhaps, and only TIG a smaller section at a time and let the metal cool. That helps a lot with keeping the beads from blowing out.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #54 on: February 18, 2015, 09:09:53 AM »
Made some patterns for the rear gussets using some tin.





Will hopefully get some made tonight using heavier metal. 

Do they need to be done on the inside and outside of the frame, or is one side sufficient?
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Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #55 on: February 18, 2015, 09:11:07 AM »
Quote from: calj737 on February 18, 2015, 07:23:54 AM
Some of that is impurities, some of those air bubbles is from tapped gas and heat. Slow down perhaps, and only TIG a smaller section at a time and let the metal cool. That helps a lot with keeping the beads from blowing out.

Aye, its a black art isn't it.  Cheers for the advice.
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Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #56 on: February 18, 2015, 02:01:47 PM »
Got the rear gussets welded in.



I'll have to search the forum for pics of the swing arm and headstock bracing, if someone can point me in the right direction?
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Offline SOHC4 Cafe Racer Fan

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Re: and so it begins, cb550k under the knife
« Reply #57 on: February 18, 2015, 02:20:49 PM »
That's some robust bracing.  Some folks also do an X brace on the back side of the frame below the carbs and a cross-brace at the bottom of the down tubes.
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1975 CB550K1 "Blue" Stockish Restomod (http://forums.sohc4.net/index.php?topic=135005.0)
1975 CB550F1 frame/CB650 engine hybrid "The Hot Mess" (http://forums.sohc4.net/index.php/topic,150220.0.html)
2008 Triumph Thruxton (http://forums.sohc4.net/index.php/topic,190956.0.html)
2014 MV Agusta Brutale Dragster 800
2015 Yamaha FZ-09 (http://forums.sohc4.net/index.php/topic,186861.0.html)

"There are some things nobody needs in this world, and a bright-red, hunch-back, warp-speed 900cc cafe racer is one of them — but I want one anyway, and on some days I actually believe I need one.... Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba." Hunter S. Thompson, Song of the Sausage Creature, Cycle World, March 1995.  (http://www.latexnet.org/~csmith/sausage.html and https://magazine.cycleworld.com/article/1995/3/1/song-of-the-sausage-creature)

Sold/Emeritus
1973 CB750K2 "Bionic Mongrel" (http://forums.sohc4.net/index.php?topic=132734.0) - Sold
1977 CB750K7 "Nine Lives" Restomod (http://forums.sohc4.net/index.php?topic=50490.0) - Sold
2005 RVT1000RR RC51-SP2 "El Diablo" - Sold
2016+ Triumph Thruxton 1200 R (http://forums.sohc4.net/index.php/topic,170198.0.html) - Sold

Offline Retro Rocket

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Re: and so it begins, cb550k under the knife
« Reply #58 on: February 18, 2015, 07:25:19 PM »
Quote from: CB750 Cafe Racer Fan on February 18, 2015, 02:20:49 PM
That's some robust bracing.  Some folks also do an X brace on the back side of the frame below the carbs and a cross-brace at the bottom of the down tubes.

Above the swingarm pivot.... ;)
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Offline Bluegreen

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Re: and so it begins, cb550k under the knife
« Reply #59 on: February 19, 2015, 09:32:06 PM »
This project is rad!
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Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #60 on: February 20, 2015, 01:47:12 AM »
Quote from: Bluegreen on February 19, 2015, 09:32:06 PM
This project is rad!

Thankyou Bluegreen, your encouragement is appreciated.  I grew up in the 70s and 80's in Northern Irelands fantastic real roadracing heyday, and I am kind of going for a "home made" look, and wasn't sure if people would "get it".  I used to marvel at people going out to risk their lives on bikes that had obviously been made in a shed!

http://rutube.ru/video/35300bbe810d83decfe636bc9d7e6527/# 
« Last Edit: February 20, 2015, 02:16:01 AM by DMcD »
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Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #61 on: February 20, 2015, 01:50:42 AM »
Called at my local engineering company today.  They estimated £120 for the rebore to take the chinese 601 pistons.  He said one cut is £80, but they would probably have to do 3 cuts.  I thought it was quite cheap, but I think he recognised me from getting previous work done there.
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Offline seanbarney41

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Re: and so it begins, cb550k under the knife
« Reply #62 on: February 20, 2015, 02:49:00 PM »
Quote from: DMcD on February 20, 2015, 01:47:12 AM
Quote from: Bluegreen on February 19, 2015, 09:32:06 PM
This project is rad!

Thankyou Bluegreen, your encouragement is appreciated.  I grew up in the 70s and 80's in Northern Irelands fantastic real roadracing heyday, and I am kind of going for a "home made" look, and wasn't sure if people would "get it".  I used to marvel at people going out to risk their lives on bikes that had obviously been made in a shed!

http://rutube.ru/video/35300bbe810d83decfe636bc9d7e6527/# 
Thank you so much for that link, DMcD.  I had never seen or heard of that movie although Joey Dunlop is a hero to me...Very cool to see something about his roots and his less famous peers, who are now just as much of hero's as him.
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If it works good, it looks good...

Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #63 on: February 20, 2015, 03:34:47 PM »
Quote from: seanbarney41 on February 20, 2015, 02:49:00 PM
Quote from: DMcD on February 20, 2015, 01:47:12 AM
Quote from: Bluegreen on February 19, 2015, 09:32:06 PM
This project is rad!

Thankyou Bluegreen, your encouragement is appreciated.  I grew up in the 70s and 80's in Northern Irelands fantastic real roadracing heyday, and I am kind of going for a "home made" look, and wasn't sure if people would "get it".  I used to marvel at people going out to risk their lives on bikes that had obviously been made in a shed!

http://rutube.ru/video/35300bbe810d83decfe636bc9d7e6527/# 
Thank you so much for that link, DMcD.  I had never seen or heard of that movie although Joey Dunlop is a hero to me...Very cool to see something about his roots and his less famous peers, who are now just as much of hero's as him.

I wondered if anyone would click on the casually dropped in link
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Offline Restoration Fan

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Re: and so it begins, cb550k under the knife
« Reply #64 on: February 20, 2015, 03:36:15 PM »
Quote from: DMcD on February 20, 2015, 03:34:47 PM
I wondered if anyone would click on the casually dropped in link

Yep.  I watched about 20 minutes of it this morning and plan to watch the rest tonight when I have more time.  Enjoyed it very much so far.
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Ron

Stella - Logan's Senior Project    78 750K http://forums.sohc4.net/index.php?topic=141761.0

Logan's Reward - CB500 and CB550 Cafes    http://forums.sohc4.net/index.php/topic,147787.0.html

Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #65 on: February 20, 2015, 03:44:48 PM »
Haha classic, although I have owned and watched it many times, strangely the Russian youtube film Was the first time I saw the Directors comments at the end!
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Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #66 on: February 20, 2015, 03:58:19 PM »
Ground off, and filled the steering lock.




Welded the steering head rivetted section, front and back, remembering not to weld round the bottom.



I have a friend with an old milling machine, so got some billet aluminium off ebay for £12 to try making footrest hangers. 





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Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #67 on: March 04, 2015, 02:59:02 PM »
Got a couple of wee bits made on a friends lathe last night including an m8 threaded boss for my Chinese adjustable and rebuild able steering damper, which I tigged on tonight.



I should have measured this before I took the engine out, I hope it clears the head.......


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Offline SOHC4 Cafe Racer Fan

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Re: and so it begins, cb550k under the knife
« Reply #68 on: March 04, 2015, 03:00:41 PM »
Quote from: DMcD on March 04, 2015, 02:59:02 PM
Got a couple of wee bits made on a friends lathe last night including an m8 threaded boss for my Chinese adjustable and rebuild able steering damper, which I tigged on tonight.



I should have measured this before I took the engine out, I hope it clears the head.......



Nice dimes on that weld!  :)
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1975 CB550K1 "Blue" Stockish Restomod (http://forums.sohc4.net/index.php?topic=135005.0)
1975 CB550F1 frame/CB650 engine hybrid "The Hot Mess" (http://forums.sohc4.net/index.php/topic,150220.0.html)
2008 Triumph Thruxton (http://forums.sohc4.net/index.php/topic,190956.0.html)
2014 MV Agusta Brutale Dragster 800
2015 Yamaha FZ-09 (http://forums.sohc4.net/index.php/topic,186861.0.html)

"There are some things nobody needs in this world, and a bright-red, hunch-back, warp-speed 900cc cafe racer is one of them — but I want one anyway, and on some days I actually believe I need one.... Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba." Hunter S. Thompson, Song of the Sausage Creature, Cycle World, March 1995.  (http://www.latexnet.org/~csmith/sausage.html and https://magazine.cycleworld.com/article/1995/3/1/song-of-the-sausage-creature)

Sold/Emeritus
1973 CB750K2 "Bionic Mongrel" (http://forums.sohc4.net/index.php?topic=132734.0) - Sold
1977 CB750K7 "Nine Lives" Restomod (http://forums.sohc4.net/index.php?topic=50490.0) - Sold
2005 RVT1000RR RC51-SP2 "El Diablo" - Sold
2016+ Triumph Thruxton 1200 R (http://forums.sohc4.net/index.php/topic,170198.0.html) - Sold

Offline bwaller

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Re: and so it begins, cb550k under the knife
« Reply #69 on: March 04, 2015, 07:13:41 PM »
I'm concerned your damper clamp is going to limit travel. In case you haven't yet, with the fork fully extended, measure from the top of the forkleg to the underside of the lower triple clamp. Then remove a forktube cap, take a spring out of one fork and fully lift the leg. You'll then see how close the top of the forkleg comes to the underside of the lower triple. Measure the distance between the same two points when fully compressed.

Obviously the difference between measurements is your total travel. (depending on the model forks 115mm or so?) Especially on the track at speed you'll want to tune your forks to use as much of the travel as possible, less 10mm or so.

Could the damper clamp go upside down above the triple?
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Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #70 on: March 04, 2015, 11:11:11 PM »
Quote from: bwaller on March 04, 2015, 07:13:41 PM

Could the damper clamp go upside down above the triple?


I think so, but there is a slight restriction in the ball joint at that angle, I'll try it tonight.  I should probably have put the engine back in to check it too before welding.....
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Offline bwaller

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Re: and so it begins, cb550k under the knife
« Reply #71 on: March 05, 2015, 03:58:50 AM »
Check your fork travel first, maybe it can be moved closer to the clamp & still be ok.
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Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #72 on: March 05, 2015, 10:03:55 AM »
Quote from: bwaller on March 04, 2015, 07:13:41 PM
Could the damper clamp go upside down above the triple?

Yip, looks like I'll have a few options.

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Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #73 on: March 14, 2015, 11:11:41 AM »
Think that's the majority of the frame fabrication done now, still footrests to sort out, but took some pics today just in case anybody wants to learn from my mistakes if this all goes wrong ;-)

























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Offline DMcD

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Re: and so it begins, cb550k under the knife
« Reply #74 on: March 16, 2015, 04:43:37 PM »
Made up a footrest hanger tonight, bit agricultural looking, but I will be lightening them on a milling machine.  I will also need to find pics of a rear brake cable setup.






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