Topic: Epwna

[B]

Just ordered Hondaman's book! Can't wait for it to show up… I figure if I'm doin this thing, I better do it right! It seems this book is one of the best resources out there. Pumped! 

[B]

Welp, hope I interpreted the cam tower mod right cuz...



If it's wrong well... I don't wanna know cuz it's too late now! I plan on using the rocker pins with the wasp-waisted center and only putting in the center bolts without the others to hold the pins from rotating. That seems to be the way of things...

Also, my brake lines came in from Slingshot! They look like they're gonna be awesome, and they came fast! Stoked!

[B]

I have been making all necessary preparations for engine parts ordering and building. For the consideration of the comity, regarding bearings:

The case says BBBBC, and the crankshaft says BABAA. That means from the factory I would have had 4 greens and 1 brown, correct? Is it safe to go that route again? I've read up on theories on this forum and come to no concrete solution, but it seems likely that most of the wear happened only to the bearings…

[JerTendo]

Where'd everybody go?
How are we supposed to build this bike without the support of this forum? 

[B]

A lot to report! After much effort the oil tank is spotless inside and spray-bombed outside!


I'm goin with a lot of black on this bike, so I really wanted the exhaust to stay chrome. Thing about 40 yr old chrome though is, it looks 40 yrs old. Solution, painted the parts that wouldn't clean up so nice. I think they came out pretty good...


Decided to replace the old petcock. No reason really, just preferred the shiny look of a brand new one... oh and there's this one other little reason.


More restored parts!


And by far the most exciting recently painted parts...

[B]

And now for the entertaining tale of how the evil entity 'UPS' was defeated by outstandingly heroic customer service. Once upon a time I sent an exchange set of cylinders in to Cycle X for some pre-915-sleeved cylinders, little knowing just how abusive the aforementioned antagonist would be. What I'm trying to say is... UPS BROKE MY PERFECT CYLINDERS!


Without going into too much detail, Cycle X took care of me and customer-serviced the crap out of me, so I ordered every part I could think of from them consisting of:

- 915 Pistons
- 915 Cylinders
- Cam
- Cam assembly
- Cam chains
- Primary tensioner
- HD Primary chains
- Upper and lower super studs (with super nuts...  )
- Super rods
- Clutch plates and springs
- Main and rod bearings
- Back cut transmission
- Oil pressure gauge

... and some other stuff like that. Can't wait to install the parts, and can't say enough about the customer service I received from those guys.

[B]

I also got a shipment in from VintageCB750


I went a little nuts and ordered exactly one metric butt load of parts but you know... sorry for partying. So now I am waiting on a substantial order from DCC as well as the parts from Cycle X, and then it should be engine building time!

[Trad]

This build is great. Nice attention to detail and clean up on all those bits pieces too.

[RainsongCB750F]

Zelda fan perhaps?
Nice build brother

[B]

This build is great. Nice attention to detail and clean up on all those bits pieces too.

Thanks, much appreciated! 

Zelda fan perhaps?
Nice build brother

Haha, HUGE Zelda fan! Greatest series of all time! I'm pumped that you picked up on the reference!

[B]

Ka-Zowie!


Sha-POW!


Fresh paint on those cylinders from Cycle X (great looking work from them btw)... What size were those jugs again?? Oh that's right, 915 CC! (This is a kids show alright? Let's keep it PG...)



Painting fins was a bigger challenge than expected, but I'm pretty pleased with how they came out. I think I'm going to shave the paint off the ends of the fins. I really dig that look and I think it'll tie the polished valve cover in with the black cases nicely (It's important that a motorcycle have good feng shui, lest it's tai chi become interrupted rendering it unable to achieve nirvana thus forever smelling like teen spirit). Trust me, the science checks out.

The CB gauge mounting bracket didn't fit the GL... now it does



And a turn signal mounting idea I'm trying on for size


 

Also I found out that I live less than 20 Min away from Hondaman himself, so my cylinder head is currently with him for port work and a valve job. The day of the engine build is nearly upon us!

[B]

My enthusiasm for posting may have dwindled, but my tenacity with a wrench has not! After receiving my cylinder head back from Hondaman (thanks dude!), it was time to build an engine! After buttoning up the cases, trying to shift and realizing we had put the shift fork in upside down... it was time to build an engine (again)! After reassembling all the way to the cylinder head, timing the cam and installing the rockers, we wondered if maybe we forgot an o ring. So we disassembled once more and it was time to build an engine! Then after getting to the point of torquing down the cylinder head again, and without going in to too much detail, I did a really dumb thing and...


You experienced wrenches will notice that you're not supposed to break studs off in the case... lesson learned. Not to be disheartened, I took the (still assembled) case to a machine shop to see what they could do for me. They informed me that if I took apart the cases they would give it a shot, but if I broke an easy out off in the stud they wouldn't touch it.
...

...

...



... I am not a smart man.

Finally I found a guy at a local shop who (after an extensive and thoroughly secure check-in process - He wrote my name on a sticky note), disintegrated the stud AND the easy out using what I can only assume was a combination of witchcraft and black magic. Thanks Russ, you truly are a wizard!

[B]

After that, it was practically smooth sailing... She's a beaut!


My ape of a brother and I decided to try out our own little method of upright engine installation... did I mention that I am not a smart man?


After the mess of tow straps, climbing rope, and ratchet straps suspending the engine from 2x4s on step ladders (well of course it sounds dumb when you say it that way...) let us down we opted for the my-brother-is-an-ape-man-so-we'll-just-lift-and-grunt-and-manhandle-it-in-by-hand method. Worked like a charm! 

[B]

So as it sits now, we have also hooked up the brakes, most of the electrical, and she shifts like butter! Start up may be just around the corner! Pics to come!

[PPG9944]

This looks like it's going to be a mean engine.  Just out of curiosity.  Where are you guys located?

[B]

I put a lot expensive parts in it so hopefully that helps  Thanks! I figure whether it runs and makes many horses, or just blows up at first touch of the start button, either result fits the description!  I'm in Westminster, CO. About 20 min north of Denver.

[PPG9944]

I was hoping you guys would be by chicago haha.  And i feel you on the expensive bits on the engine.  I'm not going gung ho like you are on mine. But the first fire will be very nervewracking haha cuz it'll either work well or blow up haha.

[B]

I figure you only yolo once, or something like that haha. I'll keep an eye on your build man, thanks for checkin mine out!   

[B]

Well the adventure never ends... Went to bolt the rotor on to the end of the crankshaft, and the bolt wouldn't thread in easy. I searched around and found the other rotor bolt in case I had the wrong one and maybe the threads differed between years... and it wouldn't go either. Tried em both in the end of the other crankshaft (you know, the one NOT already installed in the bottom of the engine I built four times already), and it threaded in like a dream. I can get the threads started into the crankshaft that's on the bike, but after about the 2nd thread it stops. My question is how foolish is it to think I can salvage it with an m12 x 1.00 tap? Or should I load it up on a trailer and take it to a shop? Worst case I do have that spare crankshaft layin around that I know has good threads, but I'd love for that to only be my very last resort... any input is greatly appreciated!

[martin99]

I would go (carefully) with the tap. Hopefully once the second thread is cut clean the bolt will thread in. Might be an idea to poke a piece of rag in the hole first to prevent any swarf getting into the oilway - remember to pull it out with some tweezers afterwards! Worst case, you might have to drill/file out those first couple of threads, don't think it would hurt. Personally I'd rather do that than strip it down, be interesting to see what others think.
 

[B]

Alright so here's the dill, pickles. The weather is getting nice and I'm getting antsy so it's time to put on my game face. I took martin99's advice and I'll be darned if it didn't work like a charm (thanks fella!)! Couldn't believe how easily the threads were fixed, and how nicely the rotor bolt went in after! Having had a good bit of luck, I should have known this would happen. I was straightening up around the house when I found this suspicious looking character...



Then the stages of denial set in almost immediately... 'I KNOW that's not an oil jet... well maybe it is but it's an extra! I didn't have extras... They're probably not that important, I'll just leave em out...' etc. Well of course I came to my senses, called up the ape himself (that's my brother... you ought to know that by now), and...


Upon removal of the engine, I had another realization. Oil jets come in a set... I had but one. So I tore my house apart to no avail, then proceeded to call every local CB contact I have made in the area over the past two years. Not a single answer, and turns out no one makes those little suckers anymore either! On a long shot I remembered where I had dumped the cardboard box in which Hondaman returned my head to me, found the box still full of packing material, and miracle of miracles would ya look at this??


By now I feel like I've built more like four or five bikes by now than just the one... but nonetheless, victory was ours! Those two tiny little pieces caused such a kerfuffle!

[B]

Having sorted out most of the GL conversion specifics, I was left with just a few bits to figure out. One of which being the fact that the dash no longer mounted to the triple tree, so I decided to try my hand at a custom one! Still needs polish and I need a bigger bit to mount the usb charger underneath the ignition switch (for when I need to download updates to the ecu  ), but I think the result is simple, effective, and will look pretty good shiny



And lastly I took care of another thing and couldn't possibly be stoked...er with the results!



Dat spray-bomb job doe! The to-do list continues dwindle!

[Restoration Fan]

I'm loving the look of this bike.  Did you do the paint on the tank yourself?

[FunJimmy]

I'm a bit late to the party but I made it!
B, your trials and tribulations should earn you a reward in BOTM when you're done.
Great build and commentary.

[RainsongCB750F]

I LOVE the tank! What a creative use of the best symbol in the world.
Keep it up