Topic: CB750 K4 Build - The Cafe Tracer

[budman]

Well, this ain't gonna work.  There isn't enough room.  I bought that outlet adapter, whittled on it in the lathe and it's just too big.  I've got about 1/4" clearance on the short side and it just isn't enough room.  Looks like I'm going to have to make some sparks.

Also my forks started leaking.  I pulled the front wheel off and used a 3/8" impact to put a little more crush on those crush washers up inside the bottom of the fork.  Hope that does it.

Think I'm going to stop for the day.  Off to order a new gas tank bung.

[budman]

I've been on vacation all last week, but before I left I did manage to plug the old bung in the gas tank and weld in a new one that is in front of the engine where their is plenty of room for a petcock.  I re-sealed the tank and started the bodywork.  Hope to finish the bodywork on Saturday and get it in primer.

Took the family to the Black Hills in South Dakota.  I figured it was time they got to experience some of the awesomeness.  Just got home yesterday.  We drove the whole trip.  I prefer riding up there on the bike, but it was still cool.  Was there for five days. Saw everything from the Badlands to Devils Tower in WY.  We got there two weeks before the Sturgis Rally so there weren't a lot of bikes.  They started trickling in the last couple of days we were there.

I bought a whole bunch of t-shirts while we were there.  Some of the current herd needs to be downgraded to working-on-the-bike or yard-work shirts.

[Stev-o]

Welcome back Bud.  I've done the Badlands on bike, many moons ago.

[budman]

Welcome back Bud.  I've done the Badlands on bike, many moons ago.

Quite a site to behold, isn't it?

[SOHC4 Cafe Racer Fan]

I bought a whole bunch of t-shirts while we were there.  Some of the current herd needs to be downgraded to working-on-the-bike or yard-work shirts.

I do the same thing.  As they get faded and ratty, they become shop rags.

[Retro Rocket]

I bought a whole bunch of t-shirts while we were there.  Some of the current herd needs to be downgraded to working-on-the-bike or yard-work shirts.

I do the same thing.  As they get faded and ratty, they become shop rags.

Or fishing shirts....

[budman]

Or fishing shirts....

...and jeans.

[budman]

I finished the body work and primed the tank.  Just need to block sand it, reprime, wet sand and repaint.  Hopefully the bung relocation fiasco will be over soon.

I've also been working on a rear brake light switch bracket.  I made it out of stainless steel plate.  Looks like it'll work just fine.

[budman]

Now I'm finally back where I was about 7 weeks ago.  I got the gas tank repainted and the leaky fork seal replaced.  There's plenty of room for a petcock now.  Probably going to get a low profile Pingel petcock.

Hopefully I can get the graphics done on the tank next week and I can start making progress again.  I don't like being in "two steps back" mode again.

[beemerbum]

I hope you've got good bits and remember to chamfer the holes....

Evidently there are three schools of thought on chamfering after drilling (1) Don't chamfer as the pads will bite better and clean themselves. (2) Chamfer a little bit, to remove burrs if any. (3) Chamfer away as you please. On all my projects, I went with #1 with excellent results. Another thing to remember: The brake was designed with a no-hole rotor. Any change will reduce the brake's effectivness. All the modern bikes with heavily drilled discs were designed that way. Also, science tells us that none of the drilled holes should exceed the disk's thickness in diameter. That makes sense.

[calj737]

Any change will reduce the brake's effectivness. All the modern bikes with heavily drilled discs were designed that way.

The holes are now incorporated to evacuate gas build up, increasing the pad's effectiveness. Slots are to remove water, holes remove gas. Hole size, pattern and count is indeed programmed so a few well placed holes is far better than a rotor that looks like a colander.

[Stev-o]

Good to hear, Bud.  You have 7 weeks to the Harvest Classic bike show to get it done!

[budman]

Good to hear, Bud.  You have 7 weeks to the Harvest Classic bike show to get it done!

As much as I would love to get the bike finished it doesn't look it's going to happen this year.  I have too many parts to still buy and not enough money to get what I need before the rally.

Are you going to have the park racer finished in time for the rally?

[Stev-o]

Good to hear, Bud.  You have 7 weeks to the Harvest Classic bike show to get it done!

As much as I would love to get the bike finished it doesn't look it's going to happen this year.  I have too many parts to still buy and not enough money to get what I need before the rally.

Are you going to have the park racer finished in time for the rally?

That is my goal.  Body work s in paint, then final tuning and it should be ready. 

[budman]

That is my goal.  Body work s in paint, then final tuning and it should be ready.

Awesome.  Looking forward to checking out the park racer in person.

[budman]

The graphics are done on the tank.  I still need to wet sand and re-clear the tank one more time.  The stripes aren't as yellow as they appear in the photos.  They're more of a tan color.

[SOHC4 Cafe Racer Fan]

That woody is coming along nice.  Are you just going to hit it with some urethane or stain the wood at all?

[budman]

That woody is coming along nice.  Are you just going to hit it with some urethane or stain the wood at all?

It'll be shot with the same urethane clear I used on the gas tank.  The walnut will get about as dark as the brown on the tank.  I have to do a little more sanding on it and it'll be good to go.

[Stev-o]

That woody is coming along nice. 

+1.  Think Don just named her for ya!

[budman]

Starting to buy parts again.  New clutch kit arrived.

[budman]

Stainless steel oil lines made.  I'm going to take them back off and polish them.

[budman]

I made this little threaded adapter so I can run a Harley style clutch cable.  Probably going to JB Weld it where it slides into the clutch cover.

[budman]

So I get up at 5:30 this morning with plans to smoke a brisket and work on the CB750 all day.  I got the brisket going and went to work on the bike.  I got the clutch pack installed, put the springs in place, bolted the lifter plate on and while torquing the bolts to spec...snap!  The lifter plate broke.  Good thing I had a spare motor, right?  I removed the clutch cover and that one is broken too.  Probably usable, but I don't want to take any chances.  Started a search on the net and they aren't easy to find.  Guess I'll hit the classifieds next.

[Stev-o]

Oh, #$%*e. Prolly the most delicate part on that motor!  I only have one spare and may need it but will send to you if you can't find one. Email member Dave, I've bought many parts from him, he's very reasonable and ships quick.

davebobco@gmail.com

[calj737]

Or Bill Benton. He's bound to have at least 100 squirreled away