Topic: 1977 cb550/650 engined barn find mono shock conversion gl1000 front swap

[stuartni]

Well as some of may know last summer i finish 1978 cb550 converting it into a cafe racer. Before finishing that bike i found another 1977 cb550 with a cb650 engine in it. Story behind the bike, the man i bought it from his wifes grandad owned the bike but had passed away. It hadn't been on the road since the late 80s when he must of modified it as it had the 650 engine, aftermarket exhaust, pod filters, electronic ignition and the main reason i wanted it a private reg XOI 5504. The bike lay in an old barn since the 80s until last year when the barn caught fire and collapsed on itself. This was found when they where clearing the remains of the building, they didn't even know it was in there. Since the bike had been sitting so long it was in very bad shape but thankfully the fire didn't to much damage to the bike and anything it did damage wasn't important to me anyway. I got a box load of spares with it so couldn't be happier.

The plan for this is a brat sort of style with a more comfortable stance as my other bike has a more race stance which does over time get a bit uncomfortable. Plan is is flat seat with rear pickup black frame/ swing arm convert to mono shock colours brown/cream

Here is a link to my first build
http://reallymeansounds.com/forum/threads/1978-cb550-four-cafe-racer-build-bike-finished.137910/

parts gathered so far
tapered head bearings
front/rear wheel bearing
handle bars
brown grips
aftermarket fuel cap
spoke kits
rear hoop
new brake rod
new brake shows
new brake pads
aftermarket starter button
new brake switch


Thought i would add a few pictures distinguished gentles mans ride we took part in, Belfast Northern Ireland









The new to me rusty gold






sat at our main workshop for the last year now back at my house where i will start the build in my shed 16 by 10 so not to bad

just before it gets its first wash in a long time





work begins I'm still unsure what tank to use i have a standard cb550 tank cb450 tank and a cx500 tank












Then all my plan changed once i seen this bike


and then this happened







new handlebars already cut down in size

All unwanted tap etc removed ad blanked

this is what I'm planing to make for the mono shock conversion


one will be the ignition switch instead of a key and the other is the push start button

[SOHC4 Cafe Racer Fan]

I already am a fan of the 650 motor in the 550 frame. Do you plan to use a modern front end?

[stuartni]

I already am a fan of the 650 motor in the 550 frame. Do you plan to use a modern front end?

Im not currently planning to the original fork tubes are shot and replacement are nearly £200 but i can get cb750 fork tubes for £60 so might but cb750 fork sliders (bottoms) and rebuild them but not sure yet.

[SOHC4 Cafe Racer Fan]

If you are not going modern, you might want to use a GL1000 75-77 front. It's a direct swap - forks, tree, brakes, etc. - and you get better handling from larger diameter 37mm fork tubes and much better brakes and twin rotors. It's a bolt on mod.

[stuartni]

If you are not going modern, you might want to use a GL1000 75-77 front. It's a direct swap - forks, tree, brakes, etc. - and you get better handling from larger diameter 37mm fork tubes and much better brakes and twin rotors. It's a bolt on mod.

Oh really i didn't know that i shall look into that thanks for the info

[SOHC4 Cafe Racer Fan]

Take a look at my 750 build string.  There are many other members who have also done this front end swap. 

[SF]

Subscribed, followed your other build too. Looks great man.

[stuartni]

Take a look at my 750 build string.  There are many other members who have also done this front end swap.

Ok being looking for gl front end 75-77 with no luck I was speaking to a local breaker i use the odd time who is pretty sure he has the forks only which is a start. Also would the likes of 1978 model not fit reason I'm asking is i can get a set of 1978 forks ok and a set of 1979 yokes no problem.

[stuartni]

Subscribed, followed your other build too. Looks great man.

thanks i shall try and upload better photos, the shed is quite limited for space and most of our main tools/equipment are at the main workshop but with 11 bikes there theres no room to work

[SOHC4 Cafe Racer Fan]

I don't think that parts from 78 an 79 will work for a direct swap. 

[stuartni]

I don't think that parts from 78 an 79 will work for a direct swap. 

ok thanks for the help i will look and see what other fronts might work with my bike as the gl stuff is hard to find here and what there is can be quite pricey as i get all parts for the front end seperatly from uk mainland but would cost me more than the likes of an r6 front end but not sure if want to go full modern like an r6 front end

[stuartni]

The rear hoop came for the mono shock conversion pretty much decided to go with the gl1000 front end swap now :cool:

[Evening Echo]

Nice looking build. Had been watching your other build as well; very nice.

[stuartni]

Nice looking build. Had been watching your other build as well; very nice.

thanks very much hoping to build a bmw r80 after this one is finished

[Evening Echo]

There's spome very cool looking BMW cafe's about. I met someone with a garage full of ex-military bikes (he's into the whole military theme) and is looking to downsize his extensive fleet. He had a couple of fairly ratty r80 st's that I looked at that might be good donors if his price was right. I'm in cork. PM me if you want to talk.

[stuartni]

There's spome very cool looking BMW cafe's about. I met someone with a garage full of ex-military bikes (he's into the whole military theme) and is looking to downsize his extensive fleet. He had a couple of fairly ratty r80 st's that I looked at that might be good donors if his price was right. I'm in cork. PM me if you want to talk.

yes father in law has cafe r80 been out on it few times lovely big machine to ride. I will pm you about the other bikes 

[mazen0822]

If you are not going modern, you might want to use a GL1000 75-77 front. It's a direct swap - forks, tree, brakes, etc. - and you get better handling from larger diameter 37mm fork tubes and much better brakes and twin rotors. It's a bolt on mod.

Its is actually not a bolt on mod as the stems on the GL1000 tree are longer then the 550 stem. its a direct swap on the 750. You have to have to use a 550 stem but otherwise its a straight swap.

[SOHC4 Cafe Racer Fan]

If you are not going modern, you might want to use a GL1000 75-77 front. It's a direct swap - forks, tree, brakes, etc. - and you get better handling from larger diameter 37mm fork tubes and much better brakes and twin rotors. It's a bolt on mod.

Its is actually not a bolt on mod as the stems on the GL1000 tree are longer then the 550 stem. its a direct swap on the 750. You have to have to use a 550 stem but otherwise its a straight swap.

Correct. I think I was thinking this was a 750 build when I wrote this particular response.

[stuartni]

If you are not going modern, you might want to use a GL1000 75-77 front. It's a direct swap - forks, tree, brakes, etc. - and you get better handling from larger diameter 37mm fork tubes and much better brakes and twin rotors. It's a bolt on mod.

Its is actually not a bolt on mod as the stems on the GL1000 tree are longer then the 550 stem. its a direct swap on the 750. You have to have to use a 550 stem but otherwise its a straight swap.

Correct. I think I was thinking this was a 750 build when I wrote this particular response.

If you are not going modern, you might want to use a GL1000 75-77 front. It's a direct swap - forks, tree, brakes, etc. - and you get better handling from larger diameter 37mm fork tubes and much better brakes and twin rotors. It's a bolt on mod.

Its is actually not a bolt on mod as the stems on the GL1000 tree are longer then the 550 stem. its a direct swap on the 750. You have to have to use a 550 stem but otherwise its a straight swap.

Good news is i got myself a 1976 gl1000 front end yokes forks calipers axle spacers speedo drive and discs all from the one bike and yes stem was 12mm to long so i removed a 12mm section from it, lathed a solid piece of bar to slot inside the stem then puddle welded it and welded the seam.

please excuse the terrible pictures doing a lot of this from the shed instead of the workshop means space and tools are very limited so i only do what i can until it moves up to the main workshop once we have more space




also bought another tank  i have problem still can't decide which one to use between the 450 and 500t tank

[Tews19]

Looks good. Nice metal skills you possess.

[SOHC4 Cafe Racer Fan]

Stuart,

You may need to swap fork springs to adjust for the much lighter weight of the bike. My ride was a bit harsh so I went with springs for the lightest weight possible with Race Tech.

The brakes when rebuilt will be a drastic improvement. Drilling and resurfacing the rotors helps too.

[stuartni]

Looks good. Nice metal skills you possess.

thanks I'm by no means an expert but hoping to get a tube notcher and pipe bender soon. Just bought a lovely new big welder making me want to weld everything 

Stuart,

You may need to swap fork springs to adjust for the much lighter weight of the bike. My ride was a bit harsh so I went with springs for the lightest weight possible with Race Tech.

The brakes when rebuilt will be a drastic improvement. Drilling and resurfacing the rotors helps too.

Ok shall look into that also thanks for the advice. Im going to get a fella in work to draw up a design (drill pattern) for the discs and get them done.

Anyone any opinions on what tank i should go with really can't decide

[SOHC4 Cafe Racer Fan]

Looks good. Nice metal skills you possess.

thanks I'm by no means an expert but hoping to get a tube notcher and pipe bender soon. Just bought a lovely new big welder making me want to weld everything 

Stuart,

You may need to swap fork springs to adjust for the much lighter weight of the bike. My ride was a bit harsh so I went with springs for the lightest weight possible with Race Tech.

The brakes when rebuilt will be a drastic improvement. Drilling and resurfacing the rotors helps too.

Ok shall look into that also thanks for the advice. Im going to get a fella in work to draw up a design (drill pattern) for the discs and get them done.

Anyone any opinions on what tank i should go with really can't decide

In my opinion the tank has to work in harmony with your seat/cowl design.  What do you have planned for the tail?

I kind of liked the CX500 tank modified with some deeper cutouts for your knees.

[stuartni]

Looks good. Nice metal skills you possess.

thanks I'm by no means an expert but hoping to get a tube notcher and pipe bender soon. Just bought a lovely new big welder making me want to weld everything 

Stuart,

You may need to swap fork springs to adjust for the much lighter weight of the bike. My ride was a bit harsh so I went with springs for the lightest weight possible with Race Tech.

The brakes when rebuilt will be a drastic improvement. Drilling and resurfacing the rotors helps too.

Ok shall look into that also thanks for the advice. Im going to get a fella in work to draw up a design (drill pattern) for the discs and get them done.

Anyone any opinions on what tank i should go with really can't decide

In my opinion the tank has to work in harmony with your seat/cowl design.  What do you have planned for the tail?

I kind of liked the CX500 tank modified with some deeper cutouts for your knees.

yes i agree. The colour scheme will be creme and brown, i have brown grips which i will get the seat covered in a matching colour then the tank will be creme with matching brown sections.

The seat/tail is just going to be all brown leather including the kick up, there wont be a pod or anything. I think the cb450 tank may work better (more old school looking) i want this be more comfortable on a longer bike run with standard foot positions and comfortable handlebars not just as much a racey look , as my other cb550 has clip ons and rear sets which i love but does take its toll on you after while.

[CBR954AD]

I don't think that parts from 78 an 79 will work for a direct swap. 

why wont the 78-79 GL forks?