Topic: CB550F Caferacer

[Canadian]

Hi all,

First of all I'm Elias, live in Europe, Belgium to be more specific. Will post some stuff about the bike!

Started about 6 months ago with this 1977 CB550F. Not Original, chopped in electrics, engine got a rattle can spray over when it was still mounted, tyres were cracked, ...

That made me decide to turn it into a cafe.

The bike as purchased:



DIY sandblasting:



Started modding the tripple tee for clip ons. Installed clip ons & made a bracket for the Original gage.







Redid my wiring:



Painted the brackets & triple tee:



Got some lights from our buddy Ebay:









Bought a seat as well, but didn't turn out pretty so decided to make one myself.



Now we're about 3 months in the build at this point, so wanted to have a hoop & started on the mold of the seat.





Taped this piece (after changing the shape a bit) & got cracking with the fiberglass:





Then bought me some biltwell grips & got the seat out of the mold.



After lots of sanding & bondo I got here:




About 1 week ago I ordered another ignition & relocated it. Still need to finish wiring (do it properly)



Got cracking on the built-in rear light I ordered on Ebay:





Then it got some time for new tyres, Heidenau K44's !



I wanted a cheap temporary solution so decided to plastidip the rims! Did some DIY sandblasting again:



And got cracking with the plastidip:





Got the seat pretty much done, need a bit more grinding. Oh and I have cut it below the black tape. Used this to have a straight line (thank you Discovery channel!)



And yesterday I mounted the wheels again, together with the plastidipped front -chopped- mudguard! And added fork boots.

I lowered the gage about 1" as well, sits nicely.






I'll be getting the engine out shortly to glass bead blast it, so it looks like new!

Then on to finishing seat, get some nice paint & upholstery!




Sorry if I made some mistakes, my mother tongue is Dutch, not English ! Awaiting your feedback, comments, tips & tricks!

Best regards,
Elias

[SOHC4 Cafe Racer Fan]

I'm a big fan of bead blasting engines in preparation for painting or powder coating, BUT once you have blasted it, it needs to be fully disassembled so you can flush ALL THE MEDIA out of every oil orifice, from the bearings, seals, and threads. Blasting while assembled is a very bad idea!

I have soda blasted assembled engines then followed with dilligently flushing with diesel, but never with glass media.

Sandblasting the engine in the frame had me concerned, too, for the same reasons. 

In addition, it's a little late to think about it, but I would have place your ignition key on the left side of the bike.  That way if your kill switch malfunctions, you can still operate the key while keeping your right hand on the throttle/brake.  If you have an extra right side-cover, you may want to swap the ignition to the left side OR just mount it using the frame mounted bracket on the 74-76 models.

[Bigsam302]

Very nice build.  I like the stance and the single gauge!

[Canadian]

I'm a big fan of bead blasting engines in preparation for painting or powder coating, BUT once you have blasted it, it needs to be fully disassembled so you can flush ALL THE MEDIA out of every oil orifice, from the bearings, seals, and threads. Blasting while assembled is a very bad idea!

I have soda blasted assembled engines then followed with dilligently flushing with diesel, but never with glass media.

Sandblasting the engine in the frame had me concerned, too, for the same reasons. 

In addition, it's a little late to think about it, but I would have place your ignition key on the left side of the bike.  That way if your kill switch malfunctions, you can still operate the key while keeping your right hand on the throttle/brake.  If you have an extra right side-cover, you may want to swap the ignition to the left side OR just mount it using the frame mounted bracket on the 74-76 models.

The sandblasting was with a low PSI, couldn't have damaged any gaskets, I've checked. 2 studs broke off while removing the exhaust, so will replace all studs to be on the safe side. Getting the engine out will be the easiest.

I wanted to have the ignition on that side so that's where it'll be I guess. I tried the lefst side but all the instruments behind the panel are in the way. Behind the panel you need to count on almost another 2" (the part of the ignition you don't see)...

Maybe I'll switch it to the frame using the bracket you say!

Tonight I'll be welding  the plate in the U-turn.



One question: due to clip ons your turning circle gets smaller. But to avoid hitting the thank, you guys weld something on the triple tee?

Thx!
Elias

[Restoration Fan]

I wouldn't be as worried about the gaskets from sand blasting as I would be whether the sand got into places that it shouldn't.

We took our engine apart and soda blasted it, which is a much less invasive media and we still had soda in holes and crevices that I would have sworn were inaccessible since we had taped portions we didn't want blasted. 

I hope you're going to be ok but personally, I would take that engine apart and clean everything before trying to run it.  Just my opinion though.

[FunJimmy]

Others have covered the media blasting concerns well so I won't chime in.
I'm saddened to see the ignition switch installed through the side cover.
Many Cafe builders discard the side covers anyway, but it's a poor (IMO) location for a switch and they're getting increasingly difficult to find in good condition. Interested to see how well the Plastidip hold up.

[Canadian]

Hi all,

Got the engine out & rear light as good as finished

Will ditch the side panels as well. Looked good without these. Will mount the ignition in the corner after welding a small triangle.

  What battery do you guys use to mount in the seat?

Are there any boxes ready (mean you can buy as is) in which you can mount your electrics?



Was a pain in the ass to get out!





@ above: right panel was already broken on several places

Brgds,
Elias

[koendd]

nice project!

ben je van Nederland of België?
ik zie in ieder geval al Jupiler staan 

ik ben van Ruddervoorde trouwens

[SOHC4 Cafe Racer Fan]

Resto Fan articulated my concerns better.  It's not your base or head gasket but every other orifice the sand will get into.  Just some friendly advice worth what you paid for it!

Note: most vintage CB side covers are either broken or brittle from age/elements.  You may want to reinforce the inside of the side cover (around the keyhole) to prevent cracking. My earlier comment was as to keeping it on the left side because it is easier to access the key since you mount/dismount from the left side AND if the kill switch fails you can still keep your right hand on the brake while turning the ignition off.

[SOHC4 Cafe Racer Fan]

Instead of welding, you can simply use the same bracket available on the 74-76 models to mount the ignition switch to the frame.

I am a big fan of Shorai lithium ion batteries -- superlight and better cranking power than a gel or lead acid battery.  Plus, the lithium batteries do not passively drain if you don't run the bike for weeks/months.  Alien Motion and others are cheaper.  Ballistic has had some reliability issues.

[Canadian]

nice project!

ben je van Nederland of België?
ik zie in ieder geval al Jupiler staan 

ik ben van Ruddervoorde trouwens

Belgie, uit Brugge, kleine wereld! Stuur gerust een PM!

@ above, any idea where I can get my hands on the bracket? Perhaps in some online shop?

Brgds,
Wannes

[GV1390]

Neat, keep it up! Oh, and ditch that tach, gauges are for sissies!

[NobleHops]

You have blasting media inside your engine. It will start and run, but if it gets into the oil pump (likely), it will steadily destroy bearings. I learned this the hard way, as at least a few others that are advising you did I bet.

At the very least, drain the oil, remove the oil sump and clean it out there, replace it and get yourself a gallon or two of kerosene, and flush what you can, straining the kerosene through a coffee filter in between uses. Change the oil filter, and when you DO fire it up, treat it to a fast oil and filter change.

Good luck, you're going to need it.

[Canadian]

You have blasting media inside your engine. It will start and run, but if it gets into the oil pump (likely), it will steadily destroy bearings. I learned this the hard way, as at least a few others that are advising you did I bet.

At the very least, drain the oil, remove the oil sump and clean it out there, replace it and get yourself a gallon or two of kerosene, and flush what you can, straining the kerosene through a coffee filter in between uses. Change the oil filter, and when you DO fire it up, treat it to a fast oil and filter change.

Good luck, you're going to need it.

I will do above, thank you.

[Doggie]

I was thinking about power washing my engine instead of media blasting.  If I plug up all openings, would there be a problem too?
                                        Thanks, Doug

[FunJimmy]

I was thinking about power washing my engine instead of media blasting.  If I plug up all openings, would there be a problem too?
                                        Thanks, Doug

Soapy water isn't nearly as problematic as abrasives.
Fire the bike up right after washing and you should be good.
You might have to change the oil if it gets water contamination but that's likely all.

[Restoration Fan]

I was thinking about power washing my engine instead of media blasting.  If I plug up all openings, would there be a problem too?
                                        Thanks, Doug

Do you plan to do that while it's still in the frame or are you taking the engine apart to rebuild? 
While power washing isn't as invasive as media blasting is, there are going to be some areas where water will reach that it shouldn't unless you're very careful.

For instance, when you're re-assembling an engine and have the cam towers off.  Underneath those are 6 holes that pervade all the way down to the cylinders.  Those holes are covered by rubber pucks.  Underneath 4 of those pucks are bolts that are used to connect the head to the cylinders.  Two of the holes are just holes with nothing beneath them, IIRC.  Well, where those bolts attach to the cylinder...all of that area there is open to the "outside world" through the fins for cooling.  So, those 6 little rubber pucks are the only thing keeping pressurized oil from getting out and leaking from around your fins.

So, if you're pressure washing with the engine still together, I would be very cautious about spraying at an upwards angle into those holes around the fins.  If you're taking the engine apart, sure...let the the pressure washer remove the grease and grime for you (as much as it can...you still may want to do soda blasting or something else as well to get it all).  Because in that instance, you're going to be likely replacing those pucks when you rebuild the engine anyway.

[Canadian]

Managed to get some work done.

Welding a plate to mount my electrics plus battery

Welded a plate in the triangle for my ignition lock, bondo'd & sanded + primered

My rear light caught fire when welding (duh...) so need to order a new one.

Made a bracket for my license plate.

Engine is off for cleaning.

Only got a small cabin to work in (it's messy ! Primer was done outside), so here it goes:







Let me know your thoughts!
Elias

[Canadian]

Update:

Engine cleaned & painted







Seat as good as done, just need to cut off some at the back, si it sits nice on the frame (without a gap on the side)





Think I got about 18 hrs in this seat to get it really nice...

[GV1390]

Looks good!

[SOHC4 Cafe Racer Fan]

Coming along nicely. Sorry to say this so late, but the taillight looks awfully small - even if it is a super bright LED.

[NobleHops]

Got a local powdercoater you work with? If so, consider humping that engine down to his shop and getting him to bake it at 200 degrees for an hour, and it will make that paint a bit more durable.

[Canadian]

The light is indeed very small, it got E4 approved (needed to use it in Europe) so all good.

It's really bright. Pics to follow!

No powdercoater in the area ... will check for baking it though!

As good as the seat gets:




Currently reworking all my electrics under the seat.

Brgds,
Elias

[Canadian]

Anyone got an idea where I can get my hands on 4 x K&N filters, at the best price?

Want them to be cones.

[Canadian]

Re-doing the wiring, and engine is back in. Oil filter bolt was really tight & didn't came off.

Grinded the mf... Ordered a new one and gettnig this next week. Hopefully it runs again!

Cleaning carbs first