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Author Topic: 76 CB550 Cafe build  (Read 87563 times)

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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #150 on: November 06, 2017, 08:09:27 AM »
The whole assembly is rusted to hell and going to get binned.  In a few minutes it will be a drill bit screw if it doesn't come out :)
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #151 on: November 07, 2017, 06:53:02 AM »
Success



Hardware off and I removed what look to be the world's worst application of tank cream.
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #152 on: November 07, 2017, 07:15:16 AM »
It was a grey epoxy with a nice layer of rust on the top surface.

I'm guessing I should cream the interior before working on the exterior?  Preferred cream?
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Offline SOHC4 Cafe Racer Fan

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Re: 76 CB550 Cafe build
« Reply #153 on: November 07, 2017, 11:28:45 AM »
I would de-rust the tank, and then apply Caswell epoxy. 
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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 tshrey

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Re: 76 CB550 Cafe build
« Reply #154 on: November 07, 2017, 11:59:03 AM »
Someone tried to epoxy the tank, did a poor job of it and it dried in a big chunk in the bottom.  In the years since that was done (bike was last registered in 1986) there is more surface rust in the tank and it coated the epoxy.  The rust color will come off the epoxy chunks if I wipe it.

How does one remove the rust from inside?  Metal rescue?
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Offline SOHC4 Cafe Racer Fan

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Re: 76 CB550 Cafe build
« Reply #155 on: November 07, 2017, 12:00:25 PM »
Quote from: tshrey on November 07, 2017, 11:59:03 AM
Someone tried to epoxy the tank, did a poor job of it and it dried in a big chunk in the bottom.  In the years since that was done (bike was last registered in 1986) there is more surface rust in the tank and it coated the epoxy.  The rust color will come off the epoxy chunks if I wipe it.

How does one remove the rust from inside?  Metal rescue?

Depends on the level of rust. EvapoRust and Metal Rescue if the rust is not too extensive.
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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 tshrey

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Re: 76 CB550 Cafe build
« Reply #156 on: February 19, 2018, 09:34:32 AM »
I just got a warning when I started this post that nothing new has been added in 90 days.  Ugh.

Got the tank all sealed, used the Dragon Blood red Caswell.  Coated the bottom of the tank (exterior) with rust converter and then primed it with 2 part epoxy primer.  Did all the body work on the top as well (several small dings and depressions) and primed that.  Left side where the emblem sat for some reason didn't come out as well as I thought, I could still see a slight depression in the badge area so I've been skim coating it and getting ready for another coat of primer.

Finally got a rear hoop; ordered the pre-formed one from Cognito.  It was 1/4" too wide for my frame so I clamped it and welded it to the frame rails, then had to go to the back and cut out about 3/8" from the center and weld that to keep it from being too bulbous.



Started with the foam yesterday to form a rear section.  Spent a lot of time on this - whenever I see a cafe that I don't like it almost always involves the proportions of the tail compared to the tank.  Pretty happy with what I've ended up with and I just finished the second layer of fiberglass.  Also realized that I should have brazed in a think piece of steel to cover the opening on the back of the tank before I epoxied it.  I figured doing it now would be a bad idea so I'm adding a lip on the front of the seat that will be color matched to the tank; I don't really like the look of the seat itself being flared up to cover this opening.

Before anyone asks, that is in fact a piece of wood :).  I was struggling with what to do for a seat pan when I came across this piece of scrap that might be the lightest piece of wood I've ever picked up.  Figured why not, it was easy to sculpt the bottom to sit nice and low on the frame rails.  My plan for a seat is to get a big piece of 3/8" thick hpde cutting board, heat it to bend the kick-up section and let my upholstery guy put foam on that and wrap the whole thing in leather and alcantara with a nice burgundy diamond stitch.




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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #157 on: February 22, 2018, 09:23:20 AM »
Pulled out the foam and tape, now working to make everything thicker so that I can sand down to make it smooth.


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Offline Marissa

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Re: 76 CB550 Cafe build
« Reply #158 on: February 26, 2018, 01:01:49 PM »
Subscribed!

Good stuff here.
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1984 Nissan 300zx - sold
2016 Ford Fiesta ST - daily
1972 Honda CB500 - infinite work in progress

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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #159 on: March 02, 2018, 11:48:28 AM »
Moving forward with adapting a CBR600rr alternator to this bike.  Because...

vs


3 pounds in rotational weight, yes please. Not to mention the increased output and reliability.  Since CR26 carbs are over a grand I might convert to EFI with a microsquirt.  At least that way I can tune the bike in a way I understand - you guys and your needle jets and float height, way too complicated.

I took as good of measurements as I could (getting measurements on a taper is not easy) and I'm drawing the adapter up in autoCAD to 3d print it at work.  If everything seats correctly I will turn the adapter on my lathe, if not I'll make adjustments and 3d print ad infinitum until it is right.  Once I get the right measurements I'll leave it here for others to use.

One thought I had - why are all these things taper interference fits?  Seems unnecessarily complicated machining for the manufacturers.  Why can't I turn the ID of the CB600rr rotor to have no taper and cut a keyway in it?  That would make turning the adapter easier.
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Offline SOHC4 Cafe Racer Fan

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Re: 76 CB550 Cafe build
« Reply #160 on: March 02, 2018, 03:59:41 PM »
Quote from: tshrey on March 02, 2018, 11:48:28 AM
Moving forward with adapting a CBR600rr alternator to this bike.  Because...

vs


3 pounds in rotational weight, yes please. Not to mention the increased output and reliability.  Since CR26 carbs are over a grand I might convert to EFI with a microsquirt.  At least that way I can tune the bike in a way I understand - you guys and your needle jets and float height, way too complicated.

I took as good of measurements as I could (getting measurements on a taper is not easy) and I'm drawing the adapter up in autoCAD to 3d print it at work.  If everything seats correctly I will turn the adapter on my lathe, if not I'll make adjustments and 3d print ad infinitum until it is right.  Once I get the right measurements I'll leave it here for others to use.

One thought I had - why are all these things taper interference fits?  Seems unnecessarily complicated machining for the manufacturers.  Why can't I turn the ID of the CB600rr rotor to have no taper and cut a keyway in it?  That would make turning the adapter easier.

Let us know if you get this upgrade sorted.  A bunch of us were hoping/waiting for Anders to develop a 32 amp upgrade for CB550 bikes but then he went silent.  If you get it working, I am sure there are others interested (including ME).
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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 bambuhiphop

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Re: 76 CB550 Cafe build
« Reply #161 on: March 02, 2018, 05:17:46 PM »
Quote from: SOHC4 Cafe Racer Fan on March 02, 2018, 03:59:41 PM
Let us know if you get this upgrade sorted.  A bunch of us were hoping/waiting for Anders to develop a 32 amp upgrade for CB550 bikes but then he went silent.  If you get it working, I am sure there are others interested (including ME).

Ditto
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75' CB550K -- Still in pieces but it rolls again!!!!

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #162 on: March 04, 2018, 01:45:50 PM »
Starting to look like a real tail section



3d print of my spacer is waiting for me in the printer at work, so I'll be able to test fit it to check my measurements. Surprising to me that there are no listings anywhere (that I can find at least) of the taper angles for various bikes.  I measured the taper of the cb550 crank at 5.5 degrees and the taper of the cbr600rr rotor at 5.3 degrees.  I'm working now to set up a taper turning apparatus to get me the .1 degree accuracy I think I need on my lathe.
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Offline DurangoCB

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Re: 76 CB550 Cafe build
« Reply #163 on: March 05, 2018, 07:10:11 AM »
Subbed!  Looking good. 
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1971 CB500 Four- current project http://forums.sohc4.net/index.php/topic,170622.0.html
1978 CX500- next in line

Offline SOHC4 Cafe Racer Fan

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Re: 76 CB550 Cafe build
« Reply #164 on: March 05, 2018, 08:55:21 AM »
Nice job shaping the seat.
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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 tshrey

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Re: 76 CB550 Cafe build
« Reply #165 on: March 09, 2018, 02:49:32 PM »
Got the 3d printed taper spacer done.  Fit is really good, so I'm going to use my measurements and try turning one on the lathe.

Can anyone speak to the material I should use?  I'm thinking aluminum just because if the fit isn't quite perfect when I crank down the retaining bolt the taper spacer will be the thing to deform.  Thoughts?





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Offline DurangoCB

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Re: 76 CB550 Cafe build
« Reply #166 on: March 20, 2018, 09:21:12 PM »
Wish I had something for you with that last question. Hope you got it figured out.

How’s it coming?
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1971 CB500 Four- current project http://forums.sohc4.net/index.php/topic,170622.0.html
1978 CX500- next in line

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #167 on: March 21, 2018, 07:50:37 AM »
Going to go with steel for the adapter.  To get a good check on my measurements I've been turning each face separately out of aluminum to make sure my measurements are really accurate.  I've got the fit onto the stock shaft perfect, so next I have to cut that out of steel rod.  Then do aluminum turns to fit into the CBR rotor before transferring that angle onto the steel rod.  For the final interference  fit I saw that people will use a little valve grinding compound and just spin the parts against each other.

Working a lot on the seat.  Almost done with fiberglass, then on to bondo (which is heavy as hell, that's why I want to get it really close with 'glass).

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Offline bambuhiphop

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Re: 76 CB550 Cafe build
« Reply #168 on: March 21, 2018, 09:02:55 AM »
I may have missed it, but what year is the rotor from the CB600rr off of? Whats the plan for the stator side?
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75' CB550K -- Still in pieces but it rolls again!!!!

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #169 on: March 21, 2018, 09:07:21 AM »
2008 CBR600rr.  Going to get the same stator, but they are $100 on ebay and the rotor is only $30.  Wanted to make sure I could make it work before I bought the stator :)

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Offline bambuhiphop

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Re: 76 CB550 Cafe build
« Reply #170 on: March 21, 2018, 09:13:41 AM »
Quote from: tshrey on March 21, 2018, 09:07:21 AM
2008 CBR600rr.  Going to get the same stator, but they are $100 on ebay and the rotor is only $30.  Wanted to make sure I could make it work before I bought the stator :)

Sweet. I'm really interested in this myself. Looks to be going really well. Nicely done.
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75' CB550K -- Still in pieces but it rolls again!!!!

Offline SOHC4 Cafe Racer Fan

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Re: 76 CB550 Cafe build
« Reply #171 on: March 21, 2018, 09:27:18 AM »
Quote from: bambuhiphop on March 21, 2018, 09:13:41 AM
Quote from: tshrey on March 21, 2018, 09:07:21 AM
2008 CBR600rr.  Going to get the same stator, but they are $100 on ebay and the rotor is only $30.  Wanted to make sure I could make it work before I bought the stator :)

Sweet. I'm really interested in this myself. Looks to be going really well. Nicely done.

Me, too!
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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 flatlander

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Re: 76 CB550 Cafe build
« Reply #172 on: March 22, 2018, 03:48:08 AM »
i'll be watching from a distance how this is going. looks really promising so far.
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #173 on: March 22, 2018, 10:10:11 AM »
Got my layout down for the outside of the taper spacer.  Not sure I've ever machined something with this perfect of a fit, there is zero slop.  Next step is the steel rod and transferring this cut to it




And the seat/rear hump is close enough in fiberglass now that I'm bondoing it today. I may have had to clear off a bunch of heavy snow from the driveway, but at least Toby got me a day off work to hang out in the garage.

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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #174 on: March 22, 2018, 02:24:50 PM »
More lathe work.  Cutting the internal taper will suck as I fiddle with stuff if I have to keep pulling the rod out to test fit it on the crankshaft (and then re-zero the rod in my 4 jaw chuck each time), so I repeated the above for the stock rotor to get an image of the crankshaft taper.  Now I have a plug to check the internal cut against.  Setting that up is next.

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