Topic: K0 1969 Build...progress

[Thunder]

So, starting with a rebuild (actually bought the thing quite a few years ago and have slowly been getting parts together)

She is the black one btw , stored at a mates garage....


Things that i needed to get... everything basically, not even the front forks were right.....
Carbs, pipes, clocks, airbox,mudguard,seat....
So i left it for a while and started trawling the net, friends, this site

Problem being here in South Africa is Ebay can be a hit and miss affair, sometimes ,if you are lucky ,you actually get the goods, but normally 3-4 moths later...
 so i tried to source as much as i could locally (difficult being K0)

Luckily i had alot of CB spares given to me by a mate (tx Tim) so i would be able to find some of whats needed.

I eventually got her home and apart, while i collected ...until i now decided to pull the trigger
and at least get her up n running with what i have

This will be a photo thing of that progress

[SOHC4 Cafe Racer Fan]

Photos not displaying. 

[Thunder]

Fixed?
So engine teardown
Some of the fins had been chipped on both the head and cylinders

and i especially love the fact you can see where screwdrivers have been hammered in on the left and right ho lever the head off....

PO's...

Anyway i am leaving alot of the marks on stuff as its part of her history

Mystery... the head appears to be sandcast but the cylinders are onot (extra hole) ... so i dont know if at some stage it had the head replaced or the sandy head was always on.
I suspect it might have been put on originally (when new) as honda mighta been emptiying out the parts bin to furfill orders




Welded up and filed down (tx gavin)





The cases also had damage with the chain having smacked them at some stage.
They had been welded but there was at least a .5mm gap around the chain area.I was hoping to get it welded properly
and machined down but the guys i spoke to said it would be Very expensive (time consuming) so i have elected to
use JB weld (our equivilent is pratleys steel) by smearing tha gap on both cases, covering with a thin sheet of plastic wrap,
bolting them together and let dry (this should allow me to "open" the cases if needed. Then when i assemble use a thin layer of hondabond around that area

Pics will explain i hope






This might not work and it might leak/weep, in which case i will have to apply more JB.
 It was not leaking before with JB it just looked really unsightly.

[Thunder]

Odds and ends that have been completed over the years whilst collecting parts



Painter did the paint in 2 stages and messed the color up so it had to be redone (the parts that didn't match/see fork ears)
Also he didn't wast to fit the stripes so i did it and took to him for the clear





The color was obtained from a goldwing part that was hidden from the sun, does anyone know if the goldwing blue/green was different from the cb750 blue/green?

While collecting i tended to get distracted from time to time and bought some others


Got the correct carbs (tx Terry) and had then vapour blasted


I had one badge so made couple more, but still need to figure out how to do the chrome



Honed the barrels


New rings and good pistons to go in
Engine assembly at  a mates workshop, was especially nice to work on an elevated bench and to have fighting room (tx pieter)

...and he knows stuff


Sprayed engine and barrels










And where i currently am...


Bugger is the small details, like i forgot to initially spray an old seat catch i sourced (k0 specific one) so itwas more hours of sanding , spraying, fitting...


So continuing on ... I will update as much as poss in the next few days as i'm hoping to have something together by the  3rd but that might be a tad optimistic.

Big things missing are the double cut mudguard (going with a later one), and original swingarm with the funny chaingard expander tube and plastic chainguard.

But the reasoning is just to get her on the road as close as to originall with later stuff to be added as i find it.

I sourced a set of HM300 pipes i had rechromed and am fitting those as well.
Repro airbox is sprayed and ready.
Stainless spokes fitted and trued, tires fitted... but then i got clever ( i work ass backwards sometimes)and decided to do the wheel bearings... wow a day later i i finally got the collars out...
Fitting bearings today... then wheels

Cheers
Thor

[hashvm]

That's some good work .. I can't wait to see the final product

[754]

Do you know 01Thomas  on here, think he is in Capetown, he did have some KO bits..
 He started a post in open forum ..cat out of the bag.
 We got some KO parts sent to Canada from him.

[Thunder]

I did not

Will give him a mail (via forum).  Even if just to make contact. I know Rattrap is building a kick $$$ CR replica and he lives around the corner... gotta try get him to post it.

Tx

[Sgt.Pinback]

Nice work and good luck finding the missing K0 parts!

[palepainter]

You are making great progress despite logistical set backs.  Really looks great!

[Stev-o]

Nice project....subscribed

[Thunder]

and i thought today i would have the wheels on....

I made the mistake of stripping one of the bearing collars/retainers, so had to spend a few hours getting another one right.
So by the end of it... back wheel on...



(shocks are place holders ) as i have to get some machining done on some Hagons i have in order to get them looking close to original as the chrome sleeve doesnt fit under the shocks top mount and needs to be enlarged.

And pics of the clocks i got from our forum resident Terry in Aus ( ;DHi Terry), with new bodies and faces from cb750faces (marcel)
which are absolutley fantastic i must say


Rattrap, a mate (on this forum as well) is over in england and is hopefully bringing me back a whole bunch of David silver blingware.

[Thunder]

BTW, anybody got tips for cleaning up the underguard (black plastic mudguard) of scratches and general nicks and stuff

Sanding with continually finer sandpaper... then heatgun....?

[Johnie]

If those meter bodies are loose in the rings double up the cushions to take up the slack. Apparently the meter bodies I got from Marcel are a little smaller than Honda's where that rubber ring cushion sits. When I had it tight the meters still spun. I did not want to use electrical tape as in the hot summer it will travel. Don't get me wrong...Marcel's cases are real nice and you can make it work.

[Thunder]

Or innertube strips?

I havn't fitted them yet...but will bear in mind, thanks.

[Johnie]

Yah, the inner tube strip will work. I had extra cushions and mated them and the ribs back to back.

[Sgt.Pinback]

BTW, anybody got tips for cleaning up the underguard (black plastic mudguard) of scratches and general nicks and stuff

Sanding with continually finer sandpaper... then heatgun....?

I tried to do so. Started with 320 up to 1200 wet... But then I realised that there are good replica for little money and it would take me too long to get a sufficient result.

[Don R]

 If you sand the plastic, a rub with a soft cloth and peanut oil gives it a nice finish when you're done. I did a chain guard that way.

[Thunder]

So work unfortunaly interrrupeted the buld and i didn't get to finish on time, but back on it, so ill just let some photos do the talking...

Magaged to collect the following over the last few years
Hm300 exhausts
4 cable carbs
Latched seat
Ducktail seat
Sidecovers

Making the badges out of silicone and plastic (in case someone decides to lift em) i still have the originals... need to get another original sidecover badge

Front guard is still wrong (need double cut) but it can wait
Chainguard is metal (plastic if i come acrross one)
Swingarm is from a later model

[Thunder]

So still to go...

I need to find the switchgear i refurbished...
Electrickery to be done
fire it up ... hopefully
chase down oil leaks.
ride


oh, picked this up as well, only been chasing one of these for many years but they have always gone for way outta my budget,but this was a lucky find



carb 3 is blocked and to get the carbs out is a bit more difficult than the cb

will update

Thor

[Sgt.Pinback]

What VIN is that K0?
I think you have mixed an ealy KO head and a later KO cylinder (with additional hole).

What fork bottoms did you take?

[Thunder]

No 9000 odd. Not a sandcast unfortunately. ..
Fork lowers were the early ones I found... AFAIK. ..
A rectangular protrusion about 8cm running down the lower with 2 holes.
They are different fro. The ones I have that are later.

Thor

[Sgt.Pinback]

Thats a very early diecat anyway.

[Thunder]

Yeah, i have mixed the head and cylinder

Whe i bought it basically nothin was still K0, i took it for engine and frame number
(see first pic, black bike) Forks, triple, clocks,seat...evrything was wrong.

Luckily i had some early K0 stuff i had collected, so i wasn't too bad to get the rest.
(carbs and clocks)

However the cylinder is definetly a later one (diecast) but the head was sandcast??

My guess is this

So sometime in it's life it had engine work. I went with the assumption that the head was original as i figure the sandcasts were made in 69 and honda mighta had leftovers when the diecast came into being.
So..initially casings were diecast and cylinder/head were sandcast.
The bike then had cylinder problems later in life and hada new cylinder installed (by this stage all that was availible was the newer diecast stuff)

Its close on 50 years ago so i am just guessing

The diecast cylinder was fairly worn so i used another that i had who's measurements were in spec allowing me to use standard sized pistons and rings.

There are things i will keep an eye out for in the coming years like original swingarm, plastic chainguard, 2 hole rear drum etc
But i will be content at the moment just to fire her up, and fingers crossed, ride her.

I have sat for the last 4 years looking at a set of chromed pipes and finally decided that she needs to go together now and be ridden.
Parts can be replaced when time and money are right

Thanks
Thor

[Thunder]

@Sgt

Late 69 ,i believe the plate indicated 11/69

Heres a pick of the forks



these the right ones?

I have been following John Wyatts and Mark Paris's books as well as the interwebs (this forum especially) trying to get it as accurate ( K Diecast) as possible ... but i have no idea what actually occurred back then (here in Soth Africa) as Honda rushed to fufill orders.




OH ... and i'm an idiot.
In my haste to get the engine in and buttoned up, i put a tappet cover on without the Rev Gear
ARRRGGGG
But i will do a few months of shakedown riding as i can't face pulling the engine rigth now...


Thanks again
Thor

[Sgt.Pinback]

Those are K1 or K2 sliders.

The front fender should be a double cut. And some more things, I´m afraid.