Author Topic: ‘78 CB550 Cafe Racer Project (Read 16109 times)

jcop550 · « **on:** February 09, 2019, 10:15:42 PM »

I have had this 1978 Honda cb550 for a few years now. My plan was always to do a cafe racer build with it. I had this thing put together and taken apart a couple times over the years. It has always been a work in progress that I would lose interest in. Now I finally got the motivation to finish this project and I couldn’t be more excited to do so. I’ll post some pictures I collected along the way and then I’ll continue to update you all with the build as it progresses!

jcop550 · « **Reply #1 on:** February 10, 2019, 12:10:41 PM »

This is where I’m at with the project right now. Completely taken down to the frame. Currently prepping the frame and engine for paint!

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jcop550 · « **Reply #2 on:** February 10, 2019, 04:58:50 PM »

Started to wet sand and try out this polishing kit I bought. I forgot how tedious wet sanding was. Some before and after pics

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jcop550 · « **Reply #3 on:** February 11, 2019, 09:01:56 PM »

I got a set of used super sport 4 into 1 headers and got a cone muffler to weld on to them with the help of my brother’s friend

The headers are in ok condition. Some surface rust, and a little bit of pitting but nothing too bad. I’m gonna try and get them cleaned up as much as possible but I think I’m going to end up wrapping them with black heat wrap

12” Shorty Cone Muffler: https://www.dimecitycycles.com/stainless-steel-shorty-universal-cone-muffler-fitting-1-1-4-inch-exhausts.html

rocs · « **Reply #4 on:** February 12, 2019, 05:14:02 AM »

Subscribed!

Looking good! Polishing looks great as well. I dont miss those days at all.

Also, saw your wanted add for a custom top triple clamp. I dont have one myself but hoping someone can help you out.

jcop550 · « **Reply #5 on:** February 12, 2019, 06:47:59 AM »

Quote from: rocs on February 12, 2019, 05:14:02 AM

Subscribed!

Looking good! Polishing looks great as well. I dont miss those days at all.

Also, saw your wanted add for a custom top triple clamp. I dont have one myself but hoping someone can help you out.

Awesome, thanks brother! You do great work

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jcop550 · « **Reply #6 on:** February 12, 2019, 05:22:01 PM »

I started to strip all of the old paint off the frame down to bare metal this evening.

Got about half way through because I need a new wire wheel after this ones wire bristles broke off. So far I’m happy with the progress!!

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jcop550 · « **Reply #7 on:** February 13, 2019, 04:51:42 AM »

Quote from: calj737 on February 13, 2019, 03:11:58 AM

Chemical paint stripper is faster, safer, and easier on your body than those wires flying off and sticking in your skin, eyes, and surrounds. Follow the stripper up with some 400 grit emery or a Red ScotchBrite.

Yeah I’m sure. I was picking those wires out of my shirt and off the floor for a while. They were everywhere. It took the paint off with ease though

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jcop550 · « **Reply #8 on:** February 13, 2019, 05:08:56 AM »

Quote from: calj737 on February 13, 2019, 05:02:41 AM

Make damn skippy certain you wear eye protection.

Yeah of course! I’d like to keep my vision lol. And a respirator for the paint dust as well

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SOHC4 Cafe Racer Fan · « **Reply #9 on:** February 13, 2019, 08:33:15 AM »

What Cal said. Get yourself a stripper!

Unless you are going to clear over bare metal, use a chemical stripper. Remember to wipe down the frame 2-3 times with acetone before applying primer/paint.

jcop550 · « **Reply #10 on:** February 13, 2019, 09:07:08 AM »

Lol thanks! I will definitely wipe it down. For now I got a stronger wire wheel and it is working like magic. Takes the paint off like butter.

Here’s a pic of my new one and what happened to the other one. So far no wire bristles flying off

I’ll add some photos of the frame when get all the paint off!

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jcop550 · « **Reply #11 on:** February 13, 2019, 10:51:24 AM »

Well here is the frame after removing all the paint. Took a little less than 2 hours all together with the wire wheel. Done with that for now. Then primer and paint once it gets warmer outside

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Kelly E · « **Reply #12 on:** February 13, 2019, 11:07:37 AM »

That looks great. Last August I sandblasted the 75' 400 Four that we put back on the road after at least 21 years in not always the best storage. It was way messier than wire wheel but a bunch faster. I used a HF sandblaster and it worked good once we figured out the best settings. Fortunately I can blast out behind the shop.

jcop550 · « **Reply #13 on:** February 13, 2019, 11:41:45 AM »

Quote from: Kelly E on February 13, 2019, 11:07:37 AM

That looks great. Last August I sandblasted the 75' 400 Four that we put back on the road after at least 21 years in not always the best storage. It was way messier than wire wheel but a bunch faster. I used a HF sandblaster and it worked good once we figured out the best settings. Fortunately I can blast out behind the shop.

Thank you! I wish I had a sandblaster but I’m stuck doing it the old fashioned way.

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Bankerdanny · « **Reply #14 on:** February 13, 2019, 01:05:12 PM »

Quote from: Kelly E on February 13, 2019, 11:07:37 AM

That looks great. Last August I sandblasted the 75' 400 Four that we put back on the road after at least 21 years in not always the best storage. It was way messier than wire wheel but a bunch faster. I used a HF sandblaster and it worked good once we figured out the best settings. Fortunately I can blast out behind the shop.

I spot blasted the frame on my 550 roller rather than doing the whole thing.

Kelly E · « **Reply #15 on:** February 13, 2019, 02:52:12 PM »

I am going to blast the 550 as well, most likely this summer after my ride in July.

jcop550 · « **Reply #16 on:** February 14, 2019, 07:01:18 PM »

Here’s an idea of what I’m going for with the seat and tank. I got a bit of work to do on the tank and I think I’m gonna keep it white. I think the white looks good with the saddle brown seat!

Also gonna have gold accents like the chain and emblems etc.

Let me know what you guys think!

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jcop550 · « **Reply #17 on:** February 15, 2019, 04:54:11 AM »

Quote from: calj737 on February 15, 2019, 03:20:24 AM

Easiest “work in the tank” to make it fit is to move the frame bungs that the tank hangs on. Simply cut them off, and scoot them forward, up or down, and then weld them back on. Done. Then you don’t mess with the tank, your seat fits, and it’s less than a 1 hour job.

Yes, I had the tank and seat on before I took apart the bike. Everything actually fits nicely. I guess you can say I got lucky lol

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Bankerdanny · « **Reply #18 on:** February 15, 2019, 10:37:54 AM »

I have that same basic seat and used it on my own 550F for a while. On a stock bike the fit is so-so because of the frame brace for the top of the fender, but with the frame behind the shock mounts removed and a hoop added like your bike I imaging the fit should be very good.

jcop550 · « **Reply #19 on:** February 15, 2019, 11:57:10 AM »

Quote from: Bankerdanny on February 15, 2019, 10:37:54 AM

I have that same basic seat and used it on my own 550F for a while. On a stock bike the fit is so-so because of the frame brace for the top of the fender, but with the frame behind the shock mounts removed and a hoop added like your bike I imaging the fit should be very good.

Oh very interesting. I didn’t know this seat would fit on the bike before the frame got chopped. Pretty cool. But yes, with the hoop welded on the back the seat fits very nicely.

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Bankerdanny · « **Reply #20 on:** February 15, 2019, 07:06:35 PM »

Quote from: jcop550 on February 15, 2019, 11:57:10 AM

Oh very interesting. I didn’t know this seat would fit on the bike before the frame got chopped. Pretty cool. But yes, with the hoop welded on the back the seat fits very nicely.

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jcop550 · « **Reply #21 on:** February 16, 2019, 05:44:43 AM »

Quote from: Bankerdanny on February 15, 2019, 07:06:35 PM

Quote from: jcop550 on February 15, 2019, 11:57:10 AM
Oh very interesting. I didn’t know this seat would fit on the bike before the frame got chopped. Pretty cool. But yes, with the hoop welded on the back the seat fits very nicely.

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Nice, looks good!

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jcop550 · « **Reply #22 on:** February 18, 2019, 07:21:19 PM »

Electronics tray from Cognito Moto going under my seat. Drilled out a hole for my ignition switch. Tested all the wiring beforehand and it will all fit well in the box.

jcop550 · « **Reply #23 on:** February 20, 2019, 08:28:33 PM »

I have been working on the tank in between doing other things over the past couple of days. It was pretty beat up with a decent scratch and dent. I was able to push the dent out using a bent piece of rebar.

To make it perfect, I used body filler to smooth out any unevenness from that big dent and scratch. As of now, it has a couple coats of white primer and it’s ready for paint and clear coat.

jcop550 · « **Reply #24 on:** February 21, 2019, 05:18:18 AM »

Quote from: calj737 on February 21, 2019, 03:47:19 AM

Looks great

Thank you!

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Author Topic: ‘78 CB550 Cafe Racer Project (Read 16109 times)