Author Topic: Black Friday - a red 1965 CB160 build.  (Read 22465 times)

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Offline Alan F.

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Re: Black Friday - a red 1965 CB160 build.
« Reply #375 on: June 04, 2022, 03:29:39 PM »
This week I've been trying walk-in visits to the RMV to title & register my Enfield 650, I'll keep trying walk-ins when possible but I've booked the next open appointment which is Friday at 2pm... Grumble.

I've started in on the dreaded task of drilling the swingarm pivot bolt end bores to 7/32". Without a workshop or even my lathe to use I've just been putting this off, until now. I charged up the old cordless drill battery and ran a few different size bits, stepping as slowly as possible up to 7/32" but the battery is back on the charger, I'll bore the final 7/32 soon. It was pretty easy for the first 2 drill sizes, the 3rd was tougher and I wasn't able to hold the bolt by hand without it spinning, I used an adjustable wrench on the head to hold it and went as slow as possible.

After the 7/32" I'll be ready to shop for some zerks, I understand 1/4-28 is a common enough thread size.

Edit about an hour later: just finished drilling both ends of the pivot bolt to 7/32".

I drilled the same depth as the stock bore, then quenched the bolt in cold water. I probably weakened it some, I hope it wasn't a big mistake, but at least that's done.

Offline grcamna2

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Re: Black Friday - a red 1965 CB160 build.
« Reply #376 on: June 04, 2022, 04:05:51 PM »
How's the rest of your project CB160 coming along Alan ?
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Alan F.

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Re: Black Friday - a red 1965 CB160 build.
« Reply #377 on: June 04, 2022, 04:48:14 PM »
Well Bill, I haven't actually done anything else with it in these past 2 months. Work and family have been keeping me busy enough.

I'm actually quite thrilled with myself at my progress today, I'd really been dreading the pivot bolt mods and a few other minor tasks, but I'll be making a greater effort to make time to get this one reassembled sooner rather than later.

Offline Terry in Australia

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Re: Black Friday - a red 1965 CB160 build.
« Reply #378 on: June 04, 2022, 04:56:09 PM »
Good job Alan, keep going and get it finished so you can ride it this summer! ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline Alan F.

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Re: Black Friday - a red 1965 CB160 build.
« Reply #379 on: June 04, 2022, 06:17:34 PM »
Thanks for all the encouragement gents, I think once I'm past the point of cleanup it'll go quicker.
Still need to go through the forks & tank, petcock & carbs, both brake plates... And detail that engine...
During assembly I'll probably want to bolt up the engine to the frame first right?

Offline Terry in Australia

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Re: Black Friday - a red 1965 CB160 build.
« Reply #380 on: June 05, 2022, 01:55:53 PM »
I guess it depends on how heavy the engine is, and how easy it is to install/remove it? Installing the engine in a CB750 before anything else is advantageous because they’re a bastaard to install otherwise, but on smaller bikes, not so much.

As you know I’ve had the engine in and out of my Suzuki T500 a couple of times to fix various things and then to swap the internals into closely matching numbered cases, and it was very easy. Does the engine hang underneath the frame on your bike? If so, probably not an issue either way. ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline MauiK3

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Re: Black Friday - a red 1965 CB160 build.
« Reply #381 on: June 05, 2022, 02:16:36 PM »
The pace will really pick up once the cleanup is done, that’s a very slow and detailed part. It always takes longer than you think.
Keep going! We want to see the bike run!!
1973 CB 750 K3
10/72 build Z1 Kawasaki

Offline grcamna2

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Re: Black Friday - a red 1965 CB160 build.
« Reply #382 on: June 05, 2022, 03:06:56 PM »
The pace will really pick up once the cleanup is done, that’s a very slow and detailed part. It always takes longer than you think.
Keep going! We want to see the bike run!!

Might be possible to seal-up all the ports tight and stand far back & use a low pressure 'pressure washer' to it after first soaking it with some Gunk engine degreaser for 1/2 an hour;especially between the fins.
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Alan F.

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Re: Black Friday - a red 1965 CB160 build.
« Reply #383 on: June 05, 2022, 03:32:22 PM »
There are no frame downtubes at all, just rear and top engine mounts. I could probably build it up to a roller then once I've got the engine detailed and everything tightened up I could set the engine up on some scrap wood at the right height and just wheel the roller over it & bolt it up.

Have I mentioned how much I hate not having a workshop?

Offline RAFster122s

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Re: Black Friday - a red 1965 CB160 build.
« Reply #384 on: June 05, 2022, 11:05:08 PM »
Alan, I can relate to the workshop issues and frustrations of roadblocks. You used to be able to buy abrasive cord that was ideal for between fin work, it was like and abrasive string of sandpaper. Worked well for areas you could draw the string back and forth between fins or between the fins and working 9n sanding the loose stuff and any oxidation back to good metal.
David- back in the desert SW!


Offline MauiK3

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Re: Black Friday - a red 1965 CB160 build.
« Reply #386 on: June 06, 2022, 08:05:10 AM »
Looks like cool stuff, never seen it.
1973 CB 750 K3
10/72 build Z1 Kawasaki

Offline RAFster122s

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Re: Black Friday - a red 1965 CB160 build.
« Reply #387 on: June 06, 2022, 11:58:23 AM »
That's the ticket, McMaster stocks good product, not sure about the eBay sellers...kinda like buying from Harbor Freight, their sandpaper generally is not worth the money Most of their tools 9n the other hand are adequate. Things that need precision tolerances for good use or proper life or excellent hear treat are not their forte. Their torque wrenches I wouldn't trust to anything other than big bolts that you can safely be in the ballpark without concern...things like engine building, better to spend more, Project Farm has a good review of big torque wrenches but nothing suitable for any precision and he included a Harbor Freight 1/2" drive torque wrench. Interesting review. I want someone to do a inch pound torque wrench analysis...

So, odds are the eBay stuff works OK but it depends on the price difference between them. Call McMaster Carr and ask them to tell you the manufacturer to find out if they are known quality like Norton and 3M and similar companies. They likely are a big abrasive maker they are buying from. The Cheap Chinese Crap (CCC)  is what you usually want to avoid, but in this case if the price break is enough it might be fine.  But yes, that it the cats meow for working between fins. Make wooden tools to slot the cord between so you can hold the cord and you aren abusing your fingers and even lattice strip you can sandwich a piece or plywood  to hold it. Then you have to get creative in tight areas you cannot easily draw the cord through. Paint stripper will kill the paint and the cord and remove the bubbled material stripped but aluminum oxidation is not fun to remove between fins and 8n tight areas on assembled motors. My CX came off an island in Rhode Island and the paint and clear coat are compromised so the cases which have the bites built in as a lump really need time at a vapor blaster but the danger of pushing abrasives into the assembled motor are too great. So SS brushes and sand paper and other things have been used and it 8s a royal pita. Same issue on my mini Cooper S that lived in Wisconsin...the block and tranny being aluminum the aluminum oxidation is not pretty. I spent 30 minutes with a wire brush knocking back quite a bit on the oil pan and underside of the motor. I just took used oil and coated the area I scrubbed back to cleaner aluminum knowing it will collect dust, dirt, better that than more white corrosion to grow. The salt melting chemicals it had been exposed to had pitted the aluminum alloy in some areas. It bugs me. The cast aluminum areas are hopeless. I just need to let it go and not be bugged by it. But I wanted a 2 door hardtop hatchback with manual transmission Cooper S Gen 3 with the reliable BMW designed and built '14 and later motor so I found a CarMax 2 door in Wisconsin and since it hasn't sold they offered to bring it from Wisconsin to Bristol TN near where I was living for $99 and I knew in 2019 finding a white 2 door hardtop was gonna be tough. I also wanted a Harmon Karden sound system option and it has the heated seats which help my back when I am having back issues. It was average milage to near high at 59k being 4 yrs old and single owner and never wrecked. So, I got a good deal as it had been marked down. Wish I had bought a 16 as I didn't know the 16 had broader seats as the 15 seats are too narrow for my big frame and the side bolsters cause issues and I have had to supplement the seat with a pad to fill the area or my sides of my back really start bothering me. The things you learn owning a car or bike...
Not regrets but just things you know having owned them.
David- back in the desert SW!

Offline Terry in Australia

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Re: Black Friday - a red 1965 CB160 build.
« Reply #388 on: June 07, 2022, 01:46:18 PM »
I watched the “Donut Media” guys test then torture torque wrenches from $50 to $500 and interestingly the cheaper tools turned out to be the best, the most expensive “Made in the USA” wrench actually exploded when they tested it  to 30 foot pounds over its 250 foot pound limit, which was probably not too much to ask considering how some folks abuse tools. The cheapest ones were tortured way past what broke the expensive one, and were still accurate to within 5% afterwards.

I was really surprised, and it gave me pause to also wonder how accurate my torque wrenches are, 40 years and God knows how many engines I’ve rebuilt since I bought them? Most torque wrenches come with a calibration certificate and should be recalibrated every year, but I wouldn’t start a business recalibrating peoples torque wrenches, I reckon I’d starve to death between jobs, if other folks are like me….. ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline MauiK3

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Re: Black Friday - a red 1965 CB160 build.
« Reply #389 on: June 07, 2022, 02:46:44 PM »
https://www.wikihow.com/Calibrate-a-Torque-Wrench

I found this diy calibration method
It’s a little fiddly but might be worth doing every so often.
1973 CB 750 K3
10/72 build Z1 Kawasaki

Offline RAFster122s

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Re: Black Friday - a red 1965 CB160 build.
« Reply #390 on: June 18, 2022, 03:37:38 AM »
https://www.wikihow.com/Calibrate-a-Torque-Wrench

I found this diy calibration method
It’s a little fiddly but might be worth doing every so often.

Thank you for that… that is helpful. I broke a craftsman torque wrench I bought back in the 80s. I didn’t realize at the time when I was young and dumb how important it was to return it to zero, so it was good I was only using it mostly for wheel lug nuts…
David- back in the desert SW!

Offline MauiK3

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Re: Black Friday - a red 1965 CB160 build.
« Reply #391 on: June 18, 2022, 06:48:38 PM »
Torque wrenches are a must, at risk of boring readers I’ll retell a story from my Marine Machinist nuclear submarine days. There was some training I had to conduct and it involved dispelling the myth that various coworkers held that they could feel a proper torque. Of course on that type of work, torque values range all over up to even thousands of foot pounds.
We had a calibration shop with a super (for it’s day) calibration tool I pitted the torque wrench naysayers against. They all failed miserably and became believers.
I love precision torque tools
1973 CB 750 K3
10/72 build Z1 Kawasaki

Offline Terry in Australia

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Re: Black Friday - a red 1965 CB160 build.
« Reply #392 on: June 21, 2022, 04:29:07 PM »
When I reinstalled the shiny new cylinder head on my little truck a couple of days ago after failing miserably the first time (the locating dowel holes in the new head wre a couple of thou smaller than on the original) I used my favourite old Australian made torque wrench rather than the expensive English one that I “borrowed” from work 30 years ago and I reckon my favourite one was more consistent. I also used my “tried and true” method of torqueing it down in smaller increments than the gasket manufacturer recommended, which admittedly takes longer, but the good news is that it’s running perfectly now. ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Black Friday - a red 1965 CB160 build.
« Reply #393 on: June 21, 2022, 07:27:28 PM »
When I reinstalled the shiny new cylinder head on my little truck a couple of days ago after failing miserably the first time (the locating dowel holes in the new head wre a couple of thou smaller than on the original) I used my favourite old Australian made torque wrench rather than the expensive English one that I “borrowed” from work 30 years ago and I reckon my favourite one was more consistent. I also used my “tried and true” method of torqueing it down in smaller increments than the gasket manufacturer recommended, which admittedly takes longer, but the good news is that it’s running perfectly now. ;D

That's satisfying  :)
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Alan F.

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Re: Black Friday - a red 1965 CB160 build.
« Reply #394 on: June 21, 2022, 10:21:14 PM »
Hey, congratulations Terry.

Offline WideAWAKE

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Re: Black Friday - a red 1965 CB160 build.
« Reply #395 on: June 22, 2022, 08:20:40 PM »
Thanks for all the encouragement gents, I think once I'm past the point of cleanup it'll go quicker.
Still need to go through the forks & tank, petcock & carbs, both brake plates... And detail that engine...
During assembly I'll probably want to bolt up the engine to the frame first right?

I’ve pulled and rebuilt the motor in my cb160 and I gotta say, probably the easiest motor I’ve ever installed on a bike.

Just put it on a little jack on the floor and lift it up.

I’m pretty sure I got the bottom in, then swung the top into place.

Maybe took 10 mins.
« Last Edit: June 22, 2022, 09:01:51 PM by WideAWAKE »

Offline grcamna2

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Re: Black Friday - a red 1965 CB160 build.
« Reply #396 on: June 22, 2022, 09:19:20 PM »
Thanks for all the encouragement gents, I think once I'm past the point of cleanup it'll go quicker.
Still need to go through the forks & tank, petcock & carbs, both brake plates... And detail that engine...
During assembly I'll probably want to bolt up the engine to the frame first right?

I’ve pulled and rebuilt the motor in my cb160 and I gotta say, probably the easiest motor I’ve ever installed on a bike.

Just put it on a little jack on the floor and lift it up.

I’m pretty sure I got the bottom in, then swung the top into place.

Maybe took 10 mins.

Alan,is this CB160 engine rebuilt ?
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Alan F.

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Re: Black Friday - a red 1965 CB160 build.
« Reply #397 on: June 22, 2022, 10:55:13 PM »
No it's still all original. I have no plans to rebuild it.

Offline Alan F.

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Re: Black Friday - a red 1965 CB160 build.
« Reply #398 on: August 18, 2022, 04:29:37 PM »
Time to get back to this one, I picked up a couple more gallons of Evaporust and a 1/4-28 tap for the swingarm pivot grease zerks today.

I've also got an idea to play out on these forks, stay tuned.

Offline Alan F.

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Re: Black Friday - a red 1965 CB160 build.
« Reply #399 on: August 22, 2022, 05:38:11 PM »
I was planning to soak the front forks in Evaporust but was hoping for a closed container this time, normally I'd get a length of pvc and some end caps but costs have gone up so off to the Internet search box I went. The solution is a clear plastic display tube marketed for signed baseball bat storage for about the price of 2' of pvc, it's 29"x 2.75" and has silicone rubber end caps. Yesterday I plugged the 1mm vent hole in each cap with some white caulk.