Author Topic: My $300 77 CB550F Project  (Read 7799 times)

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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #25 on: February 02, 2024, 05:50:57 PM »
One of the things I really like about this forum is that there are so many quality builds. There's a lot of different directions that they go and I appreciate a lot of different styles even when they are not my style. I'm blown away by some people's fabrication skills. I also get it that some people just want a good reliable older motorcycle and don't care a lot about restoring them back to new condition or upgrading performance. Older Honda's always had good sound performance. That being said, and this rubs a lot of people the wrong way, but I detest builds that are only about the looks to the extent that they degrade performance and end up with almost unrideable or unsafe motorcycles. I've watched Orange County Choppers and rarely didn't think that their typical build was a death machine. I'd feel safer riding down I195 here in Massachusetts at 165 MPH in traffic on my MT10 then riding one of those bikes at 30 MPH and trying to make a turn. There seems to be a trend where cafe racer type builds (not here) are becoming totally art projects. I lived through some of the original cafe racer years and that was about trying get better performance out of their motorcycles. More and more often I see these things with 1" of suspension travel because it looks cool. This totally blows my mind and there are people giving out advice about suspension with no clue how dangerous it is. Quite often they will double down to try and discredit people that actually are giving good advice. I want a motorcycle that performs well and that I can ride. I put on 6,000 to 12,000 motorcycle miles a year.

I'm hoping that my Honda build is going to look killer but I also want to upgrade performance and reliability wherever I can. My motor is done and I think it'll have better performance than it was originally stock. With some help, I think my electronics will be very good. This CB550 seems to get a lot of praise as a good handling platform to begin with. I'm going to get the weight of this bike down substantially. The progression of making modern motorcycles lighter is amazing. There are parts on this Honda that weigh a ton. I've stripped off everything that I can. I bought aluminum rims and am changing out every single control, button and original electrical system component. I'll be interested to get this on a scale when it's done.

Now don't get offended if you disagree.....I'm tired of black motorcycles, cars and trucks. For me, it's been done to death. IMO, on motorcycle builds, blacking out parts is an easy way around doing the grunt work to refinish old parts. If someone really just wants a machine to ride and doesn't want to spend a lot of time refinishing, I get it. This build is going to be as black free as possible. The tires will definitely be black.

Every time I see an older motorcycle with the aluminum polished out I get a little weak in the knees and decided I wanted to do that. I did my homework as I didn't know much about how builders get the results. I call it grunt work. My original trade is carpentry so I know how the dull tedious time doing the grunt work gets you to the end where people ooo and ahhhh. My motor took from June to October to get it paint ready. I wore out 2 dremels until I bought a 3rd high end one. In the process, I learned how to polish out aluminum parts. It's pretty simple, sand, sand, sand and then sand some more. Then it's polish, polish and polish again. Lots of hours. The outer cases came out pretty good. I've got a ton of hours in the frame but that gets powder coated so it's a little more forgiving. Currently I've spent the previous 2 weekends, both days working on the rear hub. Aluminum parts take a beating and my 550 only has 9700 miles on it. I figure I might finish it tomorrow if I work all day on polishing. That's strictly the hub, not the plate with the brake assembly. What else are you going to do in mid winter in Massachusetts when you motorcycle obsessed? I think it's gonna look pretty cool with new aluminum rims and new spokes.
Here's a few pictures of my progress.


« Last Edit: February 02, 2024, 06:32:21 PM by chesterburnet111 »
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #27 on: February 02, 2024, 06:53:56 PM »
I've been at this build for 2 years already but having just joined this site, I'm trying to catch up.

I needed to do some more fit out work to use my garage as a shop. I had to run a new heavy duty electric circuit out there. I bought a huge tool box and a laptop so I didn't have to run in the house to look up stuff online and play music too. With 67 year old eyes, I need good lighting and remembered seeing loading dock lights which were bright as the sun. I found a brand new one on Ebay for $85. Works like a charm.

 
« Last Edit: February 02, 2024, 06:56:12 PM by chesterburnet111 »
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #28 on: February 02, 2024, 08:19:19 PM »
I rode motocross bikes until I was almost 40. Never owned a street bike. Mostly because although I ridden street bikes, I didn't feel the same excitement as off road. I didn't ride again until I was 59. My GF asked me to go with her son to look at motorcycles because she knew I used to be into them. When she saw me geeking out over them at the dealers, she decided to buy me a Ducati Scrambler as a Christmas present. It took about 3 months and my motorcycle obsession was back. I'm on my 4th bike since 2016 plus this Honda build. I bought a 2017 Yamaha FJ09 and decided to do aftermarket suspension. Honestly, I didn't think I rode well enough to notice the difference but still dropped about $2500 on K-tech shock and cartridges. What I found out was that great suspension makes a huge difference. I traded the 09 for a new 19 MT10 and immediately ordered a K-Tech rear shock. Covid hit and I decided I was going to learn how to do forks and set up suspensions. I ordered a set of Ohlins cartridges and proceeded to install them. I read everything I could and watched a million suspension setup videos. I've gotten pretty good at it.

When I started this build, I knew I wanted great brakes and wanted great suspension without putting forks from a newer motorcycle. I bought a 2nd rotor and a set of CB750 calipers from Ebay. It's actually pretty cheap to go to a dual rotor setup. I lucked out and got some very clean used parts.

During my suspension research, I found out that having springs that match riders weight is the single most important thing you need to do. Preload doesn't make springs compensate for heavy riders. Japanese motorcycle companies tend to have very light spring rates. There is a reason why Ohlins, K-Tech, Penske, Nitron all make around 10 different spring rates for their shocks & cartridges. I'm 6'1" and about 260 lbs so I bought a set of Hagon for about $400 from Bella Corse sprung for my weight. I didn't feel like I needed to spend $800 - $1000 on shocks for a 50 HP bike. I think they'll work well for me.

Forks are more complicated. I wanted to keep the stock look so this is my plan. I bought a set of 77 CB750 forks from Ebay. They're about an inch longer than the 550 fork. I also bought a brand new set of upper tubes as there was rust on both sets and even when you clean rust off, it's probably going to be back because you can paint them to protect them. I bought a set of springs (for my weight) from RaceTech. I also bought a set of cartridge emulators for RaceTech. You have to drill the damping rods but it's not big deal as I have a drill press. The last piece was a nice set of fork caps with preload adjusters. Although I still have to deal with the spindly 35 mm fork tubes, I think the rebuilt forks will work well when I put them together. I keep thinking that getting modern upside down forks would be hard to get to work. I want to stay close to the stock geometry because I feel like it's the easiest to work with. Probably going to need a steering damper. I'll see.
« Last Edit: February 02, 2024, 08:21:47 PM by chesterburnet111 »
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Offline calj737

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Re: My $300 77 CB550F Project
« Reply #29 on: February 03, 2024, 05:52:56 AM »
Two things: you could adapt GL forks to your bike as the tubes are 39mm and brake components transfer over pretty easily.

As for the brakes, CognitoMoto James a front and rear hub adapate for modern calipers and rotors while maintaining the original spokes (I use Buchanans stainless spokes on Excel ally rims). Many have used the CBR600 (F1 I think) forks as they are not inverted but much better for adjustability and stronger than the 35mm tubes you have.

Those are all involved/mildly expensive upgrades but address your two main points specifically.

If you have taken the time to polish the ally, search Shark Hide metal protector. It’s commonly used in marine applications to protect the ally from excessive oxidation. Should make keeping your grunt work looking better longer.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #30 on: February 04, 2024, 06:06:44 AM »
3 Saturdays and 2 Sundays to get this sanded and polished out. I understand why so many people just paint them black. I've seen that there are companies that you can send these parts to get polished. I'm curious how they do it efficiently enough to make money at it. I still have to do the brake plate but that's only 1 surface so I'm hoping to get that done today and start assembling the rear wheel. New aluminum rim, spokes, sprocket, bearings and brakes shoes were about $200. I bought one of the cheap Rising Sun aluminum wheels from 4into1. I've looked at it and it's a decent looking piece. The reviews have all been about the same....it does the job and hasn't failed. I'm curious if anyone has actual experience with them.
« Last Edit: February 04, 2024, 06:24:38 AM by chesterburnet111 »
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Offline MauiK3

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Re: My $300 77 CB550F Project
« Reply #31 on: February 04, 2024, 06:47:44 AM »
Very nice work!
It's no easy task.
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10/72 build Z1 Kawasaki

Offline denward17

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Re: My $300 77 CB550F Project
« Reply #32 on: February 04, 2024, 06:58:52 AM »
Nice looking hub, it does take a while to get that OEM clear off.

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #33 on: February 04, 2024, 07:24:21 AM »
Can you clear coat these hubs? if so, what product?
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Offline calj737

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Re: My $300 77 CB550F Project
« Reply #34 on: February 04, 2024, 07:41:30 AM »
You can. But as you’ve polished them, you’d need to scuff them up for a mechanical adhesion for the clear coat. Better to use an aluminum anti-oxidant like Shark Hide.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #35 on: February 04, 2024, 09:44:36 AM »
You can. But as you’ve polished them, you’d need to scuff them up for a mechanical adhesion for the clear coat. Better to use an aluminum anti-oxidant like Shark Hide.
Who sells it? Also, where is the thread showing the modified triple clamp?
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Offline calj737

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Re: My $300 77 CB550F Project
« Reply #36 on: February 04, 2024, 10:23:25 AM »
You can. But as you’ve polished them, you’d need to scuff them up for a mechanical adhesion for the clear coat. Better to use an aluminum anti-oxidant like Shark Hide.
Who sells it? Also, where is the thread showing the modified triple clamp?
Picture here: http://forums.sohc4.net/index.php/topic,126401.msg1587661.html#msg1587661

Shark Hide you can find here: https://www.amazon.com/Sharkhide-Metal-Protectant-1/dp/B07NGMYKS5?th=1
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #37 on: February 05, 2024, 07:51:20 AM »
I took a look at the triple clamps. They are nice but not the direction I want to go with this build. I took your advice and bought that Shark Hide. I also see that you're in VA. I'm going down on a motorcycle vacation to Western NC in early June. On June 6th we're going to head up to Back of the Dragon in Tazwell VA. You should come out and ride with us for the day and lunch. I've ridden it 3 years ago and it is a seriously cool place.
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Offline calj737

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Re: My $300 77 CB550F Project
« Reply #38 on: February 05, 2024, 09:33:14 AM »
I’ve done Tail of the Dragon; doesn’t thrill me. There are far too many great roads in southwest VA and western NC that don’t get the psycho traffic, wannabe knee draggers, and title-chasing nimrods to ride it again.

One of my favorite rides is from Roanoke, west to Salem, then ride to Paint Bank. Wonderful roads through there, little to no traffic, and all the technical turns you require.

But I’d be delighted to ride sometime, I’ll be on my BMW K1300S so I can be comfy all day, trouble-free, and enjoy 175HP when necessary  8)
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #39 on: February 05, 2024, 11:54:47 AM »
Not Tail of the Dragon.....Back of the dragon in VA. which is in the area you're talking about. I totally agree, southwest VA and western NC are awesome and I've motorcycle vacationed in that area for the last 3 years.
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Online newday777

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Re: My $300 77 CB550F Project
« Reply #40 on: February 06, 2024, 04:32:03 AM »
I've been at this build for 2 years already but having just joined this site, I'm trying to catch up.

I needed to do some more fit out work to use my garage as a shop. I had to run a new heavy duty electric circuit out there. I bought a huge tool box and a laptop so I didn't have to run in the house to look up stuff online and play music too. With 67 year old eyes, I need good lighting and remembered seeing loading dock lights which were bright as the sun. I found a brand new one on Ebay for $85. Works like a charm.

Welcome aboard the forum from southern NH.
Just read through this build. Nice job so far especially the polishing.
I need to get one of those dock lights but I only see them at $138+ now.
Do you have the link for the $85 you got?
Stu
Honda Parts manager in the mid 1970s Nashua Honda
My current rides
1975 K5 Planet Blue my summer ride, it was a friend's bike I worked with at the Honda shop in 76, lots of fun to be on it again
1976 K6 Anteres Red rebuilding project, was originally my brother's that I set up from the crate, it'll breath again soon!
Project 750s, 2 K4, 2 K6, 1 K8
2008 GL1800 my daily ride and cross country runner

Prior bikes....
1972 Suzuki GT380 I had charge of it for a year in 1973 while my friend was deployed and learned to love street riding....
New CB450 K7 after my friend returned...
New CB750 K5 Planet Blue, demise by ex cousin in law at 9,000 miles...
New CB750 K6 Anteres Red, to replace the totaled K5, I sold this K6 at 45k in 1983, I had heavily modified it, many great memories on it and have missed it greatly.....
1983 GL1100A, 1999 GL1500 SE, 1999 GL1500A

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #41 on: February 06, 2024, 07:59:39 AM »
I might have caught one at the right time. I made an offer of $60 and it came back at $80. I just did a search and can't find any less than $138. I'd pay that much for it. it is really excellent. I installed on the garage rafter and I can light up all areas of the garage. Make sure you get the type shown in the link with the 2 single arms and 30 watt as they are the most adjustable super bright. Make them an offer.
https://www.ebay.com/itm/385603789880?hash=item59c7c6e438%3Ag%3AMr4AAOSwdJZjfchh&amdata=enc%3AAQAIAAAA8K7hD8vZ8wEDuZmmlSrJ0D8AcT7viA5wtgFlqkZtNIfNJgYSkg%2BiMQ649eHp1w%2FOBGtyP8XLm4X3XbEnIVJZkTfUZ2dgoPbeVVDTYiyrW9s1VygSGWO7yJCfro9WG5UFjm8ovEmtU9HbuhJCgPNl2PXIeompKo8iNyGpbCIxEJKBfQiu6sUX50hGJYeTW%2B%2BjvqIj%2FGfW3Of5rV09LRxg7ux2X4iFP3EgNunZmRIEAGwk72d%2B15Rp49jsZacOVnQwl2MGMsVvWbRsiyKRiM1NrmLFzHjSGUWVBOMSLqDgP0XHIkRe7jSkQo34MvhLje2RPA%3D%3D%7Ctkp%3ABFBM6suR8q9j&LH_BO=1
« Last Edit: February 06, 2024, 08:01:41 AM by chesterburnet111 »
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Online newday777

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Re: My $300 77 CB550F Project
« Reply #42 on: February 06, 2024, 08:03:17 AM »
OK. Thanks
Stu
Honda Parts manager in the mid 1970s Nashua Honda
My current rides
1975 K5 Planet Blue my summer ride, it was a friend's bike I worked with at the Honda shop in 76, lots of fun to be on it again
1976 K6 Anteres Red rebuilding project, was originally my brother's that I set up from the crate, it'll breath again soon!
Project 750s, 2 K4, 2 K6, 1 K8
2008 GL1800 my daily ride and cross country runner

Prior bikes....
1972 Suzuki GT380 I had charge of it for a year in 1973 while my friend was deployed and learned to love street riding....
New CB450 K7 after my friend returned...
New CB750 K5 Planet Blue, demise by ex cousin in law at 9,000 miles...
New CB750 K6 Anteres Red, to replace the totaled K5, I sold this K6 at 45k in 1983, I had heavily modified it, many great memories on it and have missed it greatly.....
1983 GL1100A, 1999 GL1500 SE, 1999 GL1500A

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #43 on: February 07, 2024, 06:44:31 AM »
I lost the wheel bearings I bought and had to order new ones and they will be here today. I'm looking forward to putting the wheel together and my first attempt at lacing and truing a wheel.

I have a question that I'm hoping to get answered. I've bought a lot of brand new nuts and bolts but there are still a bunch that I need to clean up. I've seen a video where they get them super hot and quench them in oil that leaves them with a nice blackened finish. Has anyone tried this and does it weaken the integrity of the nut / bolt? Does anyone have any other suggestions. I don't want to install all of these new or refinished parts with ugly gnarly looking fasteners.
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Offline seanbarney41

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Re: My $300 77 CB550F Project
« Reply #44 on: February 07, 2024, 08:54:46 AM »
Never heard of the quenching in oil trick...but then, blackened hardware does not sound like it it is too far removed from ugly gnarly looking fasteners.

Is all your hardware rusted?  Sure about that?  Try cleaning before you right it off.  I like 0000 steel wool soaked in wd40, then wipe off excess with rag.  Super time consuming but I am always amazed how much nice plating is left on the crustiest of bikes.  If you got solid brown, pitted rust, the plating is gone...if I am not gonna be bothered with replacement, wire wheel it, coat in wd40 and send it.  Yeah, its gonna rust again, but no worse than when you found it.

And then there is more drastic and production oriented methods like re-plating, tumblers, home plating kits, etc....
If it works good, it looks good...

Offline denward17

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Re: My $300 77 CB550F Project
« Reply #45 on: February 07, 2024, 09:08:22 AM »
I usually soak all my screws/bolts/nuts in Evaporust for a few days, then use a dremel with a light abrasive buffing wheel.

They clean up like new...

Offline calj737

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Re: My $300 77 CB550F Project
« Reply #46 on: February 07, 2024, 11:19:36 AM »
I lost the wheel bearings I bought and had to order new ones and they will be here today. I'm looking forward to putting the wheel together and my first attempt at lacing and truing a wheel.

I have a question that I'm hoping to get answered. I've bought a lot of brand new nuts and bolts but there are still a bunch that I need to clean up. I've seen a video where they get them super hot and quench them in oil that leaves them with a nice blackened finish. Has anyone tried this and does it weaken the integrity of the nut / bolt? Does anyone have any other suggestions. I don't want to install all of these new or refinished parts with ugly gnarly looking fasteners.
Quenching a bolt can generate a blackened finish (often referred to as black oxide). The trick is to not overheat the metal and bring it close to a fatigue point. Getting it super hot and quenching it makes it more brittle, even though it may have a new oxide coating on it.

Black oxide coated bolts still rust. It’s not super durable for an “exterior grade” finish. Stainless is superior in that regard.

Evaporust and a dremel works fine as long as you don’t remove the plating. That reveals the bare metal, which rusts  ;) whenever I clean stock bolts on a bike, car or truck, I always only use a loose wire stainless wheel/brush to scrub the bolt. It won’t damage the coating, removes gunk and grime, and last a lot longer than brass bristles.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #47 on: February 07, 2024, 12:30:00 PM »
Oh man..........I've been wrenching on motorcycles since I was 13 and there's still a ton of stuff to learn.
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Offline calj737

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Re: My $300 77 CB550F Project
« Reply #48 on: February 07, 2024, 01:05:49 PM »
It’s not the years in your life; it’s the life in your years  ;) And everyday is an opportunity to learn something new.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline Godffery

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Re: My $300 77 CB550F Project
« Reply #49 on: February 07, 2024, 05:54:50 PM »
 Unfortunately cleaning the hardware is only part of the process. If the original plating is compromised, then it will still need to be re-plated.
Chances are you should be able to find a local Zinc platting shop and have them do your whole batch at once.  The one in my area will do every nut, Bolt and bracket from a complete bike, for $30 bucks.  ($60 if I request the extra clear sealer on top of the Zinc)

 Here is an example of the Re-Plated hardware for a set of Carbs:
https://scontent-ord5-2.xx.fbcdn.net/v/t1.6435-9/46624453_493223701185648_2080282884584767488_n.jpg?_nc_cat=102&ccb=1-7&_nc_sid=4dc865&_nc_ohc=UjbvXWhe2r8AX88lbY0&_nc_ht=scontent-ord5-2.xx&oh=00_AfAEv_XyE6o1UZOvW0KdcmvQd2-l2vfnRwzuTBSZc6RwnA&oe=65EB9B4A