Author Topic: My $300 77 CB550F Project  (Read 8695 times)

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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #100 on: March 28, 2024, 12:39:08 PM »
I just don't have enough space to do powder coating nor the inclination to go through the process of learning to do it well.
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Offline willbird

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Re: My $300 77 CB550F Project
« Reply #101 on: March 28, 2024, 01:04:08 PM »
I just don't have enough space to do powder coating nor the inclination to go through the process of learning to do it well.

Overall it is a lot easier to setup for than painting with auto body paints, but baking bigger stuff then becomes an issue. If somebody can do a good job local I would be totally on board with letting them do it for sure.

Bill

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #102 on: April 05, 2024, 05:40:36 AM »
I'm at the point of assembling stuff and now I'm finding all of the odds and ends that I need to complete things. I have the original parts but once you finish the big stuff, you can't put rusty nuts and bolts on it. I've tried to refinish a few but they just don't come out that good. Fortunately you can find most any Honda CBs fastener new even though it's a 45 year old motorcycle.

I took a day off this week and spent the entire day doing motorcycle stuff. I bought the JW designs speedometer blank out but since I am doing dual calipers, the design doesn't interface as well with the second disc. The guy on "Ride The Miles" details his 2 disc conversion and had a neat spacer machine. I grabbed some screen shots and measured everything up and found a local machine shop to make one for cheap money.  got my tires mounted, brought the frame to a welding shop to find out how to prep to weld it back together. Also went to a custom builders shop to see what he's working on. Motorcycle days are pretty cool.

Hard to believe it was almost 2 months of weekends to get these done. I can't believe how much heavier they are in comparison to the huge wheels and tires on my MT10.

Wheel Tire Automotive tire Tread Motor vehicle
« Last Edit: April 05, 2024, 05:44:02 AM by chesterburnet111 »
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #103 on: April 12, 2024, 08:20:53 PM »
I keep thinking I'm going to get things done way faster than I actually do. I'm waiting on my welder, my machinist and my powder coat guy to get parts back so I can proceed. I need to get a rolling chassis so I can build the seat mounting. I'm also finding that the small nickle & dime parts add up. I figured that before I install the swingarm bearing kit, new shock bushing and grease fitting, I'd get it powder coated. It's ok to loose a weekend as I have a lot of yard work I need to get done. 
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #104 on: May 03, 2024, 10:29:47 AM »
I have been doing a lot of work but it feels like I'm not making much progress when in fact I am. Grunt work never looks impressive whether it's mechanical work, construction, decorating or cooking, but it's what makes everything that comes after look great. I'm still working on the frame and it's close to being done. I bought a $70 Harbor Freight brake so I can make a tray, a metal seat pan reinforcement and I want to redo the inner fender as the bend is not good enough to suit me. I've got most of the nasty tedious grunt work done and am now close to test assembling everything after which I'll send the frame off to the powder coater.

I decided to get the swingarm powder coated now because I didn't want to get it done with the new bearing kit and new shock bushings in. I just picked it up along with a few other parts I had done. The color is Mercedes silver and the pictures don't do it justice. This finish and color just pop. It's a early preview for me to see the finished color. I'm on my anti black motorcycle campaign and I have to say that IMO, when I put these powder coated parts along side the brushed and polished aluminum and chrome, the combination looks awesome.
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Offline denward17

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Re: My $300 77 CB550F Project
« Reply #105 on: May 03, 2024, 10:32:33 AM »
I like it!

Good Luck with progress.

Offline Godffery

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Re: My $300 77 CB550F Project
« Reply #106 on: May 03, 2024, 05:13:26 PM »
 Groovy!  Too many Black frames in the world.  ;)

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #107 on: May 03, 2024, 07:16:55 PM »
My thoughts exactly. Non black frames are very groovy. I really wanted to do nickle plated like a Rickman but it's not practical.
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Offline Godffery

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Re: My $300 77 CB550F Project
« Reply #108 on: May 03, 2024, 07:45:56 PM »
 I was actually going to do my last project in nickel and the quote even seemed rather reasonable for what is involved in the process, But... After calculating in the hours required to properly prep the frame to get a nice smooth homogeneous finish, it tipped into the realm of ridiculou$.  =/

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #109 on: July 24, 2024, 07:43:11 AM »
I'm still working on this build. I've been trying to find a good welder and nobody wants to do this type of work. I'm not a welder and this has stalled me since the winter. About 3 weeks ago I went out for a ride on my MT10 and 2 minutes out I spotted a cafe racer and I followed him to an ice cream parlor right down the road. I introduced myself and was checking out his build which was a Kawasaki 250 cafe racer that was a seriously cool budget build. What made it so cool was that he did a bunch of custom fabricating which was beautiful quality. I asked if he welds and said yes, he has a small hobby motorcycle business. A couple of days later I brought my frame over to his little shop which is called Lizzie's Choppers - He lives 2 doors away from the LIzzie Borden murder house.


I told him my plan, what I had fabricated and what needed to be welded. Not only did he weld, but made suggestions and improvements. It is so cool getting to work with someone like this. This is the only part of this project I couldn't control and it's exceeding my hopes and expectations. He also has no head for business so I had to insist on paying him almost double what he asked. It's a matter of respect and doing the right thing. He's also somebody that I can learn from and generally pretty cool to hang out with.


In the mean time, I have been doing stuff also. I'll be picking it up in the next day or so and now finally begin to put it together and test fit everything. My motor, wheels, forks, swing arm are all finished and ready to install. Once I get it all fit up, I'll take it apart and send the frame to my powder coater. It's satisfying to realize that the grunt work is behind me. Assembly is generally pretty easy on these bikes when you do the grunt work well.


I'll post some pictures of the frame when I pick it up. It won't show well in pictures until it gets sand blasted and powder coated but it's excellent prep and fabrication. Hopefully with the easily over $8000 in parts I have to hang on the frame , it'll look like something.   
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Offline newday777

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Re: My $300 77 CB550F Project
« Reply #110 on: July 24, 2024, 08:46:52 AM »
That is great news. Looking forward to seeing it coming back to life.
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 grcamna2

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Re: My $300 77 CB550F Project
« Reply #111 on: July 24, 2024, 10:58:19 AM »
That is great news. Looking forward to seeing it coming back to life.

+1  8)
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #112 on: July 24, 2024, 07:32:42 PM »
Here is the frame ready for finish sanding and then test assembly. It looks a little rough because it's unfinished but it's some nice fabrication. The tail section is restored back to stock to work with the tracker seat. All of the electronics and battery will fit in the trays which will leave the center section completely empty. I made a plate to go in the section where the lower fender would be. Not an original idea as I've seen it done on other builds. It will keep the pods dry if I get caught in the rain and it looks pretty cool.
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #113 on: July 25, 2024, 06:17:51 AM »
Any suggestions on how? I s there a caulk that would work?
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Offline MauiK3

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Re: My $300 77 CB550F Project
« Reply #114 on: July 25, 2024, 07:41:58 AM »
Silicone caulk or perhaps Bondo
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Offline denward17

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Re: My $300 77 CB550F Project
« Reply #115 on: July 25, 2024, 07:58:22 AM »
Isn't there an automotive seam sealer that would work? 

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #116 on: July 25, 2024, 08:18:43 AM »
Great suggestion. You are right. There is and that will work.
TY
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Offline BenelliSEI

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Re: My $300 77 CB550F Project
« Reply #117 on: July 25, 2024, 02:30:29 PM »
I was actually going to do my last project in nickel and the quote even seemed rather reasonable for what is involved in the process, But... After calculating in the hours required to properly prep the frame to get a nice smooth homogeneous finish, it tipped into the realm of ridiculou$.  =/

Just read this and curious what the total was for bright nickel? I want to have my Rickman CR750 replated but not sure I actually trust anyone I have talked with!

Offline Godffery

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Re: My $300 77 CB550F Project
« Reply #118 on: July 25, 2024, 02:41:58 PM »
I was actually going to do my last project in nickel and the quote even seemed rather reasonable for what is involved in the process, But... After calculating in the hours required to properly prep the frame to get a nice smooth homogeneous finish, it tipped into the realm of ridiculou$.  =/

Just read this and curious what the total was for bright nickel? I want to have my Rickman CR750 replated but not sure I actually trust anyone I have talked with!
At the time (2019) I was quoted about $600 to $650. (not including swingarm) Though Prices for everything has shot up a great deal since then, so I would expect it to be substantially more now...?

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #119 on: July 25, 2024, 03:40:08 PM »
I saw my first Rickman at Slager Forbes motorcycle dealership in NJ around 1970. I never forgot how gorgeous those nickle plated frames where. I was originally thinking of doing a faux nickle powder coat but they just don't look the same.
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #120 on: July 28, 2024, 07:04:50 AM »
I bought a tube sander. Hopefully it saves time and work.

One of my main goals was to upgrade the suspension to closer to modern standards. I've lost about 40 lbs since I started this build and when I ordered all of the suspension stuff, I ordered with springs for a 250 lb rider. I realized that this thing will be terrible to ride now and had to bite the bullet and buy new springs which i did. Can't make an improperly sprung bike handle. No way to set sag when the weight is that far off.
« Last Edit: July 28, 2024, 07:06:52 AM by chesterburnet111 »
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #121 on: July 28, 2024, 12:23:36 PM »
I installed fork caps with preload adjusters. It's easy to add or remove oil to change rebound and compression to a degree or go up or down in oil weight. I got a lot of feedback from Race Tech on setting up. I want to keep the stock look and I think this is as good as it can be. I'm not a fan of putting upside down forks and changing over to a single shock rear. I want a unique 77 CB550 but that still is recognizable as one.
« Last Edit: July 28, 2024, 12:26:38 PM by chesterburnet111 »
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #122 on: July 28, 2024, 08:53:07 PM »
The fork caps are very good quality. There are some cheap ones on Ebay that look similar but are junk. I know Wilburs have a good reputation but I haven't seen anyone that carries them. I went with Hagons which were about about $450 with the spring rate I wanted. I can't see investing too much more than that on a 50 HP motorcycle that isn't going to be my daily rider.   
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #123 on: August 26, 2024, 07:50:40 PM »
I'm making progress. Doing a mock up and I've got it rolling. I've been working on motorcycles since I was a kid and there are still so many things to figure out. I bought this a s a basket case and don't have the advantage of taking it apart and seeing how it goes back together. Thank God for forums, YouTube and having a 77 Honda parts book.

This is what I've accomplished so far this summer:

I bought a universal seat / fender from a European company. I was trying to figure out how to mount it and found Tuffside seats and was looking to see how they do it. I was so impressed with his process that I bought his version which is CB550 specific. It's real nice quality.   

I got the from forks and wheel installed and the front wheel was totally bound up. I'm doing dual discs and a speedo delete as I'm going with the Motogadget speed sensor. It's a little tricky because the speedo blank out part is designed to work with the mechanical speedo base. I also tried turning the forks around so the calipers face the rear. I ended up calling Jeff from Godferry's Garage and he diagnosed the bound up wheel on the phone. He explained why the front side install was the better way and so I swapped it back and problem solved. I also got a master cylinder set up from him that is way cool. I'm very appreciative of his help and guidance.

I also picked up a set of Rox risers so my handlebars will clear the preload fork caps. Borrowed a couple of sets of handlebars to see how they look and feel and then bought a set of Renthals. Since I have all Motogadget controls, I needed to buy a throttle. There aren't a lot of choices for a simple pull style and I didn't want a Chinese piece. I settled on a Domino and it will work with the Murrays Carb cable.

I had bought a set of Cognito rear sets. I called them and asked if they would work on an F model and they explained that I had to modify it and get a pivot from a K. Apparently I wasn't clear on that my 550 is a 77. They only work up to 76 which I found out when trying to install them. (If anyone is looking for a set, message me. I also have a tracker seat. Both brand new) This really sucked as I hate the way the stock pegs look. I
took a shot and bought a set of 98 Yamaha YZ 125 - 250 steel pegs. As it turns out, it's a simple modification. Grind about a quarter inch of the the tube that the pin goes through, Get a grade 8 or better 3/8" bolt and make the mounting hole a little larger and they fit nicely and look pretty cool.

I have a few frame mods that I didn't account for. Nothing terribly difficult but they have to be done. I thought a lithium battery would fit in the tray under the seat but no such luck. I'm going to take Cal's advice and put a battery box above the swingarm pivot. I haven't investigated what the best way to do that is. I'm wondering if it needs to totally enclose the battery and hoping I can find one prefabbed. Any advice is welcome.

My painter lives here in Massachusetts from May to September and the Florida in the winter so I had to get my seat, front fender and tank over to him. He does custom motorcycle paint and I had to rush as I don't want a non motorcycle guy to do the paint. It's a bit premature but they are all test fitted.

The guy that does my welding now is a good fabricator and we've become friends. I had bought a brand new sand blasting cabinet and compressor from a guy that decided he wasn't going to use them for $200. When I got them home I realized I don't have the space for the cabinet and traded it to my welder for the rest of the work I need. Worked out pretty well.

That's pretty much where I'm at. I'm hoping to get the frame done and over to the powder coated by the end of September. We'll see....the road to hell is paved with good intentions. Mostly I'm really enjoying the process. 
Below are some pictures.
« Last Edit: August 26, 2024, 08:09:29 PM by chesterburnet111 »
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #124 on: August 26, 2024, 08:00:39 PM »
I think the gas tank I have is from another year K as it has the clips for the chrome trim on the bottom and I don't think the F model had that. I bought a new petcock for it and it doesn't fit. The nut is too small for the fitting. I've spent a considerable amount of time trying to figure out which one it is and apparently there a few different tanks that Honda used. My painter has the tank so I can't measure the fixture. This tank has no overflow or vent tubes if that helps. I could use some help.
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