Author Topic: CB550 Cafe Interceptor - Gentleman's Roadster (Read 345749 times)

aussie · « **Reply #75 on:** January 29, 2009, 08:40:09 PM »

Quote from: FunJimmy on January 29, 2009, 07:31:19 PM

Here are the headlight ears after welding.
Everything fits perfectly!

Now do I dress the welds and polish or powder coat?

Jimmy dress the welds and polish them, no point in covering up a piece of work like that.

Ecosse · « **Reply #76 on:** January 29, 2009, 08:43:27 PM »

Quote from: aussie on January 29, 2009, 08:40:09 PM

Jimmy dress the welds and polish them, no point in covering up a piece of work like that.

+1

Jinxracing · « **Reply #77 on:** January 29, 2009, 09:47:43 PM »

Nice machine work and welding Jimmy. Those welds look so good I wouldn't even dress them...show them off!

The machine work lends kind of a modern look to the front end, have you thought about anodizing?

fastbroshi · « **Reply #78 on:** January 30, 2009, 10:10:29 PM »

Jimmy you magnificent bastard, it's coming right along. Keep it up.

fastbroshi · « **Reply #79 on:** January 31, 2009, 07:00:26 PM »

Oh yeah, whoever did your welding did a good job. Why was that one section brazed? Maybe because the gap was so big? I thought that building up the weld might be stronger than a brazing.

MCRider · « **Reply #80 on:** February 01, 2009, 06:30:05 AM »

FJ: Could you post a closeup picture of the area where you welded the steering neck to the frame downtubes. I'd like to see how the powdercoating filled this area.

On my project the rivets are becoming exposed. The powder coating people said not to use bondo on them as it will pop off in the oven. They even said that jbWeld and possibly brazing might also pop off. Anyway they would not be responsible for it.

So as we discussed via PM, I will weld the steering neck to frame tube gusset as you have and leave the rivets alone.

Any other closeup of your work like the sidestand mount that you filled would be interesting.

The powder coating people (understandably) will not commit to how much the powdercoat will fill irregularities.

I'll be using sandpaper on a grinder as much as possible to clean up the chickens--t factory welds.

Thanks!

FunJimmy · « **Reply #81 on:** February 01, 2009, 03:26:47 PM »

MCRider

At 400F the powder coating ovens are too hot for any Bondo or JB Weld that’s for sure.

Brazing has been used on bicycle frames for years without any issues at all.
Interestingly when I media blasted the Dresda swingarm I discovered that it’s all brazed together.
I would have thought was arc welded.

Powder coating does do a good job of filling minor imperfections and smoothing out the edges.
I’ll take a couple of close ups when I’m out in the garage tonight.

Cheers
FJ

MCRider · « **Reply #82 on:** February 01, 2009, 04:28:53 PM »

Thanks FJ. Your feedback this week has been very helpful! Pics will be appreciated.

Thanks Unc. That's good to know. I have been smoothing my welds with a dremel tool and the sandpaper barrels. It is doing a better job than I expected and i don't think I'll need any filler. But that's a good thing to know.

FunJimmy · « **Reply #83 on:** February 03, 2009, 03:46:30 PM »

I really liked the idea of relocating the ignition switch under the tank.
It cleans up the top triple tree area nicely leaving just the tach mount to worry about.
Problem is that the ’77 CB550’s didn’t have an under tank option and once the frame was powder coated I couldn’t weld any mounts on.
There are two 6mm threaded holes on the right side of the frame just under the coils that provide the perfect place to mount the switch.

The ignition switch bracket is made of three pieces.
The cylinder and cap will be bonded together with epoxy once anodized black.
The mount plate will have three set screws to hold the cylinder in place.
If I want the ignition switch on the left side of the tank, simply unscrew and rotate.

MCRider · « **Reply #84 on:** February 03, 2009, 04:26:19 PM »

Quote from: FunJimmy on February 03, 2009, 03:46:30 PM

I really liked the idea of relocating the ignition switch under the tank. It cleans up the top triple tree area nicely leaving just the tach to worry about mounting up there. Problem is that the ’77 CB550’s didn’t have an under tank option and once the frame was powder coated I couldn’t weld any mounts on. Interestingly there are two 6mm threaded holes on the right side of the frame just under the coils that the plastic harness box bolts to. Since I removed that harness box last year, those mounting holes made the best ignition switch mounting point I could have hoped for.

This ignition switch bracket is made of three pieces. The cylinder and cap will be bonded together with epoxy once anodized black. The mount plate will have three set screws to hold the cylinder in place. If I want the ignition switch on the left side of the tank, simply unscrew and rotate.

Man that's a nice looking piece. The early CB750 had its ignition below the tank left sidefront. The big thing was to move it up to the handlebar with an aftermarket bracket. Sold tons of those brackets. Used one on mine, but the tank bag would always hit it when I turned hard left. I always have a tank bag when I'm travelling.

Now you've got me thinking. Do I have a better bracket made for up top that puts the switch clear of the bag, do I move it back to original, oops theres a gusset in the way. I saw someone here moved theirs to the rear below the tank on the left side. Oops there's a gusset there too. Guess I better drag out the switch and do some mock up before powder coating.

My old Triumph (and my SuperHawk) had it in the sidecover. Don't know if there is enough room behind it.

But looks like you solved your problem nicely.

FunJimmy · « **Reply #85 on:** February 03, 2009, 04:50:12 PM »

Earlier last year I bought a second engine on ebay and this is the bottom end opened up for cleaning and inspection.
The crank bearings are in excellent condition and well within specification.
You’ll also see that lower case is completely free of primary chain wear marks that are common on high mileage engines.
Tranny looks real good too. I think this engine has relatively low mileage.

Toxic · « **Reply #86 on:** February 09, 2009, 08:14:41 AM »

Jeez you have some mad skills.

Awesome build, I'm kind of speachless.

squirley · « **Reply #87 on:** February 09, 2009, 08:39:22 PM »

Nice looking stuff you've got going there Jimmy. That ingnition switch retainer is looking very nice, about the location that I moved mine, but I like your style much better...guess I will have to go back to the drawing board now.
Keep the pics coming...!!!!

Jens

FunJimmy · « **Reply #88 on:** February 10, 2009, 09:07:45 AM »

Thanks guys.

While the engine is getting the full treatment, the painter has possession of all my bodywork, and I’m stoked with the direction it’s heading.

No pictures to show yet, but of the several themes that we discussed, he agreed that “Project CB550i Interceptor” was the most interesting.
I’m not a great color guy especially when it comes to multi color schemes, but you know you’ve got the right guy when he can tweak a concept and balance the proportions to perfection right before your eyes.

Stay tuned.

Jimmy

FunJimmy · « **Reply #89 on:** February 10, 2009, 02:56:17 PM »

Quote from: raymond182 on February 10, 2009, 12:49:05 PM

550i as in fuel Injected?

I wish I could say yes, but no....as in interceptor!

tiretread · « **Reply #90 on:** February 26, 2009, 07:29:06 PM »

That is one beautiful build. Can't wait to see the completed project.

FunJimmy · « **Reply #91 on:** February 27, 2009, 08:24:00 PM »

Thanks to Kemp, I found these rare 59mm Yoshimura racing pistons.
Getting new rings with the three piece oil rings was a challenge, but finally came together.
Stock pistons weighed 160 grams without rings each and the Yoshimura pistons without rings weigh 152 grams. 5% lighter than stock!

[

FunJimmy · « **Reply #92 on:** February 27, 2009, 08:24:32 PM »

Here, you can see that compared to stock pistons the Yoshimura pistons have a raised center for increased compression and deep valve reliefs for high lift cams.

FunJimmy · « **Reply #93 on:** February 27, 2009, 08:25:12 PM »

With higher compression pistons and a CB650 cam, head porting was a must, and who better to perform that magic than MReick.
Stage II port work, Kibble valve springs and a three angle valve grind.
Should be a good setup with the Web Cam 58a camshaft installed.

FunJimmy · « **Reply #94 on:** February 27, 2009, 08:26:32 PM »

With the higher lift of the 650 cam came some clearance issues.
Easily remedied with the Dremel tool and a carbide cutter.
Interestingly only about 40% of the cam lobes required additional clearance.

FunJimmy · « **Reply #95 on:** February 27, 2009, 08:27:10 PM »

With things buttoned up, it’s time for paint.
I just hung the engine from the garage rafters with tie downs and gave it a couple of coats of Duplicolor Aluminum.
Once dry to the touch, I heated the paint with an industrial heat gun.

aussie · « **Reply #96 on:** February 27, 2009, 08:54:38 PM »

Looks good jimmy, will be interesting to hear how much extra go it has now. Tossing up myself about a 650 cam and 750 pistons.

fastbroshi · « **Reply #97 on:** February 28, 2009, 06:25:25 AM »

Did you do any testing to see what compression ratio those pistons yield Jimmy? Going to be interesting. Say I wonder if that's the head I sent Mike? Maybe I'm contributing to your build and didn't realize it

FunJimmy · « **Reply #98 on:** February 28, 2009, 11:48:40 PM »

Fast

No I didn't run any compression ratio numbers.
These pistons don't have that large of a dome to be too concerned about.
The modified 750 pistons used in the “Gentleman’s Express” appear to have higher domes than these.

FunJimmy · « **Reply #99 on:** February 28, 2009, 11:52:11 PM »

Trial fit with freshly painted tins.
I've always loved the white, red and blue paint scheme of the VF750F Interceptor.
It's the inspiration for my paint so I see it fitting to call this the Café Interceptor!

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Author Topic: CB550 Cafe Interceptor - Gentleman's Roadster (Read 345749 times)

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