Topic: My new build - Lets keep this one nice :)

[babyfood1217]

*disclaimer: I know I know, you would think I have learned to keep my mouth shut, camera off, and imagination at a standstill, but I guess I didn't learn from last time, so...

Welcome to the start of my next build! (fireworks and champagne fall from the heavens)

So I decided I really like the idea of an undertail, so I had to give it another go.  This time however, I did a little more planning.  No chopping of the frame at critical points this time.  Exhaust routing will be a little friendlier to the eye, and things will be done up right.  Besides, I'm not rushing it this time because I have a spare frame to do the work to (thanks cleveland.)

So here are a few pics.  I already did the frame alterations, and the tank/seat idea isn't for sure, but I have shoebox full of little sketches that all point to this general plan, so I figured why not. 

[greenjeans]

I really like the shape of the tank/seat.  that's nice.
You building the the tank & seat pan ?  Out of.....

[babyfood1217]

Well, I think for the time being I am going to do a fiberglass tank.  Relatively cheap, and reliable.  However I am extremely nervous about such a fragile tank in the event of a crash.  I have yet to dump my bike, which means I am going to at some point.  F-glass crushes and cracks, and I really don't want to beome a fireball.  I have started to shape/cut-out paper templates that would help me section together a metal tank, but I do not have the funds to follow through with this yet.  Steel would be ideal, aluminum next on the list.  I was gonna do Stainless, but enough people pointed out the difficulties I would face with my materials and tools.  Seat will be steel, and I have no idea how I am going to upholster it yet.  I want to find a shop where I can check out different foam densities and cover materials (leather is ideal but expensive, and I need really stiff foam.)  I know I want to retain the hinge-effect so I can keep my registration and maybe a tool or three under the seat.  Maybe I could even rig the seat lock back up.

[xtalon]

Bfood, I for one am glad you didn't 'learn your lesson' as you put it.  It's your bike so if you like it, that's all that matters, but thanks for continuing to share.

I like your new concept.  Please keep us updated.

--xTalon

[chrisf]

For the tank, you could always do a GRP tank but use a fuel cell bladder on the inside. Basically, the bladder will hold the fuel and the GRP tank will cover it up. Race cars are required to use a fuel cell w/ a bladder and you can find companies to custom make the bladder portion.

What's wrong with stainless? Working with the material isn't so bad and it welds nicely.

--Chris

[BobbyR]

It's got some style. You will probably refine it as you go along.

[KB02]

It's very reminiscent of a Ducati Monster. I like it.   

Seriously, that actually give me an idea for my K8 "parts" bike... Hmmmmmm

[Sam Green Racing]

What's happened to Chris, he's not been active since the 26th June.

He posted in the travellers community that he was coming to the UK for the month of July but didn't respond to any of the replies.

I PMed him and nothing

Sam.

[babyfood1217]

God it feels good to be back!  Just had a return flight to the states a few days ago and man, I couldn't have looked forward to that day more.  7 weeks in a tent in England amidst record breaking terrible weather, 14 hr days of either running an iron-melting furnace or laying iron tablets into concrete for 200 some odd meters...man, what a summer.

First off, Sam, I'm sorry I couldn't get ahold of you while I was over there, limited internet access and a terribly full schedule meant I had no time at all to do anything, ever!  Seriously, it was a great experience, and next year, I will buy you a pint when I come back.

So, update on the bike.  Where to begin...

Yesterday, I got bored because the weather here in Wisconsin has not been cooperating with my desires to take the bike to work or out for a ride, so I jumped back onto my project I left here when I left for Europe:  To redo my undertail exhausted '76 CB750k using a new frame, exhaust, tank, seat, wheels, etc...  The engine will remain the same (except for a strip-down, cleaning, and new clutch plates.)  When I left, I had the frame welded up and the can in place, so yesterday, while thinking about how the exhust was going to be routed, I decided it would be easier to work things out if I had a rolling chassis to deal with, so I started.

Working under a tarp in the rain sucked but for 5 hours are steady work I got pretty far.  Taking bits and pieces off and seperating them into labeled ziplocks, I made sure I wouldn't lose or forget anything.  Managed to get the swingarm swapped and a spare rear wheel, but left the forks on until this morning. 

Right away after a coffee and a kiss from the GF, I got to work.  Lifted the front end up, dropped the wheel, off'ed the top clamp, and unbolted the nut on the steering stem.  Lost my grip, dropped the lower clamp/stem to the ground with all the ball bearing.  SH*T.  I found all but one, and I figure since I'm only dry fitting everything and the bearings themselves are rather pitted, I have time to look into getting new bearing (perhaps with a retainer - Are those available for these bikes?).  Got everything put back together, and I have to say I'm pretty excited!!!

[babyfood1217]

Side shot.  The rear wheel that's on there is stock, going to be using a 17" with 130/70 or 130/90 rubber.  Pulled the fork tubes up in the clamps a small amount, but will adjust as the build continues.  The tank is only on there to help my visualize the new seat/tank combo and frame slider positions.

[babyfood1217]

Deatil of the frame modification.  Essentially just a new, raised truss to hold the can in place and provide support for the seat.

[babyfood1217]

New passenger peg mounted.  Higher and further back than stock, also a bit further out from the frame.  Original pegs though

[babyfood1217]

Rear end detail.  Much cleaner than my first attempt, and without compromising frame integrity.

[babyfood1217]

New bars (Titec brand.)  Actually, old bars from my slalom (bicycle) racer.  31.8mm clamping area, and 7/8ths grip area means I won't have to modify anything for the controls, but I will need a means of clamping the bars to the forks...

[babyfood1217]

And I'm thinking I'll try these.  I'll machine them from billet at my dads machine shop, and treat them and the bars as a normal set of clip-ons.  Because the bars already have a bend in them, I can keep the holes in the clamp completely perpendicular (easier set-up for machining), and instead rotate the bars for minute adjustments.

[GoatBaSS]

Very Nice. 

[eldar]

sure sounds like you have something going there.  I think the undertail exhaust would be really cool.

[my78k]

Agreed...off to a good start. You're a brave man...not so much for tackling the project (although that is a feat unto itself) but rather for choosing to share as you go after the way you were treated last time... 

If the progress continues I suspect you will have begun to redeem yourself in the eyes of some of these guys

Dennis

[babyfood1217]

Ahh, I guess the cool thing is that deep down, I think we all can appreciate, to some extent, the things that we are all doing to our own rides.  Whether it be a full on restoration, or a way-out-of-left-field modification or seven, I would like to think that we can all understand that gushy, warm feeling we each seem to get when going at it with our bikes.  Anyhoo...

I got my measurements made out for the bar clamps, and am itching to get into the shop and get the machining done (I'm thinking about anodizing the clamps, but that is purely aesthetic.)  I decided to move ahead with the hydraulic clutch conversion (inspired by Maksutt), and am going to look for a matching front brake master cylinder as well.  No parts purchasing will happen until after I get this semester of school paid for, but right now, the purchase list looks a little something like this...

-front and rear tires (don't know which make/model yet)
-progressive rate fork springs
-fork seals
-possibly new fork tubes (If I can find a decent price)
-SS braided front line - direct from MC to the caliper
-steering head bearings (tapered? - best place to source from?)
-possibly new swingarm bushings (mine aren't too bad, but...)
-engine gasket set (last one was from ebay - good non-ebay source would be?)
-taillight/indicators
-aftermarket speedo (small size)
-oil temp/pressure gauge
-header wrap for all sections of exhaust except can
-new coils (hopefully dyna or accel)

And the fabricate list looks like this...

-fiberglass tank
-seat (modified stock pan, custom foam/upholstery work)
-headlight bracket (will lower shell a couple inches and pull it in a bit)
-gauge cluster bracket (will center and lower the tach, and mount speedo/oil gauge on either side
-swingarm spools (already made a rearstand)
-bar clamps (31.8mm and 35mm holes, 90 deg. offset, aluminum)
-fenders (probably SS sheet)
-clean up top clamp (grind off stock bar mounts, fill in recesses with weld filler)
-all mounting plates/hardware for hydraulic clutch conversion
-remainder of exhaust piping (can to header) including mating sections
-heatshields for exhaust sections
-reroute all electrics to a panel/organized compartment under the seat
 

[babyfood1217]

Reviving a topic that has not been updated for a while...here goes...

So as I finish up my last semester of undergrad, I've been thinking about my bike alot.  Don't ask why, I just have.  A few updates:

My shop to work in is my back porch.  A small, unheated, drafty space with squirrels chattering in the eaves outside.  It is as cold in this space as it is outside, but at least it doesn't snow or rain here.

[babyfood1217]

I did finally get the new triple clamps made for my bars.  Cleaned them up and put them on.  I only had mild steel bolts at the time, but they will be stainless before riding season comes.  Here is a pic with the clamps, bars, and the very brand new gauge mount with the new speedo and the old speedo (tach is undergoing restoration/modification, and the speedo is just for fitment.)

[babyfood1217]

Here is the cockpit from the riders POV.  Handlebars keep the stance upright and wide (think supermoto wide.), but because of the bend in the bar, I can adjust for a lower and tighter clip-on stance.  Cable routing will be ok, and stock lengths should be good too.

[babyfood1217]

Should have noted:

-I ground the lower clamping sections off of my upper fork clamp.  Will weld/fill in the left side holes, but retain the right side for mounting my ignition switch bracket.
-Gauge bracket is 1/8" 304 stainless steel, with stainless mounting hardware.
-Hydraulic clutch donor is an '85(?) Honda VF1000R (would have to double check on that one...)  Plate to mount the slave cylinder will either be magnesium or aluminum.  I want to adapt VF1000R front brakes if possible, but the stock front brake will do for now, otherwise the MC would be gone.

[BobbyR]

Hey, keep up the good work. Big job, my hat is ff to you.