Author Topic: Sandcast Restoration - Done (for now)  (Read 54157 times)

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Offline Old Scrambler

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Re: Sandcast Restoration
« Reply #75 on: March 14, 2010, 02:59:32 PM »
Mark.......this is a great thread. Could I come and visit for a while?  I could sleep in my van out back or at the shop!

Seriously, I have an idea..........Would you be interested in putting your pics and story together for a video (powerpoint) presentation during the Vintage Motorcycle Classic at Road America?  Its June 11-13 in Elkhart Lake, WI.  I could arrange for club space and have a canopy or large tent with a few chairs for viewing maybe once on Saturday and again on Sunday. I could arrange for the screen and a digital projector. Of course this would be the place to display your bike(s).

Let me know on this thread or PM me.
Dennis in Wisconsin
'64 Triumph Cub & '74 Honda CB750 Bonneville Salt Flats AMA Record Holder (6)
CB750 Classic Bonneville Racer thread - http://forums.sohc4.net/index.php/topic,135473.0.html
'63 CL72 Project(s)
'66 CL77 Red
'67 Triumph T100C
'73 750K3 Owned since New
'77 750F2 Cafe Project
2020 ROYAL ENFIELD Himalayan

Offline markb

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Re: Sandcast Restoration
« Reply #76 on: March 15, 2010, 07:10:28 AM »
Old Scrambler,
Thanks for the compliments.  I'll contact you offline.
Mark
« Last Edit: March 15, 2010, 07:23:15 AM by markb »
1969 CB750 sandcast #97 restored - Sold Restoration thread link
1969 CB750 sandcaxt #576 - Sold
1969 CB750 sandcast #1553 - Sold
1969 CB750 sandcast #1990 - Sold
1969 CB750 sandcast #5383 restored - Sold Restoration thread link
1970 CB750 K0 restored - Sold
2010 H-D Tri Glide Ultra Classic (Huh?)

Offline markb

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Re: Sandcast Restoration
« Reply #77 on: March 15, 2010, 07:21:55 AM »
For those interested here's a drawing of my hook.  I liked some of the hooks shown on another thread but don't have the resources for cutting or welding so this worked good for me.  One advantage is the clamp collars on the top bar can be adjusted to balance the load (get the motor level).  Next time I'm going to get some loop straps made up so I don't have to mess around with the ratchet straps.
 
Disclaimer:  If you make one from my drawing it is up to you to determine if it will support the load you intend to lift.  If your motor drops and breaks into a million pieces, I am not responsible.  Also you need to be very meticulous when attaching the straps so that they won't slip off or cause damage to the motor.
1969 CB750 sandcast #97 restored - Sold Restoration thread link
1969 CB750 sandcaxt #576 - Sold
1969 CB750 sandcast #1553 - Sold
1969 CB750 sandcast #1990 - Sold
1969 CB750 sandcast #5383 restored - Sold Restoration thread link
1970 CB750 K0 restored - Sold
2010 H-D Tri Glide Ultra Classic (Huh?)

traveler

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Re: Sandcast Restoration
« Reply #78 on: March 15, 2010, 08:39:18 PM »
Mark, I only have one objection....you started this thread by stating your K0 restoration was a practice bike....I BEG TO DIFFER, Sir!

Your K0 is absolutely Gorgeous!  If it is ever for sale, please let me know.  I would rather have a K0 with the pressure cast motor than a sandcast.....don't get me wrong, I love sandcasts....but ANY K0 is just simply awesome!

So, please...for me, give the K0 some love...she isn't just a learning bike (to me anyway).

I wish it was mine! :'(

~Joe
« Last Edit: March 15, 2010, 08:41:26 PM by traveler »

Offline markb

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Re: Sandcast Restoration
« Reply #79 on: March 16, 2010, 06:32:38 AM »
Thanks traveler.  I hear what you're saying about calling it a practice bike.  Makes it sound like I wasn't serious about it.  i certainly didn't start out thinking it would be good practice, I just tried to do the best I could and learned a lot which is making the second project go faster and better.
Mark
1969 CB750 sandcast #97 restored - Sold Restoration thread link
1969 CB750 sandcaxt #576 - Sold
1969 CB750 sandcast #1553 - Sold
1969 CB750 sandcast #1990 - Sold
1969 CB750 sandcast #5383 restored - Sold Restoration thread link
1970 CB750 K0 restored - Sold
2010 H-D Tri Glide Ultra Classic (Huh?)

Offline fasturd

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Re: Sandcast Restoration
« Reply #80 on: March 16, 2010, 06:41:52 AM »
Great info and pics on the engine placement. We will be using that idea on the next couple of bikes!!!
13 in the garage and counting...

Link to my link...   http://forums.sohc4.net/index.php?topic=58422.0

Offline markb

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Re: Sandcast Restoration
« Reply #81 on: March 20, 2010, 04:11:38 PM »
I decided to tackle the rear end next.  The brake arm should be installed first otherwise it's a real pain and you might have to take something apart to get it in.


Then I did the center stand.  I hook up the spring first and then start the pivot shaft on the left side and tap it in.  No problem streching the spring when you can get at it like this.


I left my rear swingarm bushings in when I had it painted so I made a tool to remove the bushings.  The hex part has to be counterbored deep enough for a bushing to fit in and the diameter is slightly larger than the bushing.  The round part is slightly smaller than the bushing.  I've used a couple of the right size sockets and some redi-bolt and a couple of nuts to do the same thing but this is easier.  In hindsight I would have made the round part longer and machined a hex on it so I wouldn't have to put a channel lock on it to get it tight.


The tool works good for putting them in too.


Here's the swingarm in place.


You have to make sure that the brake arm is pivoted forward when you intall the swing arm.  I put my brake lever on and wedge it down to hold it in place.


Got the shocks on and battery box in too.  The new flat round rubbers that go in the inside of the box about kicked my a$$ even after I warmed them to make them softer.  Tomorrow I'll finish putting the electrical bits back on the box.
« Last Edit: March 20, 2010, 04:15:53 PM by markb »
1969 CB750 sandcast #97 restored - Sold Restoration thread link
1969 CB750 sandcaxt #576 - Sold
1969 CB750 sandcast #1553 - Sold
1969 CB750 sandcast #1990 - Sold
1969 CB750 sandcast #5383 restored - Sold Restoration thread link
1970 CB750 K0 restored - Sold
2010 H-D Tri Glide Ultra Classic (Huh?)

traveler

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Re: Sandcast Restoration
« Reply #82 on: March 21, 2010, 09:31:04 AM »
At some point, your sheet metal rollaway is going to start to buckle from the weight..yes? ;D

The detail you are going to....are you going to ride this bike?  Serious question.  It will more than likely be a good candidate for a museum sell to raise $$$ for another project.

~Joe

Offline markb

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Re: Sandcast Restoration
« Reply #83 on: March 21, 2010, 04:10:25 PM »
traveler:  Actually the cart is rated for 500 lbs.  I've had a complete bike on there except for the front wheel which won't fit and no problem.  If you notice the frame is sitting on some 2x4's that run the full lenth of the cart to help distribute the load to each end.  And yes, I'll ride it on nice days just like my K0.  It's good to run them a bit.

First thing today I finished up the electricals on the battery box and put in the tool tray.  Next I decided to tackle the front end.  First thing I noticed was I forgot to replace the fork stem bearing races while the frame was still bare.  Last time I did it on the hydraulic press and ended up scuffing the frame a little and I tried to tap them in but it just wasn't going well (I don't like the hammer around the new paint) so I decided to make a tool to assemble the races.  While I was at it I made one for assembling the cap on the top triple clamp so I wouldn't have to use a hammer and a screwdrive and nick up the fresh zinc.


Here's the tool ready to press in the races.  It lined them up perfectly and they went right in.


I got the front forks on so now there's finally some color!  I rebuilt and refinished the forks last summer so they were ready to just put in.  They go on easy after you remember to position the "D" washers in the top triple clamp.  And I got all my balls back in without dropping any, all 37 of them.  I actually like that part.  I thought about putting tapered bearings in but then it wouldn't be original (as if anyone would know).  It's getting fun now when you can see some progress.  It was a good day.  
« Last Edit: March 22, 2010, 02:49:50 AM by markb »
1969 CB750 sandcast #97 restored - Sold Restoration thread link
1969 CB750 sandcaxt #576 - Sold
1969 CB750 sandcast #1553 - Sold
1969 CB750 sandcast #1990 - Sold
1969 CB750 sandcast #5383 restored - Sold Restoration thread link
1970 CB750 K0 restored - Sold
2010 H-D Tri Glide Ultra Classic (Huh?)

Offline Magpie

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Re: Sandcast Restoration
« Reply #84 on: March 21, 2010, 09:15:07 PM »
It's a beauty!
Cliff.

Offline Simpson

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Re: Sandcast Restoration
« Reply #85 on: March 22, 2010, 09:40:27 PM »
Mark, you have some great ideas for special tooling. Especially like the swing arm bushing tool. Best idea yet that ive seen. Your patience and planning is inspiring. Makes my 1st build seem disorganized. Nice job, its fun learning from all you guys.
1970 CB750 K0
1975 CL/CB 360 Mix

Offline markb

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Re: Sandcast Restoration
« Reply #86 on: March 23, 2010, 04:14:14 AM »
Thanks Simpson.  My first build, the K0, was disorganized.  Here's some examples.  I was ready to put the pistons on and then decided to order the rings, wait a week.  Bought seals when I came to need them instead of all at once.  More lost time.  I probably lost months overall and instead of doing other projects in the meantime, like polishing parts or cleaning the carbs so that they would be ready to slap on, I got hung up on waiting for parts so I could finish that step.  This time I kept track of everything during the tear down and ordered it right away.  And I remembered what was a pain last time and do what I can to make it easier like assemble things in the right order or make the tools.  I've got another sandcast waiting in the wings so I'm already thinking ahead on that one so time spent on making the tools will just make it go that much faster.  I'm a lot more organized this go round and its coming out better and I'm having more fun too.
Mark
1969 CB750 sandcast #97 restored - Sold Restoration thread link
1969 CB750 sandcaxt #576 - Sold
1969 CB750 sandcast #1553 - Sold
1969 CB750 sandcast #1990 - Sold
1969 CB750 sandcast #5383 restored - Sold Restoration thread link
1970 CB750 K0 restored - Sold
2010 H-D Tri Glide Ultra Classic (Huh?)

Offline Simpson

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Re: Sandcast Restoration
« Reply #87 on: March 23, 2010, 06:15:03 AM »
These bikes have re-enforced the most basic important lesson in life besides organization.
"Do it right the first time"  ;)
Replace all wear items, and fix anything suspect, don't leave it for chance.
Seems you learned that a long time ago.
Sorry to derail...
1970 CB750 K0
1975 CL/CB 360 Mix

Offline Old Scrambler

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Re: Sandcast Restoration
« Reply #88 on: March 23, 2010, 05:55:18 PM »
Its looking REAL nice!  I kind of know what you mean by a practice bike.  I have restored five of the CL77 HONDA 305 Scramblers and each build gets a little more organized. Last year was  the time to partially rebuild my 750 K3. Not a restoration.....just a little replacement of worn or rusted parts. With this build for a model, I am getting inspired to tackle the K0 thats been sitting in parts under my bench for about 10 years.
Dennis in Wisconsin
'64 Triumph Cub & '74 Honda CB750 Bonneville Salt Flats AMA Record Holder (6)
CB750 Classic Bonneville Racer thread - http://forums.sohc4.net/index.php/topic,135473.0.html
'63 CL72 Project(s)
'66 CL77 Red
'67 Triumph T100C
'73 750K3 Owned since New
'77 750F2 Cafe Project
2020 ROYAL ENFIELD Himalayan

Offline markb

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Re: Sandcast Restoration
« Reply #89 on: March 25, 2010, 05:23:50 AM »
I managed to get my exhaust spigots and carbs in last night.  That's where it will stay for now.  I'm leaving today for 10 days of vacation and plan on hitting it hard when I get back.
1969 CB750 sandcast #97 restored - Sold Restoration thread link
1969 CB750 sandcaxt #576 - Sold
1969 CB750 sandcast #1553 - Sold
1969 CB750 sandcast #1990 - Sold
1969 CB750 sandcast #5383 restored - Sold Restoration thread link
1970 CB750 K0 restored - Sold
2010 H-D Tri Glide Ultra Classic (Huh?)

Offline SohRon

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Re: Sandcast Restoration
« Reply #90 on: March 27, 2010, 07:01:53 AM »
This is an amazing build. You're doing a fantastic job resurrecting what is truly an icon of our sport. Anxious to see it done, but glad you're taking your time to do it right!

Only one small thing I wonder about, and that's the method of mating the engine to the frame. Please forgive my ignorance, but are you saying that this...



...consisting of hook, block, tackle and 45 minutes of slow insertion is easier than this...
 


...accomplished in less than three minutes with the same results? Are the 750 frames really that much more complicated than the 550s? Just curious, because my logic cell (all one of it) starts to hurt when I think of this...

Anyway, keep up the good work. Beautiful job!
« Last Edit: March 27, 2010, 08:12:47 AM by SohRon »
"He slipped back down the alley with some roly-poly little bat-faced girl..."

Assembling my '74 CB550: http://forums.sohc4.net/index.php?topic=86697.0
Assembly of the Right-hand Switch (a rebuilder's guide):  http://forums.sohc4.net/index.php?topic=80532.0
Installing stock 4X4 exhaust: CB500-CB550 K: http://forums.sohc4.net/index.php?topic=82323.0
CB550 Assembly Manual: http://forums.sohc4.net/index.php/topic,151576.0.html

Offline Caaveman82

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Re: Sandcast Restoration
« Reply #91 on: March 27, 2010, 08:10:59 AM »
Mark, you are doing great man. I'm quite jealous, it's beautiful.
Do not act as though you could kill time without injuring eternity. - Dave Thoreau

Offline markb

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Re: Sandcast Restoration
« Reply #92 on: March 28, 2010, 05:49:04 PM »
SohRon,
I can't speak for the 550's, but for me after doing it both ways I think the engine hook is easiest for me.  It might take a little longer but there is no effort to it at all.  Working smarter instead of harder is the way I like to go.
Mark
1969 CB750 sandcast #97 restored - Sold Restoration thread link
1969 CB750 sandcaxt #576 - Sold
1969 CB750 sandcast #1553 - Sold
1969 CB750 sandcast #1990 - Sold
1969 CB750 sandcast #5383 restored - Sold Restoration thread link
1970 CB750 K0 restored - Sold
2010 H-D Tri Glide Ultra Classic (Huh?)

Offline markb

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Re: Sandcast Restoration
« Reply #93 on: April 04, 2010, 06:56:16 PM »
I just got back from a vacation yesterday so I finally got a chance to do a little more.  I put on the rear fenders, chain guard, rear wheel, fork lock, coils and oil tank.  I was going to polish the rear hub and brake panel but I'm starting to run out of time to get this thing running so that will have to wait until next winter.  I might have to take off the oil tank.  I think I remember last time having to remove it to hook up the rear brake switch and points wire.  But before I do that I need to put on the wiring harness (I should have done that before now) but I want to try to repair the end that goes in the headlight bucket.  I'll document what I'm doing on that.  Here's a pic of my progress.
 
1969 CB750 sandcast #97 restored - Sold Restoration thread link
1969 CB750 sandcaxt #576 - Sold
1969 CB750 sandcast #1553 - Sold
1969 CB750 sandcast #1990 - Sold
1969 CB750 sandcast #5383 restored - Sold Restoration thread link
1970 CB750 K0 restored - Sold
2010 H-D Tri Glide Ultra Classic (Huh?)

traveler

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Re: Sandcast Restoration
« Reply #94 on: April 04, 2010, 07:49:30 PM »
Mark,

You know....I really love what you are doing here...but I have to ask....

When you talk about polishing the rear hub, etc......is that the way it was stock, or is that just a personal preference?

~Joe

Offline markb

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Re: Sandcast Restoration
« Reply #95 on: April 05, 2010, 05:35:56 AM »
Joe,
Maybe I shouldn't have said polished.  I do the same finish as the motor covers, the brushed satin finish look.  I'll want to do something to the rear hub and brake panel someday because there is a small amount of pitting and oxidation but not very noticeable from a distance.  I guess its what I think is close to original.  If anyone has a different opinion I would love to hear it.
Mark
1969 CB750 sandcast #97 restored - Sold Restoration thread link
1969 CB750 sandcaxt #576 - Sold
1969 CB750 sandcast #1553 - Sold
1969 CB750 sandcast #1990 - Sold
1969 CB750 sandcast #5383 restored - Sold Restoration thread link
1970 CB750 K0 restored - Sold
2010 H-D Tri Glide Ultra Classic (Huh?)

Offline Old Scrambler

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Re: Sandcast Restoration
« Reply #96 on: April 05, 2010, 06:03:50 PM »
Mark......I really appreciate your detail.........you have studied what the bike looked like in the showroom rather than what someone else did to their restoration. So many bikes get over polished! All of the originial aluminum on the K0 and K1 models had a slight bit of satin finish as if the final factory polish wheel was 0000 steel wool and then clearcoated. I cleaned my sandcast bike more than a few times as I used it to demonstrate how smooth the motor ran when I was selling new Hondas in '71. As the models progressed, the finish seemed to improve, especially when the well polished Z1 showed up in '73.

And I have made the same move by forgettng to install the swithes and wireharness before the oil tank goes on. It is also much easier to install the breather tube from the tranny to the tank before the inner fender and wheel are in place. Since you powder coated the frame, you may want to check for good grounding contacts.  I've had that problem, especially to get the taillight circuit to work.  Your doing a great job!
Dennis in Wisconsin
'64 Triumph Cub & '74 Honda CB750 Bonneville Salt Flats AMA Record Holder (6)
CB750 Classic Bonneville Racer thread - http://forums.sohc4.net/index.php/topic,135473.0.html
'63 CL72 Project(s)
'66 CL77 Red
'67 Triumph T100C
'73 750K3 Owned since New
'77 750F2 Cafe Project
2020 ROYAL ENFIELD Himalayan

Offline fasturd

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Re: Sandcast Restoration
« Reply #97 on: April 06, 2010, 05:36:38 AM »
Hello Mark,

I love your projects attention to detail.

It would be a great tool if we documented the finish of each of the SOHCs. While I was going through my 400 project it was interesting to note that there were many different finishes on just the motor and even an individual cover would have, polish, brushed and painted surfaces and the painted surface at times was clear coat on one edge and painted with clear on the other).
If we could get some pictures of original bike finishes (I will get some from the 400 when my new camera arrives) We could have a thread with photos and maybe a few "how to's".
If nothing else it gives everyone a starting point. When you look at how many bikes got polished or chromed parts right after they left the dealer sometimes "period correct" has a little wiggle room.

Your bike looks fantastic and your lift bar info has me psyched to get into the motor on my 750 projects.

Are you going to be showing the Sandcast at the Minnesota VJMC or AMCA show?

Good luck,
Bill
13 in the garage and counting...

Link to my link...   http://forums.sohc4.net/index.php?topic=58422.0

Offline markb

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Re: Sandcast Restoration
« Reply #98 on: April 06, 2010, 05:46:52 AM »
Dennis,
It is hard not to over restore but I'm trying.  As long as I don't modify anything I figure it can always be undone or redone.  I think the chroming that I've had done is overdone but its something I can't do and chromers just don't seem to want to "tone it down" so I'm OK with it.  It sure looks good.  
By the way, I didn't have the frame powder coated.  To stay as original looking as possible I went with a single stage urethane paint.  My painter does something to cut the gloss back to 90% and I think its really close to the original.  Even with paint grounding can be a problem so I sand off the paint on the frame where ground cable fastens on with the motor mount bolt and put on a dab of dielectric grease.
Bill,
Good idea.  I'm always looking for ways to improve the look.  And yes, I hope to have it ready for the Minnesota VJMC show in May.
Thanks for the compliments guys,
Mark
1969 CB750 sandcast #97 restored - Sold Restoration thread link
1969 CB750 sandcaxt #576 - Sold
1969 CB750 sandcast #1553 - Sold
1969 CB750 sandcast #1990 - Sold
1969 CB750 sandcast #5383 restored - Sold Restoration thread link
1970 CB750 K0 restored - Sold
2010 H-D Tri Glide Ultra Classic (Huh?)

Offline Old Scrambler

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Re: Sandcast Restoration
« Reply #99 on: April 06, 2010, 07:44:35 AM »
Good call on the paint......I do the same with a small amount of hardener. It cuts the shine a little and protects against fuel spills.

Oh the chrome shop stories I can tell..........I had custom chrome parts on a few bikes as far back as the late '60s. One thing I have found locally is to have patience with the shop. They all think you want show chrome. For my CL72 & CL77 projects I tell them to do my work when its time for them to change the vats or tanks of material. I also tell them to polish the copper and nickle to a bright satin shine....not a mirror shiine.  On exhaust pipes, its criticle to keep the nickle to a minimum time in the tank because if it gets too much electro-plating time it gets brittle and it cracks with heat expansion.  I also had a small local shop that put what he called whitner in the chrome tank. That kept the shine down on my exhaust pipes. I took a good original pipe along to show him what the finished job should look like. Too bad he went out of business soon after he finished my job. Now I use another shop but sometimes its years before I get the most difficult parts back........of course I take in several of each part because I first invested in a good parts inventory by tearing down a dozen bikes.  I may not have that luxury for doing a CB750. 
Dennis in Wisconsin
'64 Triumph Cub & '74 Honda CB750 Bonneville Salt Flats AMA Record Holder (6)
CB750 Classic Bonneville Racer thread - http://forums.sohc4.net/index.php/topic,135473.0.html
'63 CL72 Project(s)
'66 CL77 Red
'67 Triumph T100C
'73 750K3 Owned since New
'77 750F2 Cafe Project
2020 ROYAL ENFIELD Himalayan