Author Topic: Café Project Chela (My CB400F)  (Read 9451 times)

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Offline Slams77

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Café Project Chela (My CB400F)
« on: January 25, 2010, 04:18:35 PM »
Hello All,
I joined the forum back in April of 2009, shortly after I bought my 1977 CB400F.  It seems to run fine other than an issue due to a missing air filter (air box has screen mesh in its place) and the electric starter not working, although I like kick starting and considered removing it.  There aren’t any engine oil leaks, carb leaks, or leaky fork seals, and I would like to disassemble the complete bike and start my café build.  The engine will remain stock since I figure I will gain a little power by reduction of stock parts and possibly by adding some air filter pods.  Since it is light and nimble, it will be an ideal bike for the type of riding I like to do which is canyon carving, so any performance additions will be clip-ons, tapered head bearings, rear sets, master cylinder/brake caliper rebuild, drilled rotor, stainless brake lines, and the cb550F fork swap to name a few.  With that being said, is there any place I should start first or do I just have at it and start the disassembling process?  This is a project I will be getting into blindly so any information along the way would be great since this will be a learning process start to finish.  I live in Los Banos, CA, but I have family in San Jose/Milpitas Area.


« Last Edit: January 31, 2011, 09:25:59 AM by Slams77 »

Offline hoodellyhoo

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Re: Café Project SS Chela (My CB400F)
« Reply #1 on: January 25, 2010, 08:01:32 PM »
Hope you get that front brake situation figured out ;D

Nice looking bike. I just love those stock 400 headers.
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Offline Slams77

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Re: Café Project SS Chela (My CB400F)
« Reply #2 on: January 25, 2010, 08:54:57 PM »
Hope you get that front brake situation figured out ;D

Nice looking bike. I just love those stock 400 headers.
Thanks, it's a baby wash cloth modification lol.  I've already rebuilt the master cylinder and I just need to reassemble the caliper, but now that I've decided to do the tear down, I'm going to wait on it.

Offline Terry in Australia

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Re: Café Project SS Chela (My CB400F)
« Reply #3 on: January 26, 2010, 02:57:19 AM »
I reckon you should leave it alone and enjoy it mate, it looks really nice just as it is! ;D
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Offline Slams77

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Re: Café Project SS Chela (My CB400F)
« Reply #4 on: January 26, 2010, 05:24:12 PM »
I reckon you should leave it alone and enjoy it mate, it looks really nice just as it is! ;D
Thanks, I do like it as it stands, however I really like the look of the bum stop seats and nicely formed tanks.  I also want to do the performance mods which is why I've decided to go the cafe route.  It's gonna be a long process but with time, patience, educating myself in the process, and of course the biggest thing, money, I'll eventually get it to where I want it.

Offline RickB

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Re: Café Project SS Chela (My CB400F)
« Reply #5 on: January 24, 2011, 09:11:31 PM »
I'm eagerly awaiting this build. Particularly interested in what you're doing with the master cylinder and new tank and seat.

Offline seaweb11

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Re: Café Project SS Chela (My CB400F)
« Reply #6 on: January 24, 2011, 09:45:46 PM »
I'd ride the crap out of that all day the way it is. 8)
Go find a $500.00 beater to start a tear down project.  You don't even know her yet, and already you want to lift her skirt ;)

Offline Slams77

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Re: Café Project SS Chela (My CB400F)
« Reply #7 on: January 25, 2011, 12:48:49 AM »
I'm eagerly awaiting this build. Particularly interested in what you're doing with the master cylinder and new tank and seat.
RickB, I’ve been following your thread and if I haven’t said so already, your bike is turning out amazing.  I’m going to use a mikesxs slim-line master cylinder but I will to have to fabricate a spacer to clear my clip-ons.  The tank is most likely going to remain stock, although I did consider a 350 tank and wanted to know if it was a direct bolt on or if you had to make any modifications to make yours fit.  I’m going with a manx style seat, but I still haven’t got around to how I will bolt it on. 

I'd ride the crap out of that all day the way it is. 8)
Go find a $500.00 beater to start a tear down project.  You don't even know her yet, and already you want to lift her skirt ;)
Once I put the stock air box and filter back on I rode the bike around town and on the back roads, I even took it up to 80 mph (at least that is what was on the speedo) for a short stint, and it actually felt very stable.  You are right though about not knowing her and I do feel a little guilty when all I can do right now is go out to the garage and sit on her instead of taking her out to the twisties. 

Offline Slams77

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Re: Café Project SS Chela (My CB400F)
« Reply #8 on: January 25, 2011, 01:31:18 AM »
It’s been a while since I started my build but I have made progress.  After deciding to go with clip-ons rather than the clubmans I initially installed, I took the stock triple tree, cut off the handle bar mounts and used a flap disc and files to shape everything.  I then went over it with various grits of wet/dry sand paper to smooth it out, polished it a little and this is what I ended up with.



Offline SixGun

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Re: Café Project SS Chela (My CB400F)
« Reply #9 on: January 25, 2011, 04:40:22 AM »
It’s been a while since I started my build but I have made progress.  After deciding to go with clip-ons rather than the clubmans I initially installed, I took the stock triple tree, cut off the handle bar mounts and used a flap disc and files to shape everything.  I then went over it with various grits of wet/dry sand paper to smooth it out, polished it a little and this is what I ended up with.


NICE!  :)

Offline Syscrush

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Re: Café Project SS Chela (My CB400F)
« Reply #10 on: January 25, 2011, 10:28:14 AM »
The engine will remain stock since I figure I will gain a little power by reduction of stock parts and possibly by adding some air filter pods.
Good - internal mods on a 400 don't really make sense to me.  Do your research before going to pods, though - they can make the bike very difficult to tune.

Quote
Since it is light and nimble, it will be an ideal bike for the type of riding I like to do which is canyon carving, so any performance additions will be
I'd say it'll be a workable bike for that type of riding.  Anything with sporting pretensions built in the last 20 years would work better (although not necessarily be more fun).

Quote
clip-ons, tapered head bearings, rear sets, master cylinder/brake caliper rebuild, drilled rotor, stainless brake lines,
Those all sound like excellent ideas.  Along with the tapered head bearings, you probably want to look at swingarm bushing refresh.  And to complement the brake work you're planning, look into some nice brake pads, too - I've liked EBC HH pads on my other bikes, but don't know the common wisdom for good pads on a CB.

Quote
and the cb550F fork swap to name a few.
I don't know anything about the CB400 forks, but the CB550 ones are not particularly good stock.  Race Tech sells their cartridge emulators and springs for both the 400 and 550 - your 400 forks with the right springs, the RTCE's, and a good brace will work better than a stock 550 fork.

That work done to the front plus some genuinely good shocks in the rear will make a bigger difference to your bike's manners, comfort, and safety than any other mod you can do.

If you're going to have the bike all apart and do brake and suspension upgrades, then consider some bracing of the frame and maybe the swinger, too.

Quote
With that being said, is there any place I should start first or do I just have at it and start the disassembling process?  This is a project I will be getting into blindly so any information along the way would be great since this will be a learning process start to finish.
Plan your work, and work your plan.  Since you have a road-legal runner right now, break your plan down into phases, doing the easy stuff first.  Try to break it up into small 2-to-4 week chunks and ride it in between mod sessions.  Take a systematic and orderly approach, and figure that everything you do will take at least twice as long as you expect - and probably have to be revisited afterward at least once to correct some mistake.

And most importantly, POST PICS!!!  ;D
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FWIW, I'm not a shill for Race Tech - I've just got a thing for good suspension and the RTCE's are the most cost-effective mod for these old damping rod front ends.

Offline Slams77

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Re: Café Project SS Chela (My CB400F)
« Reply #11 on: January 25, 2011, 02:04:33 PM »
Thanks everyone for your interest and comments with my build.

Great advice Syscrush it is very helpful.  I kinda wish I hadn’t jumped into it with both feet because now it is partially disassembled and sitting in my garage instead of out on the road.  I have done other modifications since my original post and I will try and list pics and details of what I have done in sequential order to show the progress.

Offline scroggins5000

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Re: Café Project SS Chela (My CB400F)
« Reply #12 on: January 25, 2011, 03:46:11 PM »
Great work on the triple trees!

Offline stay youth

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Re: Café Project SS Chela (My CB400F)
« Reply #13 on: January 25, 2011, 05:08:12 PM »
Hi Great bike, i love mine, you should join this forum
http://bayareavintageriders.com/index.php

Its for us bay area locals. I once spent a night after breaking down in Kings city, cool area great for riding i bet. If you need any help I would be happy to assist Im located in downtown SF. I got tons of spare 400f parts and have rebuilt my bike completely like your doing

Check out this site for some great mods for the 400f, he's located in South Africa and is great to deal with
1976 cb400f

Offline Slams77

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Re: Café Project SS Chela (My CB400F)
« Reply #14 on: January 25, 2011, 07:12:08 PM »
Hi Great bike, i love mine, you should join this forum
http://bayareavintageriders.com/index.php

Its for us bay area locals. I once spent a night after breaking down in Kings city, cool area great for riding i bet. If you need any help I would be happy to assist Im located in downtown SF. I got tons of spare 400f parts and have rebuilt my bike completely like your doing

Check out this site for some great mods for the 400f, he's located in South Africa and is great to deal with

Thanks for offering your assistance, it’s always good to have resources and thanks for the link I’ll take a look at the bayareavintageriders forum.   I didn’t see a link attached for the site in South Africa, is this by chance 400fourstore.com? 

Offline Slams77

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Re: Café Project SS Chela (My CB400F)
« Reply #15 on: January 25, 2011, 09:32:08 PM »
After shaving the bar clamps off of the triple tree, I fabricated my own prototype of an indicator light cluster instead of using the rather large stock unit which was just too bulky.  I made it using aluminum tube I picked up at the hardware store and some anodized tubing which houses the LED’s.  The new cluster is now 1 inch square and it incorporates the oil light, neutral light, both left and right winkers and resides next to my mini speedometer.  Being that this is my first shot at a cluster I am happy with it but now the mental gears are spinning and I have other designs in the works.  The current cluster however does have its pros and cons.

Pros: Smaller, lighter, LED’s offer increased visibility, longer lifespan, draw less current, and the cluster is inconspicuous

Cons: Riveted to gauge bracket instead of bolted to it, cluster is non-serviceable (one LED goes out the whole unit has to be replaced) and although inexpensive to make I had to purchase a flasher relay unit (around $20.00 + shipping) to get it to work properly


Offline Syscrush

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Re: Café Project SS Chela (My CB400F)
« Reply #16 on: January 26, 2011, 06:07:56 AM »
I fabricated my own prototype of an indicator light cluster
That is beautiful.

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Pros: Smaller, lighter, LED’s offer increased visibility, longer lifespan, draw less current, and the cluster is inconspicuous
Yup!  Although the lower current draw really doesn't matter in this application.

Quote
Cons: Riveted to gauge bracket instead of bolted to it, cluster is non-serviceable (one LED goes out the whole unit has to be replaced)
Doesn't matter.  If they're mounted properly and sent the proper voltage, there's no reason for an LED to go out in your lifetime.  When I did a custom set of LED indicator lights for my SV, I potted all of the circuitry and the LED's in a project box, buried under about 1" of poly resin.  Don't sweat it.

Quote
although inexpensive to make I had to purchase a flasher relay unit (around $20.00 + shipping) to get it to work properly
Worth every penny!

Great work.
Life is precious: wear your f'n helmet!
There's nothing more expensive than a free bike...
FWIW, I'm not a shill for Race Tech - I've just got a thing for good suspension and the RTCE's are the most cost-effective mod for these old damping rod front ends.

Offline Kanticoy

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Re: Café Project SS Chela (My CB400F)
« Reply #17 on: January 26, 2011, 06:22:57 AM »
That looks awesome! Very clean!

Offline stay youth

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Re: Café Project SS Chela (My CB400F)
« Reply #18 on: January 26, 2011, 11:43:16 AM »
Hey sorry he is the link i was referring to


www.ttr400.com
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Offline kajtek

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Re: Café Project SS Chela (My CB400F)
« Reply #19 on: January 27, 2011, 02:35:29 AM »
looking good, i plan to do the same to my top triple just cant bring myself to start as i know its gonna take ages!

light cluster looks very cool, in the end i got rid of the whole cluster and just have a light in the headlight bowl for neutral...

ashley
1978 honda cb400f supersport

Offline kajtek

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Re: Café Project SS Chela (My CB400F)
« Reply #20 on: January 27, 2011, 03:58:27 AM »
also.. do you have a good photo with the manx seat fitted, side view so i could see the proportions, its something im considering..

thanks

ashley
1978 honda cb400f supersport

Offline Slams77

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Re: Café Project SS Chela (My CB400F)
« Reply #21 on: January 27, 2011, 04:04:18 PM »
also.. do you have a good photo with the manx seat fitted, side view so i could see the proportions, its something im considering..

thanks

ashley
Here is a side view with the Manx seat.  I have not mounted it yet, although I am thinking about going with a seat pan/base that would bolt under the seat using threaded rivets and then mount it to the frame using the existing mounting brackets; only my fabricating skills and resources are limited.  I purchased it from Clubmanracing.com: Part# A941 Manx Racing Seat Short Wideline No Cutout - 10 ¼” front widths.  They do offer a narrow version too, but I went with this one since it fits over the frame rails.  I am however considering the narrower 9” width version (due to my rather tall height, a whopping 5’6”.:() and maybe bolt it up to the frame using a system that integrates Dzus fasteners for quick removal and installation.


Offline Owned

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Re: Café Project SS Chela (My CB400F)
« Reply #22 on: January 29, 2011, 06:38:13 AM »
What headlight mount are you using?  I'm struggling to find units I like for the 33mm tubes.
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Offline Slams77

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Re: Café Project SS Chela (My CB400F)
« Reply #23 on: January 29, 2011, 05:04:54 PM »
What headlight mount are you using?  I'm struggling to find units I like for the 33mm tubes.

They are custom units.  There is a great thread over at “Do The Ton” which shows how they can be made using ¾” aluminum trim channel.  I followed the build instructions, and then played around with the design a little bit until I came up with something that worked for my bike.  The solid ones pictured above on the bike are the same as the ones in the how to build, whereas the ones I’m running now are drilled and a little beefier looking.  It took a little work and creativeness but I’m happy with the results.


Offline popssss

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Re: Café Project SS Chela (My CB400F)
« Reply #24 on: January 29, 2011, 06:53:56 PM »
I just found your post and I like what you've done.

You've turned a nice bike into an even nicer one.
I like your fab work, it's giving me good ideas.

any tips on polishing aluminum?