Topic: '71 CB750 Stocker 2 Rocker Cafe build ** now with VIDEO **

[ksmith0034]

This project started from a bike that I got from my wife's uncle in the summer of 2006. It had been sitting in his garage for 30 years, and he wanted someone who was interested in fixing it up and riding it. Since I always try to do the right thing, I volunteered to step up to the challenge and take it off his hands. For free!

The only catch: I can NEVER sell it. Well then, I guess I'll just have to make her my own, won't I?

Follow along as I have a go at turning this 1971 Honda CB750 stocker into a custom Cafe Rocker!

[ksmith0034]

I am pulling the info from my original build site www.stocker2rocker.com (now defunct) and putting it here where it might actually do some folks some good.  Here is the rundown of progress that has been made thus far:
8/27/06 - Picked up my '71 CB750
5/14/07 - Disassembly BEGINS!
5/20/07 - Ripped to the frame and drive train
5/28/07 - She's ALL broken down!
6/02/07 - Pulled top end off motor and began prepping frame for powder coater
7/31/07 - Picked up cylinders from machine shop
9/01/07 - Dropped off cylinders and head for paint
9/28/07 - Dropped the frame, tank and seat at WBS to have them fabricate some brackets
11/??/07 - Picked up cylinders and head
??/??/08 - Picked up frame, tank and seat from fabricators
7/03/08 - Picked up frame from powder coaters
7/11/08 - Dropped off swing arm at chromer
8/10/08 - Put engine back in frame

[ksmith0034]

We had to drive from Columbus Ohio to Washington DC to pick her up.  But hey, I can't complain - she was FREE!!!

[ksmith0034]

The first step was to strip the bike down. As you see here, the bike is up on the jack, and I have removed all of the junk from the frame. Keeping track of all the parts is an ongoing chore! I am using zip-lock baggies and a sharpie to mark each bag.  I took photos of EVERYTHING before I began, and will try to take more as I go.

[ksmith0034]

My goal is to keep it kinda traditional...take off the unnecessary and polish up and repaint whatever is left over. Not gonna grind any welds, but might cut off a few brackets here and there.
I spray painted the unnecessary tabs to be cut off with orange spray paint - this is what happens when you don't watch out for over spray! - It is now welded back on.

[ksmith0034]

Parts are a-flyin' off now!
We had a bugger of a time gettin the motor out. It kept snagging on everything! So we layed the whole mess on its side and lifted the frame off the motor. WOW! Are we geniuses or what?

[ksmith0034]

WARNING: Lesson to be Learned!!!

Do NOT try to dislodge the head by pounding on fins...even WITH a rubber mallet! The fins are FRAGILE!!!

[ksmith0034]

I had my cylinders bored to match my Wiseco 836 pistons at Columbus Colweld in Columbus Ohio. They quoted me $100 over the phone, but when I picked up the cylinders they charged me $222.04! That's more than DOUBLE the price they originally quoted! I'm glad I wasn't buying a car from them!

Needless to say, I will NEVER go to them again for machine work. I don't mind paying the money for quality work, but don't change the price on me by over 200%

LESSON: Always get quotes in writing when dropping off parts.

[ksmith0034]

I bought all my top end parts from CycleX. Nice folks and very helpful in picking out the right parts to mach my needs.

Stud removal was a bit tough. I let them sit in PB Blaster for a few days, then had my brother apply propane heat to the cylinders (NOT THE STUDS!!!)
I then used an impact wrench set on the lowest setting to back them out. No problem!

I used heavy duty APE studs based on EVERYONE's recommendations. Then are definitely a LOT beefier than stock!

I did the double-nutting technique to drive them in, then torqued to APE's specs
(not Honda's)

[ksmith0034]

*** NOTE:

Install pistons BEFORE installing studs. It would have been a LOT easier to install the wrist pin clips if I had done it that way!

[ksmith0034]

I couldn't find a ring compressor that would fit these pistons, so I compromised and used basic hose clamps. There isn't much room, but the clamps worked like a charm. Make sure you use 2 clamps for the UP pistons. Don't try to do it one at a time. (trust me!) - Be careful not to scratch the pistons.

[ksmith0034]

Adjusting the valves wasn't too bad. I don't know how much fun it would be once the motor is back in the bike and you have to get at them though those little valve adjusting holes!!!

Using a long wrench on the crank is a LOT easier than trying to get a precise turn using the kick starter (DUH!)

[ksmith0034]

I decided not to spend 287 hours polishing the valve cover. So I bought a chromed one off Ebay for $105.  Could I have found one cheaper?  Maybe...

[ksmith0034]

I shipped my hubs to TAS Motosports. (www.tasmotorsports.com)
They set me up with a nice set of chrome wheels (16" rear), stainless spokes and Bridgestone tires. They just got a new truing stand, and mine were first on the stand! Hoops, spokes, tires, lacing, truing, mounting, balancing and shipping came to just under $600. Not too bad for quality family work!

[ksmith0034]

I'm starting to buy some parts! I also purchased a new front end off Ebay and a Dunstall seat from Carpy.
What do ya think of the original glass Dunstall tank?!? (gonna paint it black, of course!)
$400 from a SOHC4 forum member.
Dunstall seat - $160 Ebay (Carpy)

[ksmith0034]

Apparently this front end is different than my stock front end (with 6+ tubes). The steering tube was too short, but the top bracket is a lot nicer than my stock, so Mark at WBS used a combination of the two sets to make one sweet setup. I can't wait to get it all mounted up. I will sell the leftovers once I get everything back from WBS.
Front end - $150 Ebay

[ksmith0034]

The frame and motor mounts fresh from the powder coaters. $300 from Streetwerkz in Columbus Ohio.

[ksmith0034]

The engine is heavy.

The frame is light.

Put the frame over the engine. Trust me, this was easy!!!

[ksmith0034]

Since then, I have rebuilt the front forks (progressive) and had a machinist buddy replace the swingarm bushings (they were STUCK!!!).  The swingarm (with new felt and plastic bushing thingies), front and rear wheel are now installed.

[scunny]

looking good. do you need to line the tank ?

[ksmith0034]

looking good. do you need to line the tank ?

Yes I do.  I bought Caswell tank liner as recommended by some folks on this forum.  From what I understand, pump gas will eat through the fiberglass in fairly short order!

[ksmith0034]

What do you think, should I change out the kickstand while I'm at it?

[bgfootball67]

Man, making some progress on the bike.  Looks great.  You gonna have her done for riding season this year?

[ksmith0034]

Hey Ed, glad you found me.  Yes, I fully intend to have it rideable this summer.  However, there's a small snag: I got laid off from my job last Thursday.  While I will have a little more time to work on it now (not much, gotta find a new job!), we are in a spending FREEZE.  That means I can't order the Dyna, rear sprocket/chain, headlight/turn signals, or get the carbs cleaned/rebuilt until I find full-time employment.  But this thread isn't about my sorry life, it's about turning this old skool stocker into a rip roaring rocker!

[ksmith0034]

Ok, I found a couple pictures my machinist buddy sent me of his shop-made swingarm bushing puller.  Four pieces and a driver - pretty nifty!