Topic: CB550 Cafe build - 1st bike build, but not 1st build

[Tintop]

Too bad about the injury, nasty stuff.

In any build there is lots of "stare at a while" time. You're in a perfect situation for that part.

Then finishing will be a cakewalk!

Thanks for the encouragement.

Problem is I spent 1 1/2 years planning; and had just put the 1st coat on the cases; and the pipes just arrived.  Thinking maybe I can layout a custom harness one handed, but a lot is going on hold.  Have always had a rule - only I do the final assembly of my projects.

On another note - are you going to Mosport for the VRRA Vintage Festival this August?  Would love to see that 750 again.

[bwaller]

Well the plan was to make Mosport then Indy for the GP, but I may have to re-do part of the Fast School that was rained out Thursday so I can get my race license. That may screw up my Mosport plans.

[Stev-o]

Sorry to hear.

Being an "ex-carpenter", I never fight with a skill saw [or tablesaw] - you'll never win.

[Flying J]

Just found this build. Sorry your hurt. i had a run in with a table saw once. those are powerfull machines. Ill be keeping an eye on this build though. Take care

[Tintop]

thanks to all for the kind words.

now back to my regularly scheduled programming.

on Tuesday I'm planning on going to the shop (no the doctor doesn't know ), maybe Wednesday also to get things going again.  a friend has offered to be my 2nd hand to help mask the engine for painting (says for free, but coffee / donuts / lunch / beer? ) just need the swing arm grease felts to assemble the rear (on order, may get there), so will get everything ready.  best news, the exhaust has arrived so maybe I will get to try the headers on the engine.  also figure now is the time to start on my custom harness, and layout the electrics in the tail.   will post some pictures. 

electrical plan:
HID head light
aftermarket bulb turn signals (may change to LED)
500 dash (polished) & ignition (EMGO)
77 550 controls
77 horn & relay
Hondaman ignition with nos TEC points, and new condensers
Dyna 5 ohm coils, Dyna wires
odyssey PC310 dry cell battery
solid state solenoid
stock regulator & rectifier (for now)
electronic flasher
Custom Dynamics LED combined running / turn / brake light (Warrior)
LED licence plate lights

will be using an all black wiring kit from Centech (except retained stock stuff, like controls) with gray tubing and tape.  each wire's function is labeled every 12"'s.  used a car version for my solo 1 super seven, neat stuff.  comes with a three circuit, thermally fused panel.

and yes, more pictures to follow.

[Tintop]

got to the shop today  , and got paint on the engine.  masking with a flipper was fun

decided to try something different for the engine colour, that would work with my gray frame.  decided on a VHT engine paint called Titanium Blue.  barrels are VHT low gloss, and the rocker box VHT black wrinkle.

1st coat - sure is blue 


not sure  what I'm going to do with the filter housing yet

masking for the barrels


rocker box finished in black wrinkle - had time to start adding the polished, alloy, and SS pieces.


minor clearance problem , I can have nice socket allen's, and ugly adjuster caps / or ugly screws and nice alloy caps
decided will use some button allen's.  nicked the paint trying to get things to fit


going back Thursday, should have engine in, and back end on. may do 1st fitting of exhaust.

[traveler]

A blue motor.....wow...that's different.

flat black touch up paint and a toothpick will fix the knicks.

~Joe

[Tintop]

A blue motor.....wow...that's different.

flat black touch up paint and a toothpick will fix the knicks.

~Joe

yeah it sure it blue, think it might work though.  as for the nick, its just one of a couple spots I need to touch up.  the 1 1/2 handed masking wasn't perfect

Brian

[traveler]

Just tell yourself over and over.....my hand is fine...my hand is fine....and then use it.

I dare you......

[Tintop]

Just tell yourself over and over.....my hand is fine...my hand is fine....and then use it.

I dare you......

they gave me extra straps, so I now offically have a 'shop set'.  just hope I can get the black paint off the splint before my next appointment

[Tintop]

got to the shop today, and made great progress, but not before I got bored last night and decided to detail the sprocket

easier to mask than the engine, but cutting out the holes....



Put the disks on the front wheel, along with the modified speedo drive (thanks BWaller)


then the fun part, getting ready to install the engine.  used pipe insulation to protect the paint.

then in, using the 'drop frame over engine method'.


next came the rear suspension, so that pipe clearance could be checked


finally the moment I've been waiting for (2 1/2 months ) 1st loose trial fit of my Swarbrick 4 into 4 550 pipes. did get 3/4 to sit perfectly but they moved slightly before I could get picture  these should sound fantastic




headers sitting loose, but in basic position.  oil changes should be fun


looks like I am going the have to do some minor detail grinding of the spigots to get them sitting in the ports just right.  also remove some burrs so things slide together nicely.  #1 header may need to be tweeked, but there is mandrel equipment next door.  next is fitting the wheels.  rear to check clearance while exhaust is fitted, and the front so I can finally fit my old school fork brace, and front fender.

[FrankenFrankenstuff]

Very nice. I like your choice of frame color. I am rocking the white prime rusty look myself. Were is that Blue tank? This looks like it will be a great bike to showcase on of my custom covers.

[Tintop]

thanks Frankenbike.  fitting a Monza cap to the tank, then off to painter next week, along with seat and fairing.

cover has been ordered, will post a picture when installed.

[Elniniomuchachos]

got to the shop today, and made great progress, but not before I got bored last night and decided to detail the sprocket

easier to mask than the engine, but cutting out the holes....



Put the disks on the front wheel, along with the modified speedo drive (thanks BWaller)


then the fun part, getting ready to install the engine.  used pipe insulation to protect the paint.

then in, using the 'drop frame over engine method'.


next came the rear suspension, so that pipe clearance could be checked


finally the moment I've been waiting for (2 1/2 months ) 1st loose trial fit of my Swarbrick 4 into 4 550 pipes. did get 3/4 to sit perfectly but they moved slightly before I could get picture   these should sound fantastic




headers sitting loose, but in basic position.  oil changes should be fun


looks like I am going the have to do some minor detail grinding of the spigots to get them sitting in the ports just right.  also remove some burrs so things slide together nicely.  #1 header may need to be tweeked, but there is mandrel equipment next door.  next is fitting the wheels.  rear to check clearance while exhaust is fitted, and the front so I can finally fit my old school fork brace, and front fender.

  :oThis whole post is looking damn good. That black rear hub is a nice touch, usually people just paint the whole wheel black but that chrome and the black hub look awesome! I wish I had the money for those ppipes I've watched video of them and they sound so crazy. Are you gooing to go black on them? I think that would look pretty sweet on your bike ...Like the ol' cr750 racers. that light blue color goes pretty good with that grey frame. almost looks silver at first, because the frame... This thing is going to look sweet when it's complete!!! What are you doing for a seat? A guilairi replica would look cool. Though that is the only cafe seat that I would ever put on mine....

[Tintop]

thanks for the compiments Elininiomuchachos.  the seat is an airtech cb750 sbk.  gives me lots of room for electrics in tail, and I really like the back cut angle to the tailing edge.  the opening its creates will house my LED tail light / turn signals.

[KB02]

Do yourself a favor and get the rear tire and chain mounted before doing any final adjustments to your pipes. I bought the Benji 4 into 4 pea shooters for my bike. They were built on a CB750 frame, but he didn't leave clearance for the chain. I had to adjust my mounting point a little bit to make them fit.

[Tintop]

thanks for the 'heads up' KS02.  rear wheel goes in Saturday, however chain / wheel clearence doesn't appear to be a problem, am doing the initial fitting with suspension in full droop for that reason.  chain runs inside the swingarm, and beside the front bracing tube.  the notched engine mount spacer shows its location / path.

[traveler]

VERY cool!  I went with the MAC 4-1, and didn't know about these pipes.

Hmmm.....like where you're going with this.  Is this a street bike, or race bike?

~Joe

[Tintop]

VERY cool!  I went with the MAC 4-1, and didn't know about these pipes.

Hmmm.....like where you're going with this.  Is this a street bike, or race bike?

~Joe

it's for the street.  motor is basically stock, a slotted cam sprocket is the only internal change I'm planning to do later.  will have to see how load the pipes are, as I may have to install baffles.  can't see how it will be any worse than the Harleys, and pocket rockets around here though.

[Tintop]

got some things done on saturday, but mainly tried to figure out my remote oil filter setup.  that post is in sohc4 bikes.

did get front wheel assembly finished - disks on and torqued, speedo drive installed, mounted in 78 forks while my old school fork brace is fitted.  also stuck the airtech fender on the tire to check radius match.  all will be fine.  plan is to trim ears off fender, and mount to the underside of the brace.  this will mount using the upper caliper bolts, like the stock fender.  also have a t-shirt with a perfect gt501 tread pattern up the front.



my hondaman rebuilt rear swing arm is also finally in place, all lubed up as per instructions.

[traveler]

Looks great....and you now know your engine motor mounts are tight!

~Joe

[Zig]

Nice work on the bike, the pipes are a thing of great and wonderous beauty, good choice.
Got a link for the dudes that did your plating?? I have a boxful of stuff that needs replating.
Zig.

[Tintop]

Nice work on the bike, the pipes are a thing of great and wonderous beauty, good choice.
Got a link for the dudes that did your plating?? I have a boxful of stuff that needs replating.
Zig.

thanks Zig, I'm also looking forward to hearing it come to life.   will post a video when the time comes.

nothing plated yet, that said I used two great shops in the Toronto area (Mayfair & Aero Tube) each for different reasons   all that shine is  polishing - rims / hubs / triple / cases.  the billet stuff is polished / anodized, and as I promised myself to never use regular allens again after the Seven (rust! ) most fittings are SS. 

just spent a couple of days doing assembly.  needed to start attaching things electrical so I can get harness done.

right side up finally.  tried test fit of brace - time for plan B


plan B - spent today taking off the 78's forks, putting on the rebuilt / refinished 77's (gold valves). looks like I will use a more modern fork brace, and mount the fender like the Manx.  started installing the front brakes / battery & tray / bar and controls.


old school rear mount duals using 550 forks, still some fitting to do, but real close out of the box.


rear end is done, just need to install / torque new sprocket nuts, and fit chain.


next up is fitting pipes, then out to get coated. 

[sander]

That engine looks beautifull!! Nice build!

[Tintop]

That engine looks beautifull!! Nice build!

thanks Sander, I love billet and polished alloy.

have been following your build, impressed with what you have done.