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

[Tintop]

I have always wanted a Cafe Racer, and had thought (in the day) my buddy's 550/4 was a great bike.  So when the chance came to acquire a complete 77 550, and a 78 engine in movable storage (frame with title), I took it.  I have not taken pictures of the deconstruction.  Old greasy parts, and my bloody knuckles look just like everyone else.  

This is the before:

While it looked reasonable from a distance, up close the rust gods were hard at work.  If not for the chrome, I'm not sure there would have been any pipes.  Easy to remove though, but so much for making anything back on Ebay!  The following pictures are of various areas of the frame build, along with pictures of some of the restored / rebuild / new parts waiting to be installed.

First fitting of the seat (Airtech CB750 SBK) and tank (76 750F) in the new mounts. The front tank mounts have been moved forward to tighten gap the at front, and 1/8 added to the stops to protect the tank.


The new seat and tank mounts.  Back edge of the rear mount will be blended into the electric tray over the tubes.


New rear frame tube with improved gusseting around the shock pickup.


The new rear tank mount, using a NOS 750 tank rubber to make servicing easy.


Always loved those 70's SBK swing arms, and the 550 could use the help so...


Closeup of the swing arm gussets, and rear set bobbins


Rear set mounting plate rough outs, with holes for frame bobbins, peg, and exhaust.


Pegs will look like these destined for a TZ 250


Got out the Master Cam, and came up with this for the Odyssey dry cell to mount it behind the engine.  After fitting, more polishing


The swing arm bracing decided the fate of the centre stand so paddock bobbins have been added (sorry for the focus)


Some of the bling stuff - either new / restored / or rebuilt.  The hubs are waiting for WM2, and WM3 Borrani rims from the polisher, and SS spokes to arrive.


I am going to be using dual front disks, with dual stock calipers, and a modified speedo drive.  The ones from the 77 & 78 were pretty ratty, so I sent them off to be checked for true, refaced, mirror drilled (for dual setup), and refinished.


More bling, but the useful kind, the completed brake calipers


The 550 forks - rebuilt with new stanchions, and Race Tech Gold Valves installed.


Sometimes you get lucky, a pair of NOS Boge shocks for a CB550.  Now the backend will work like the front


No pictures of the 77 engine yet (stripped 78 in the frame), but these are some of the polished parts


It looks like the frame and swing arm will be ready to go to powder coat next week, and I should have my custom Centech wiring harness ready by then.  The wheels should also be laced about the same time, so the next pictures should be of a rolling chassis.  Can't wait.  I'm also waiting for the SS bolts, and the exhaust kit to arrive - a Swarbrick 4 into 4 replica of the Honda 'bent pipes', like Hailwood's.  It will need some fitting for the 550, and then coating.  The carbs should also be back from cleaning shortly, and ready for reassembly.

[Staggerlee]

Well you're off to a helluva start; I'm looking forward to seeing this one come together.

[Bonafide]

Very nice sir ... very nice. Looking fwd to seeing the finished product.

[cdoggy81]

Love the work & direction so far. Keep it up!

[Hannibal Smith]

Looking great so far! Everything is era plausible, and should come out looking old school. Good blend of black and silver.

[Tintop]

Thanks to all for the encouragement.  More progress over the pass couple of days.

Electric's tray tacked in, along with the cross member with threaded inserts to attach rear of seat.  An 'engine turned' alloy panel will fill the back opening and have an R1 LED tail light / turn signals mounted through it.


Just tacked together for now, but the back is now complete.  Also added have been the seat mount bobbins.  I am planning on using an 18 gauge steel strap with threaded inserts weld to it that go through the seat pan & seat.  These will slide through the bobbins and be secured from the bottom with 6mm SS Allen's.


Battery tray mounted, and 1st trial fit of a brake side peg (using TZ 750 bracket for mock up) to determine hole locations / length of brake rod, and brake pedal pickup point / height.  Final shape of peg bracket will be determined when exhaust is fitted, and attach point located.


Byron - my welder at CMR Racing Products (a shameless plug OK, but credit were it is due) - he gets the kodoos for all the good welds, but also the blame for any ugly ones.


Picking up the frame and swing arm Saturday, for drop-off to be powder coated - yeah!  Still have to decide the final colour shade.  Frame will be a grey, just note sure if it will be light or dark, swing arm will be black.


 

[Tintop]

Looking great so far! Everything is era plausible, and should come out looking old school. Good blend of black and silver.

Thanks Hannibal - keeping it period, and old school, while adding some hidden modern upgrades (Race Tech, Dyna S) has been my objective.

[Old75_ratafe]

looking pretty good are you sticking with 4 into 4 or doing the 4 into 1 route?

[Tintop]

looking pretty good are you sticking with 4 into 4 or doing the 4 into 1 route?

Exhaust will be 4 into 4, but not a stock set.  Swarbrick Racing in the UK make an exact replica of Hailwood's 500/4 pipes.  They should be here in about another week (in kit form).  Will then put the 78 stripped engine back in to do the final fitting; while I paint / detail the 77's rebuilt engine.

[Old75_ratafe]

very cool, IDK just something about 4 - 4's I really like I like the 4 into 1's on the cafe's look good but gotta love the way the 4 into 4's fit.

[Tintop]

couple of more pictures of final additions to frame

steering damper installed with fixed mount on frame, and Ceriani fork leg mount.  will be going with a 'drag bar' rather than clip-ons because of bad back.  bar attach will be a cb500 polished dash with new black face.  x4 3/8's holes have been drilled in each battery tray support bars since this picture taken


seat now attached, mounting plates will be hidden under seat padding / upholstery


seat mounts / attachments as seen from the underside (bolt and washer will be replaced with SS)


licence plate mounts welded on, and sized to take SS LED plate bolts / lights combination. you can just make out the slots were the LEDs are hidden.


still have to paint lower triple (primed), top triple polished and steering stem fitted with new bearings. You can see the wires for the licence lights at the back. 


Tommorow its time to strip it down, and off to the powder coater.

[Tintop]

Finally an update to my 550 build's progress.  I may actually get to ride this year.  Unfortunately the camera decided to take an early holiday, and died after two pictures!  Will post more of the completed wheels later this week.

Just back from powder coat, packing for the trip to my assembly area.

I wanted a grey frame, like the tube frame ones in vintage race cars.  Jury is still out, but it's growing on me.

Better shot of the swing arm.  Finish is 'factory'+, well worth the $50.

[Tintop]

More progress today - the carbs are back from being ultrasonic cleaned, and micropolished.  I also received my new helmet, a NOS Arai Phil Read replica.  Now I have to be on the road this year.

First look after unpacking 

The CAD looks orange in the picture, but is more gold in natural light.

Not sure they were even this clean from the factory

This one had 1/16" of dried varnish in the bottom.  Now that its clean you can see were someone has tried to clean the over flow .

The fresh CAD parts

Bell crank, carb supports, idle adjust screw, assorted springs

More CAD parts - mounting bolts & screws, float bowl screws, even the air screw springs, and internal stuff.


This weekend's project has been decided - start the carb rebuild.  Modifications planned include: lift stock needle x1 notch / modify main jet emulsion tube, set float at stock.  Couple of other possible changes contemplated.  Engine has fresh top end (1st over), points ignition with HM transistor module, black (5ohm) Dyna coils, 7mm wires, and will run race 4 into 4 pipes.  Carbs will be fitted with FCR 60mm velocity stacks, and foam socks (for street).  Am working on an air box design, but it wasn't part of the original 'picture', so making it fit / work / look good is proving challenging.

[Godffery]

Dude…!!!! Your buddies welding skills are awesome!
Did he do the swingarm mod’s as well?

Also; where did you send the Carb parts off to & how much did they charge for that service? They did a grate job!

BTW; could you please post a link for the exhaust you ordered?

   Godffery's Garage
 http://tinyurl.com/yfrw4fc  

[Tintop]

Dude…!!!! Your buddies welding skills are awesome!
Did he do the swingarm mod’s as well?

Also; where did you send the Carb parts off to & how much did they charge for that service? They did a grate job!

BTW; could you please post a link for the exhaust you ordered?

   Godffery's Garage
 http://tinyurl.com/yfrw4fc  

Yeah, Byron's skills are pretty good.  Now I want him to weld some alloy parts.  All the modifications to the frame were designed by myself (with background research).  The final swing arm was a compromise.  As for the exhaust it comes from: http://www.swarbrick-racing.co.uk/  They are made to order, expensive, and take forever to get; but the quality, and exactness of reproduction are worth it.  The carbs were done by Jeff at Paltech http://www.paltech1.com/  He has done MG / Jag carbs for me before.  They come out restored, but not over restored - i.e. buffed to death; they also don't tarnish as quickly.  For the 4 PD's - ultrasonic cleaning (all) / micropolishing alloy parts / new CAD on balance about $300.  Like working with all new parts.

[Godffery]

Thanks man; good stuff!

[Stev-o]

Very impressive build so far...

[Tintop]

Very impressive build so far...

Thank for the continuing encouragement.  I'm reaching the final assembly stage, and just replaced my camera, so more pictures soon.  Took these today of the last trial fit of my gauge mount.  Had the three pieces waterjet cut from my CAD drawing, then drilled them for 3Mx15 buttons.  Uses the stock ignition mount points.  If I wasn't using the 500 dash the later ignition switch would fit.  Dash has a new black with silver letter face, to replace the original 'wood grain'.  And yes I know, the green and yellow are reversed, I like green for 'turn'.



Also finally got the 77 engine back (3 months to do a top end  ).  Am trying the modified engine stand idea that's been suggested by some members.  Very cobbled up, but it works.  Just remember to put on the nuts.   Been de-greased, some final cleaning with Simple Green, Scotch pads, wire brushes, and then paint. 

from the back, still some 'knuckle killers' to remove.

Should have painted, and ready to go into frame by week's end.

[Raef]

WOW....

 lots of time thought and money in that pile....

very nice

[Tintop]

Couple of additional pictures of the gauge mount.  Had to hand file the two notch's so brake line and wiring could pass through.

Back side

[Tintop]

so last Thursday was not a good one    Had fight with a table saw at work.


good news 1: still have all my digits
bad news 1: there is tendon / nerve / lots of tissue damage
bad news 2: 2 months+ healing, then rehab - so much for getting to ride this year!
bad news 3: no alcohol / no smoking (was quitting anyway) / no caffeine (Tim's bottom line is going to take a hit!)
good news 2: I'm left handed, so some things are still possible, just don't stand to my left, as that arm pit is difficult to reach!
good news 3: as I'm now off work, lots of time for my project's final assembly, just not sure how its going to work one handed.
bad news / good news: washing dishes is impossible / the store next door sells paper plates & cups

[Raef]

Being in construction, I about wet my self when I read the first line.

Rehab sucks nothing but hard work and pain and if you don't push the limits it just don't get stronger/ more flexable.

How bad is the nerve damage? any feeling in the fingers?

 I have some nerve damage on the left side of my face frome a car wreak, I used to droole  not any more, unless I'm really drunk.

Well good luck, were pullin for ya

Mark

[Raef]

another feel good story I got my elbow in a fan blade on a running work truck = split the ulna and radius 3 screws each, Back to laying brick in 8 weeks

[Tintop]

Being in construction, I about wet my self when I read the first line.

Rehab sucks nothing but hard work and pain and if you don't push the limits it just don't get stronger/ more flexable.

How bad is the nerve damage? any feeling in the fingers?

 I have some nerve damage on the left side of my face frome a car wreak, I used to droole  not any more, unless I'm really drunk.

Well good luck, were pullin for ya

Mark

thanks Mark. know all about rehab pain, did in my left shoulder pitching fast pitch 20+ years ago.  they have already done the internal micro surgery, and I have good feeling, its the tendon that's going to take a while.  glass / knives make nice cuts, saws take chunks, nuff said.

Brian

[bwaller]

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!