Topic: CB750 40 Special (finally done)

[mrrch]

This is what I have to start with, 77K frame, 76F engine and alot of nos parts.
A few questions

Will older K2 fork tubes work in the 77 lowers?I used 79 uppers (1/2 inch longer and different caps were required)
What prep needs to be done to the chrome rims if they are to be powder coated?

More questions will follow

I'm in gathering mode right now

[bjb87gta]

As far as the rims go, I would ask your powder coater. If he prefers to sandblast to get good adhesion, there is a good chance he can do it himself, or has someone he can trust to do it. You could also find a plating shop, and they can remove the plating, but I have to think that might be expensive. Good luck with your project.

[mrrch]

How difficult would it be to install dual disc's up front?
I have another rotor & caliper, looks like the stock hub will accept the second rotor. I was thinking of going with a digital guage set so the speedo drive would not be an issue. Will the stock master cylinder handle a second caliper?
77 CB750K

[mrrch]

Frame is bare

Engine

[Bonafide]

How difficult would it be to install dual disc's up front?
I have another rotor & caliper, looks like the stock hub will accept the second rotor. I was thinking of going with a digital guage set son the speedo drive would not be an issue. Will the stock master cylinder handle a second caliper?
77 CB750K

Not hard at all. Basically a bolt on set up. The stock M/C wont work - doesnt flow enough. Some use a Goldwing M/C - but I prefer a new/updated and use a Nissin (5/8th bore). Good luck with your project.

[mrrch]

Engine coming apart

Front end stripped off

Still rounding up parts
Tank is derusted and ready for modification
Front forks are apart for polishing,new seals & upper tubes
Front wheel is apart for hub polishing(older hub), black powdercoating for rim and dual discs are being pieced together

[mrrch]

Intake manifolds are on order
Manifold clamps on order from Pelican parts ($13.25 with shipping for 8 clamps)
Gas tank filler neck will come form ebay ($32 vs $89 from others/not exact but will work)
Connector kits coming from Vintage connections
Headlight mounts from Mikes XS
Bargains to be had with some digging
Bonus is that I am a service manager at a Honda shop(cheap OEM parts)

[mrrch]

Okay it called the 40 Special because I want to have it completed by my 40th birthday in mid September.
Front wheel relaced,new bearings,polished hub

Cylinder cleaned up and ready for paint,deglazed bores,cleaned up pistons and new rings ready

Top clamp stripped and ready for polishing

Footpegs getting some fresh paint

Forks are being polished and reassembled next week I hope
Inquired about brake rotor drilling(will be getting the twin disc setup)
Spokes arrived today off of backorder so rear wheel disassembly will start next week as well hopefully
Have to run to the border to pickup 8 packages of stuff (why does shipping into Canada have to cost so much more?)

[traveler]

My PERSONAL advice:

Be patient.  Take it one step at a time.  What you have is VERY doable.  Will it be a stock 100 point resto?  NEVER!  So, build it to fit what YOU want!

Getting the rims and motor done is a good step.  Sandblast and powdercoat the frame gloss black would be a good next step....followed by some All Balls neck tube bearings, and some rebuilt forks.

Once the motor is back in, then you are looking at a tank, seat, rear fender setup, electrics, rear shocks, and a boat load of little details.

Good luck!

~Joe

[mrrch]

It's getting a Honda orange/red frame. Trying to locate a good pic to show my inspiration (Hint-I'm into MX & vintage MX bikes). I was thinking of powder coat but may opt to paint the frame for now until everything is finished.

[mrrch]

It's like Christmas in June!
Ran to the border today to pick up 9 packages full of good stuff (still waiting for my seat/tail section though)
Forks will be together tomorrow,engine cases getting painted when it's less humid.

I got a rear brake stay from a CR125 that will look pretty trick once modified to fit & polished up
New fork boots,intake clamps,brake light switch,centerstand(won't work with a Yamiya pipe though),stainless bolt kit for engine,brake pads,78F master cylinder(for $20 did I think it was going to be good? full of dry crusties)

[mrrch]

Too humid to paint/cases are ready
Had to JB weld a small crackaround the countershaft area but it was cracked from a gear exploding on the inside.

[mrrch]

Headlight with nice brackets(courtesy of Mikes XS) ready to go.
Forks are assembled but I need different fork caps (79K forks use a different cap/on order)

Cases are being painted this morning.

[mrrch]

Mmmm  Fresh Paint

[mrrch]

Lower end is put together mostly

I was thinking of painting the cylinder head gold (cylinder is aluminum colour/valve cover would be polished aluminum)
Any thoughts?

Also I have to look into the mods for the rocker towers


I think all I have to do is drill out the 8 cast marks on each set and remove the four silver bolts?

[mrrch]

Ordered my exhaust this afternoon, went with the black mac 4-1 from Niche Cycle ($278 shipped) Yamiya was too much,Carpy never has stock. I'm not fond of the muffler on the Mac, I think it will get reworked a little by angling the muffler upward (maybe shortened a touch as well). Seat/tail section is in at the border, just need time to go pick it up so I can start some frame work. I wanted to paint my head gold but could not find a pic until I found the Pepsi racer thread so now I'm going for it but mine will have a gold valve cover as well with polished tappet caps. I'm getting tired of polishing bits and pieces but they do look good when done (I'll try to posts pics of the top clamp,brake master cylinder,brake caliper (I just noticed i have 2 different styles of calipers and arms/one has wider set bolts than the other/any body wanna trade?). Ordered my bigger main jets and pods on Friday. Gel battery arrived last week so I can start building a new battery box. Need to order brake hose kit from Slingshot next week. Rear wheel is apart for polishing and new spokes. Pics later.

[Alan F.]

Okay it called the 40 Special because I want to have it completed by my 40th birthday...

That's a good idea, I wonder if I'll get mine done before my 40th in February? 
-Alan

[mrrch]

Top end is coming together just waiting for replacement rocker arms.
Notice the extra oil holes,new carb boots & clamps(carbs are ready/pods filters showed up today)

Shiny bits are starting to go back onto engine.
Found out my shift fork shaft was in backwards so I had to pull it out with a magnet and reverse it(hole goes to the outside/I put it in the way the PO had installed it/the honda manual does not mention it)
Polishing, what a chore! but the end result is equal to the effort put into it.

I think i even firgured out how to install this prestolite ignition without instructions.

Rear hub is sanded and ready for polishing, swingarm was sanblasted today.
Exhaust,tail section and a few other bits are at the border awaiting pick up this weekend.

[mrrch]

Work is progressing

[rickmoore24]

interesting color combo, I'm looking forward to seeing her back in one piece. Great job!

rick

[mrrch]

Slowly but surely the build is progressing.
Rotors are being resurfaced and drilled this week.
Motor is mostly done, just need to have a small dent & crack welded up on the stator cover.



I'm growing sick of polishing.
Started to mock up the tank & seat, extra bits have been removed from the frame

I'll work on the seat base tonight(carpentry required/have to build a wedge shaped box for under the seat.

[mrrch]

I'll be picking grit from my body for days.
Before sandblasting

During

After pics to come.
Ordered brake hoses yesterday.
Drilled rotors mailed back to me today.
After

A little bondo work required where things were cut off,sand and another primer coat then we'll hit it with colour next week.

[mrrch]

We have colour!

I have to touch up some spots but Duplicolour says to let it cure for 7 days or it might wrinkle the next coat.
Oh well,I have lots of other items to attend to.

[HondaNorway]

I want my motor to look like yours!!!!!!!!!!!! 

Btw, do you heat the paint in an oven? Like, putting the painted parts in an oven? If so, did you have to struggel to get the white rubber dots out of the cylinder? And why are they there?

GREAT project 

Greetings from Norway,

-Stian

[mrrch]

No I did not heat cure the engine parts in an oven. It has been very hot here so I left them outside in the sun for a few days to harden. The rubber pieces are there for vibration I think, I just painted over them.
Honda had some models with gold coloured cylinder heads (CB1100F maybe?) I like the look of the old Honda CR motocross bikes with gold FMF heads on them (that's what gave me the idea)
I hope to have the engine back in the frame later next week.