Topic: I Need Help Making My Battery Box! And Advice On Cafe Seat?

[campbmic]

I have a 1975 Honda CB550. I'm slowly turning it into a cafe racer type bike.

Battery Box-
I've trimmed away all the electrics that I can and still have the bike running. I also just picked up my new AMG battery from batteries plus which measures 6"  x  2.5"  x   3.5"

http://www.batteriesplus.com/product_search/32634-Werker-12V-7-dot5AH-AGM-Battery--dot187-Terminal-WKA12--7-dot5F.aspx

Sourced from batteries plus for $30!

So, now that I have everything ready all I need is to fabricate a battery box for everything to sit in under my seat. I figured I could attach it where the negative terminal of the battery traditionally attaches to the frame. This is a great example of what Im trying to make by "Architect"


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I don't have very easy access to a welding source and want to ride! So I was wondering if anyone had some tips on making one without having to weld? I'm sure its a long shot but I figured if ANYONE would know it would be you guys   

Also, if anyone has some designs madeup for their bike's custom battery box please post them! I'm guessing I'll probably have to get one machined up from scratch and need a solid blueprint!




Cafe Seat-
While working on cleaning up the triangle I took off the seat and rear fender and I'm reallliking how clean the back is looking! I was wondering if anyone had any good resources on making your own cafe seat. So I can start planning the next part of my build!


Thanks guys

[KingCustomCycles.com]

Check the "how to" section of my site for seat fab ideas.  One way or another, you are talking fabrication and that falls into welding and steel, rivets and aluminum, or fiberglass and resin.  Pick your poison, buy the tools, learn the techniques and you will have your parts in no time.  Almost all do it yourself custom bike parts are one or all of these.  KingCustomCycles.com

[The_Crippler]

For the battery box, you could probably get a light-duty metal brake from a hardware store and some standard pop rivets.  From there, get some sheet metal and get to folding.  

[campbmic]

what is a metal brake?

[campbmic]

ahh nevermind lol, I think one of those would be pretty expensive

[KingCustomCycles.com]

A metal brake bends lengths of sheet metal like for guttering or aircraft skin.  Many of those tools are heavy shop equipment that a local trade school may let you borrow.  Same goes for circle punches, shears, and slip roll formers and english wheels.......:-)

[Bluegreen]

Use a bench vice as a break (use wood in your clamps) and a pop rivet gun. Make it out of cardboard first so your tabs work, then copy it onto aluminium. If you want it watertight caulk the inside with Geocelll. My take on it.

[The_Crippler]

ahh nevermind lol, I think one of those would be pretty expensive

I guess it depends on what you consider expensive.  For something small with light-weight sheet (like a battery box would be) something like this is just the thing.  (I've used them more for computer cases):

http://www.harborfreight.com/18-inch-bending-brake-39103.html

A bench vise can work in a pinch, but I've never gotten a clean enough bend for my tastes (But I'm picky.)

[tango911]

i have a 550 battery box you could modify it maybe.  hit me up

[campbmic]

I have a battery box already from when it was stock but I cant get it to work under the seat at all

[WilliamA]

If you can sketch out your battery box and get the metal cut, a local sheet metal shop could form for you for a small fee.

[The_Crippler]

That's not a bad idea at all.

[ryani]

Here's the one my friend bent and welded for me.  I plotted the dimensions on flat 16ga sheet and he bent and welded it up for me.  You could do the same at a local welding shop.