Author Topic: First Bike Build CB550k (Read 13727 times)

jiggliemon · « **Reply #25 on:** June 08, 2012, 01:59:02 PM »

I started in on the tank fab portion while I wait for some parts. I traded my 550 tank for a 750 super sport tank as I like it longer && it was going to save me a bit of body work (in stretching).

I started with cutting out the stock tunnel since it wasn't going to fit on the 550 frame. I was going to have to create all kinds of brackets to make it work, and in reality I wanted to add a rake to the tank, so the camel hump would be the tallest point of the tank.

I created a little buck so I could make the new tunnel a little more solid to work with. Also, i needed something symetrical for when I start the hammering. My friends shop has a Harbor Freight shrinker/stretcher, but it's not really cut out for this sort of radius, so I had to cut small sections in order to make it bed around the corners. These things were sons of #$%*es to weld, since it's 20ga && @1/4" wide... the torch was melting the metal at every opportunity.

You can see the tank shell inside the new tunnel here. The rear will sit about 3" higher than the stock tank, however I might make that more like 5", since I'd like to take some height off the front of the tank to make the radius match the new tunnel.

I bought some 1/2" solid stock to bend up in order to create the knee tucks. The solid stock is to add a radius to the tucks so it's not a hard joint to butt weld.

I need to make a battery box, a seat pan and mount the rear shocks still.

More later.

fastbroshi · « **Reply #26 on:** June 08, 2012, 07:08:07 PM »

That's looking good. Smart call on using the F tank, better looking shape than the 550s. I'm just learning about welding; would tig have been the better choice here?

jiggliemon · « **Reply #27 on:** June 11, 2012, 03:18:16 AM »

Quote from: fastbroshi on June 08, 2012, 07:08:07 PM

I'm just learning about welding; would tig have been the better choice here?

By torch I mean Tig torch. The main problem I had was that I tried welding directly on top of the buck. Apparently it didn't work so hot & I had to put an aluminum plate between the steel ant the wood.

Really though, 20-22 gauge steel is so thin, it's very difficult to weld regardless of method.

I might try Ox/acet welding the tank since it will fuse at 1/2 the heat. Hopefully reducing distortion? We'll have to wait and see.

I just hope I don't screw this up. It's a very expensive 'undo'.

jiggliemon · « **Reply #28 on:** June 11, 2012, 07:11:37 PM »

I started assembling the forks and bars so I can test the tank out, and better fit it. I had bought those super bearings a while back to replace the stock ones (all the loose bearings) but never put them in, so this was also the bearing install.

I had read a thread on here that said if you aren't using the stock headlight ears, you're save to install the bearing on the neck with out a spacer... So i decided to try with out a spacer, and as you can see, it's really close - 1mm close.

At the shop today I cut up some brackets for the upper shock mounts, and am using some DOM tubing for the sleeves.

sinister902 · « **Reply #29 on:** June 12, 2012, 11:15:36 AM »

When this started out with you saying it was your first bike build, I was not expecting such quality fabrication. Nice Work!

jiggliemon · « **Reply #30 on:** June 12, 2012, 05:58:04 PM »

Quote from: sinister902 on June 12, 2012, 11:15:36 AM

When this started out with you saying it was your first bike build, I was not expecting such quality fabrication. Nice Work!

Well it's my first bike but not my first project. However it's been 6 years since I've cut a tube or touched a torch. And I do have the luxury of working at my friends truck shop. He has all the nice tools (except a mill, i need a mill)

jiggliemon · « **Reply #31 on:** June 13, 2012, 09:07:39 PM »

I mounted the shocks (mainly so I can wheel this thing around the shop). I'll weld the brackets in once I get the motor back in. Does anybody know the proper swing-arm angle?

In addition to the shocks, I also got my new battery. So of course that means I need to create a battery box.

I ordered some butt welding clamps and clecos so I can start welding up the tank some. I think I have a little more planishing to do on my lower 1/2 to give the front of the tank a full radius, instead of a full 3" of vert.

Until that stuff comes in I'll be patching up all the stock crap honda thought I wanted (like a filler cap).

jiggliemon · « **Reply #32 on:** June 16, 2012, 01:50:50 PM »

I tacked up the lower 1/2 of the tank today. For the tank this is a big milestone. it means I can start doing some additional shaping like the knee dents and start the tunnel.

I took the liberty of photoshopping the tank onto my frame to see what it would look like. What do you think?

Mcwilliams570 · « **Reply #33 on:** June 16, 2012, 02:22:02 PM »

That tank look great man awsome job I really like the flow of it...

Matt

Bluegreen · « **Reply #34 on:** June 16, 2012, 02:28:17 PM »

Stoked on this !! I really like the tank lines.

Ecosse · « **Reply #35 on:** June 17, 2012, 07:58:33 AM »

looks really cool.

but unless you plan on putting the filler in the rear you'll never top off the tank with gas.

jiggliemon · « **Reply #36 on:** June 21, 2012, 09:06:33 PM »

I got started on the seat pan.
Here's what the seat will ultimately look like

I'll be starting the dome part tomorrow.

Bluegreen · « **Reply #37 on:** June 21, 2012, 10:22:34 PM »

This is becoming my favorite build right now. Have you given any thought to making your seat lines/profile match the tank?

jiggliemon · « **Reply #38 on:** June 21, 2012, 10:34:11 PM »

Quote from: Bluegreen on June 21, 2012, 10:22:34 PM

This is becoming my favorite build right now.

That's quite a compliment coming from someone w/ quite a nice build under his sleeve.

Quote from: Bluegreen on June 21, 2012, 10:22:34 PM

Have you given any thought to making your seat lines/profile match the tank?

Well my first goal will be just to get a shape laid down, as i'm going to be pounding the hell out of the steal by hand. If I can get something reasonable in a short amount of time i might take a stab at being creative.

I've been toying w/ the idea of adding some rolled lines in the hump to match the tank, but I'll have to mock something up after the dome is hammed out to see if it actually fits. I'll post some mocked up shots to get some opinions before I start the whole welding process.

Also I've not figured out what to do about tail lights. Im not excited about making one (i hate plastic) but i'm also not thrilled about what's available. Any ideas?

Maybe just mount a strip under the hoop? Go cheap and leave the brake lights on the same bracket as the license plate?

Bluegreen · « **Reply #39 on:** June 21, 2012, 10:45:32 PM »

Quote from: jiggliemon on June 21, 2012, 10:34:11 PM

Quote from: Bluegreen on June 21, 2012, 10:22:34 PM
This is becoming my favorite build right now.

That's quite a compliment coming from someone w/ quite a nice build under his sleeve.

Quote from: Bluegreen on June 21, 2012, 10:22:34 PM
Have you given any thought to making your seat lines/profile match the tank?

Well my first goal will be just to get a shape laid down, as i'm going to be pounding the hell out of the steal by hand. If I can get something reasonable in a short amount of time i might take a stab at being creative.

I've been toying w/ the idea of adding some rolled lines in the hump to match the tank, but I'll have to mock something up after the dome is hammed out to see if it actually fits. I'll post some mocked up shots to get some opinions before I start the whole welding process.

Also I've not figured out what to do about tail lights. Im not excited about making one (i hate plastic) but i'm also not thrilled about what's available. Any ideas?

Maybe just mount a strip under the hoop? Go cheap and leave the brake lights on the same bracket as the license plate?

Thanks! Your bike is going to rule.
I went cheap and have my turn signals/integrated brake lights on my license plate. I'm pretty happy with them, they're bright but hidden. I also wasn't too concerned about everything being period correct though. If it was small and light it won out over period correct and clunky.

jiggliemon · « **Reply #40 on:** June 25, 2012, 09:24:29 PM »

So here's the deal. I think the steel is too thick for the tools that I have.

I've got harbor freight mallets, English wheel, and planishing hammer. A shot bag and two tuck pucks.

The steel I'm workin with is 20ga. And no matter how hard I hit the steel I can't produce a decent tuck. I might need to get a tucking fork. Does heating the steel up w/ a little flame help loosen the metal like with aluminum?

I was able to get a little crown on my low crown piece, but the back will need some more love.

Anyone with a lot of sheet metal experience have tips?

jiggliemon · « **Reply #41 on:** June 26, 2012, 09:46:31 PM »

Quick update, the rear of the bump is not so easy to beat into shape.

I don't think I have the tools or the experience to accomplish it with one piece of steel.

Tomorrow I'm going to trim it down a little bit and apply some heat to see if it helps to move some of the material around.

A metal form and a hickory slapper would be really nice at this point in time. But it will also make my bump a $200 piece of steel.

On another topic, I just saw this site and it made me very jealous of his skills. http://crowemetalco.com

jiggliemon · « **Reply #42 on:** June 27, 2012, 09:36:23 PM »

I couldn't make the rear of the bump out of one piece. So I cut it in 1/2 and it was a breeze.

I know full well it should have been made with two pieces only; but just not today.

fastbroshi · « **Reply #43 on:** June 27, 2012, 10:22:11 PM »

Quote from: jiggliemon on June 26, 2012, 09:46:31 PM

On another topic, I just saw this site and it made me very jealous of his skills. http://crowemetalco.com

Not sure about his metal shaping skills per se, but he's made his own fenders and and seat bump by hand it looks like which is admirable. The 750 pictured looks great. Have you heard of Ron Covell? His website needs to be updated badly and doesn't represent his work well in my opinion, but his metalworking skills are first rate. He travels internationally doing metal workshops.

jiggliemon · « **Reply #44 on:** June 28, 2012, 10:40:18 AM »

There's not a lot by way of sheet metal, but the other stuff is what caught my eye.
Here's some of the things that really stood out for me:

He made his own brake light assembly
http://crowemetalco.com/post/17136081377

This throttle housing was made very well and clean
http://crowemetalco.com/post/15234075219

This throttle is also really cool for a Triumph
http://crowemetalco.com/post/4889285228

The levers on the CB project
http://crowemetalco.com/post/1154050817
http://crowemetalco.com/post/1274099087

Flying J · « **Reply #45 on:** June 28, 2012, 11:51:32 AM »

My cafe seat was made from 3 pieces and i think it looks great. So i would worry about cutting it up.

jiggliemon · « **Reply #46 on:** June 28, 2012, 04:57:04 PM »

Your seat looks awesome. Polished makes it even more the better.

I think aluminum would have been the better way to go for me as well.

Well here it is, unfitted and raw, but 90% there.

jiggliemon · « **Reply #47 on:** June 28, 2012, 06:52:08 PM »

Also I wanted to put up some pictures of my buddies recent finished project. It's a Harley cafe style with all the fixins.

Not a ton of fab work, but it's a clean overall look compared to most Harley's rolling around.

Madigan Motorsports
Menifee, CA

jiggliemon · « **Reply #48 on:** July 01, 2012, 01:05:23 AM »

Im on the hunt for a headlight bucket that I saw on the Crowe metal site.
Does anybody recognize what brand this light bucket is? The letters on the side read something to the effect of CED? CEG ?

I made a thread about it here: http://forums.sohc4.net/index.php?topic=109280.0

Also I could use a good leather guy (or girl)

shaun · « **Reply #49 on:** July 01, 2012, 07:40:41 AM »

Quote from: jiggliemon on July 01, 2012, 01:05:23 AM

Im on the hunt for a headlight bucket that I saw on the Crowe metal site.
Does anybody recognize what brand this light bucket is? The letters on the side read something to the effect of CED? CEG ?

I made a thread about it here: http://forums.sohc4.net/index.php?topic=109280.0

Also I could use a good leather guy (or girl)

have a look at sportster head lights this is one on my sortster cafe . and it as a rubber on it that takes 2 rims one big one small .it will take 2 small ones maybe ?

by the way cool build mate

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Author Topic: First Bike Build CB550k (Read 13727 times)