Author Topic: The Beast transformed into...  (Read 31933 times)

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Offline gnarlycharlie4u

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Re: The Beast transformed into...
« Reply #100 on: March 11, 2012, 03:49:36 PM »
lol those zip ties scare the #$%* out of me.



The rearsets look great though, good job!

Offline Freaky1

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Re: The Beast transformed into...
« Reply #101 on: March 13, 2012, 12:07:48 PM »
Thanks, I had the shocks already polished in that picture and had removed about half a dozen before I decided to take that picture.
That which does not kill you leaves cool scabs which turn into awesome scars.

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Offline Freaky1

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Re: The Beast transformed into...
« Reply #102 on: March 30, 2012, 05:03:04 AM »
Moving right along, it's been a pretty mild winter even by Colorado standards and seeing the few bikes out has been tough but now that it's really starting to warm up there are so many more I've got to get this done. I was able to get the oil & gas tank clear coated so those will be sanded and rubbed out possibly this weekend. I also have all my little bits polished and ready to go and I started to really get into the wiring. But bad news on the rear fender, to say I was unsuccessful is an understatement! The first bad thing was air bubbles, I knew I had to be careful but those things are a pain. Then my resin mixing job was not good, first batch set up too quick and combined with little air bubbles we were going down hill fast. Then my last batch of resin didn't get enough hardener so it never set up and the releasing wax I used didn't play nice either. My mold was junk, the plaster I used just came apart and I'll just stop there and say massive fail.



I have the wiring moving along nicely and should make some nice headway this weekend also. It is going to be tight with everything under the gas tank but it should work out.



I'm going to pick up some shorty handles for the brake and clutch because they are just too long for my setup. I made some minor changes to the headlight mount but this should also be buttoned up this weekend.

That which does not kill you leaves cool scabs which turn into awesome scars.

'77 CB750F Come on...were almost there!

Offline gnarlycharlie4u

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Re: The Beast transformed into...
« Reply #103 on: March 30, 2012, 07:48:27 AM »
Moving right along, it's been a pretty mild winter even by Colorado standards and seeing the few bikes out has been tough but now that it's really starting to warm up there are so many more I've got to get this done. I was able to get the oil & gas tank clear coated so those will be sanded and rubbed out possibly this weekend. I also have all my little bits polished and ready to go and I started to really get into the wiring. But bad news on the rear fender, to say I was unsuccessful is an understatement! The first bad thing was air bubbles, I knew I had to be careful but those things are a pain. Then my resin mixing job was not good, first batch set up too quick and combined with little air bubbles we were going down hill fast. Then my last batch of resin didn't get enough hardener so it never set up and the releasing wax I used didn't play nice either. My mold was junk, the plaster I used just came apart and I'll just stop there and say massive fail.



I have the wiring moving along nicely and should make some nice headway this weekend also. It is going to be tight with everything under the gas tank but it should work out.



I'm going to pick up some shorty handles for the brake and clutch because they are just too long for my setup. I made some minor changes to the headlight mount but this should also be buttoned up this weekend.



wax is a pain in the butt.
cover the fender in tinfoil (maybe a little elmer's glue to make it stick.)
coat the tinfoil in resin.
lay your glass.
coat the glass in resin.
lay another layer.
coat that in resin.
repeat last 2 steps as necessary.

leave it to dry and it should be good.

You might wind up with some tinfoil in your fiberglass but it's easy to sand off.

Offline Syscrush

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Re: The Beast transformed into...
« Reply #104 on: March 30, 2012, 09:38:25 AM »
You might wind up with some tinfoil in your fiberglass but it's easy to sand off.
Also, you can get teflon-coated aluminum foil.  In your grocery store beside the regular foil.
Life is precious: wear your f'n helmet!
There's nothing more expensive than a free bike...
FWIW, I'm not a shill for Race Tech - I've just got a thing for good suspension and the RTCE's are the most cost-effective mod for these old damping rod front ends.

Offline gnarlycharlie4u

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Re: The Beast transformed into...
« Reply #105 on: March 30, 2012, 10:31:03 AM »
You might wind up with some tinfoil in your fiberglass but it's easy to sand off.
Also, you can get teflon-coated aluminum foil.  In your grocery store beside the regular foil.

yeah that's what i meant, sorry. use the non stick stuff. also make sure you use the dull side facing out. glue down the shiny side.

Offline Freaky1

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Re: The Beast transformed into...
« Reply #106 on: March 30, 2012, 11:21:28 AM »
Exclent advice! Now all I have to do is make another mold, mine did not survive the first attempt. The actual fender I have is one that I cut up and glued together from Carpy and a stock plastic one, the tire side is where all the glue is. I need to make a new mold from the top side of the fender. Any advice on what to use for the mold? I have a fiberglass supply shop nearby that I was going to hit up for info but if either of you have a "backyard" solution I'm all ears.
That which does not kill you leaves cool scabs which turn into awesome scars.

'77 CB750F Come on...were almost there!

Offline Freaky1

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Re: The Beast transformed into...
« Reply #107 on: April 05, 2012, 08:31:22 PM »
Quick update as the spring heat and the sounds of motorcycles in the distance are making me very excited. I've been getting the wiring together, it has been a bit of a challenge because I don't have a headlight bucket to cram all the excess wiring into. I got the "dash" finished and everything up there in, and cleaned up the headlight mount a bit so just a bit of adjustment and it will be done.



More to come soon!!
That which does not kill you leaves cool scabs which turn into awesome scars.

'77 CB750F Come on...were almost there!

Offline Freaky1

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Re: The Beast transformed into...
« Reply #108 on: May 14, 2012, 08:43:31 PM »
So I've been doing some work, not nearly as much as I'd like but my shift at work is going to change soon and then my tie with my kids will be pretty limited for the next year so I'm trying to cram as much time in with them as I can. Plus I've really been working on the wiring and do you really want to see pictures of wires? Well now that I'm all but done with that part I'll throw one up so you all can see it.



The clutch and throttle cables will need to be shortened, but I've got other things going on and that's a minor item. As you can see I ran some wires through the frame, 8 to be specific. I tried to pick the best point, that wasn't too close to an edge or where it would get pinched by the gas tank. I ran some short pieces of shrink tubing over the runs then a larger piece over the full length of the run that goes inside the tube. I also had to redo the spark pug hangers, my original design was more in the way then I would have liked so I decided to change them. I had the battery box in but trying to fish the wires out at the end was a major pain with it in. I've test fitted the gas tank and nothing is in the way or rubs so major sigh of relief there. The tab for the Gordon kit that is near the big starter wire has been rounded off since this picture.

I put the carbs on so I could make sure the wiring didn't interfere with the throttle. I had sent the slides off to Cycle X to have them cut so they will have to come off again. Hopefully I'll have some more pics this weekend when I get the battery box and oil tank in, maybe you shouldn't hold your breath though. ;) :o ::)




That which does not kill you leaves cool scabs which turn into awesome scars.

'77 CB750F Come on...were almost there!

Offline Freaky1

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Re: The Beast transformed into...
« Reply #109 on: June 26, 2012, 11:19:56 PM »
Ok so I've been doing some more work trying to get this thing on the road. I found a fiberglass supply shop not far from my house and went in to get some professional direction. An hour later I came home with the right stuff, some great advice, along with some things to clearly avoid, I felt pretty good about this. First I had to make the mold the right way, then I was all set.



 I was pretty happy with how it turned out but maybe this winter I'll give it another go haven't decided yet. It fit nice but I did find that my original had a funny twist that because it was somewhat flexible wasn't noticeable when it was on the bike. Really though, I can't imagine anyone but me staring at it long enough to notice, secretly I'd like to be wrong about that though.





Since I got rid of the giant aluminum hangers the swing arm bolt and the foot peg bolt were way too long. I plan to have Hondaman work me up a old style swing arm set this fall and that bolt is much shorter so this is only a temp solution. I took them down to one of the best shops in the world, Black Widow Cams. This place is on the south side and Craig is great, he cut them down and turned my threads by hand on his lathe, true craftsmen are too hard to find anymore, amazing.



Due to the way I designed all of this I have found that it needs to be put together in a very specific order. I have to put the fender on first, then the oil tank, then battery box. The oil tank is ready and so is the battery box (after a few mods and a fresh coat of paint), so this weekend it all goes together. Then I can wrap up the wiring and be one giant leap closer to being on the road.


That which does not kill you leaves cool scabs which turn into awesome scars.

'77 CB750F Come on...were almost there!

maduncle

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Re: The Beast transformed into...
« Reply #110 on: June 26, 2012, 11:57:27 PM »

Wow - sweet work on that rear fender, that is going to look great.

Offline Brown Bomber

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Re: The Beast transformed into...
« Reply #111 on: June 27, 2012, 07:36:00 AM »
Look-in good! Those oil lines are sweet, who did the crimps?
Keep the Shiny side up!

1987 ZG1000 "King Crimson"
1972 CB750K2 "Stout"
1976 CB500T "Witch's Promise"
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Offline Syscrush

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Re: The Beast transformed into...
« Reply #112 on: June 28, 2012, 10:31:25 AM »
Wow. Loving that fender.
Life is precious: wear your f'n helmet!
There's nothing more expensive than a free bike...
FWIW, I'm not a shill for Race Tech - I've just got a thing for good suspension and the RTCE's are the most cost-effective mod for these old damping rod front ends.

Offline Brown Bomber

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Re: The Beast transformed into...
« Reply #113 on: June 30, 2012, 05:08:32 AM »
Ok so I've been doing some more work trying to get this thing on the road. I found a fiberglass supply shop not far from my house and went in to get some professional direction. An hour later I came home with the right stuff, some great advice, along with some things to clearly avoid, I felt pretty good about this. First I had to make the mold the right way, then I was all set.


So what was the right stuff and what kind of advise did they give you?
Keep the Shiny side up!

1987 ZG1000 "King Crimson"
1972 CB750K2 "Stout"
1976 CB500T "Witch's Promise"
1973 CL450K5 Cafe Project
I'd rather go homeless than chromeless

People get maddest when I've told the truth.

Keep your friends close, and your enemies closer.......
                                                                          Vito Corleone

Offline brandEn

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Re: The Beast transformed into...
« Reply #114 on: June 30, 2012, 01:01:24 PM »
This build is coming along nicely. Your fender looks tits!

Offline Freaky1

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Re: The Beast transformed into...
« Reply #115 on: July 07, 2012, 05:48:35 AM »
Thanks everyone, it has been a much longer road then I intended but that thing called life kept getting in the way. The hoses were done at a Parker store, it's a place that does different lines for industrial uses, air hoses, hydraulic stuff, and the like.

As for the fiberglass, the first thing on the right path was to but the border around my original mold. That kind of seemed like a no brainer after my first attempt though, even though it  didn't occur to me. I had tried a kit you can get at any auto parts store and the resin and especially the matting I used this time worked so much better. The matting was so much easier to work with which was huge. I got some good release wax, and I know there are suitable substitutes out there but this stuff just seemed to go on better and produced a much more slippery result plus I didn't need to put as much on. But the biggest difference was this little bottle of green stuff, I'll get the name later, that you can spray or brush on. It dries into this film that makes separation so much easier. It also really helped with some of the small pock marks and air bubble holes that crept up along the way. Total cost? The auto parts store kit I believe was about $20 and everything I bought from the fiberglass shop was about $50. But I picked up enough of everything this time to make my mold and the fender and I have enough left over to make another fender if I'd like. Plus the advice on mixing the resin, which the auto parts kit was a bit vague on, along with any stupid questions I came up with. If I do another one I'm going to pick up some black pigment to help with the color. It won't replace paint completely but it certainly will reduce the amount of paint and visibility of nicks, chips, and dings.     
That which does not kill you leaves cool scabs which turn into awesome scars.

'77 CB750F Come on...were almost there!

Offline caferacer750

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Re: The Beast transformed into...
« Reply #116 on: August 19, 2012, 07:40:55 AM »
Can't wait to see what it looks like all done

Offline Freaky1

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Re: The Beast transformed into...
« Reply #117 on: August 20, 2012, 09:49:06 PM »
Had some rough times lately, my new job switched my hours and killed all of my home time with my wife and kids, which meant all my bike time became wife and kids time. That was not really a bad thing unless your trying to go those last few inches of a marathon. Then about a month ago my dad, who had been sick with one thing after another for the last 5 years, found out he had very advanced leukemia and was given weeks or maybe a month to live. I've spent most of the time since then back in Omaha with my mom and dad, which cost me my job. The job thing was somewhat of a blessing but a week and a half ago my dad died and so it has been a pretty rough time lately. I really think I need to get back on the horse and get my bike done to help me out but I haven't really been able to. When I do get back into the shop I'll certainly post but I'm not sure when that will be.
That which does not kill you leaves cool scabs which turn into awesome scars.

'77 CB750F Come on...were almost there!

Offline Don R

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Re: The Beast transformed into...
« Reply #118 on: August 20, 2012, 10:10:59 PM »
Hang in there Freaky1, our thoughts are with you. Condolances on your loss, been through it myself.
No matter how many times you paint over a shadow, it's still there.
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Offline Syscrush

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Re: The Beast transformed into...
« Reply #119 on: August 21, 2012, 05:48:42 AM »
We're just a bunch of bike freaks on the web, you don't owe us any explanations.

Take whatever time you need.

Good luck to you and your family.
Life is precious: wear your f'n helmet!
There's nothing more expensive than a free bike...
FWIW, I'm not a shill for Race Tech - I've just got a thing for good suspension and the RTCE's are the most cost-effective mod for these old damping rod front ends.

Offline SF

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Re: The Beast transformed into...
« Reply #120 on: August 21, 2012, 02:00:50 PM »
sorry to hear I hope easier times comin your way.
92 wr250 sold
98 zx6r sold
04 zx10r
73 cb350 twin
75 cb550f
75 cb550f
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rgid springer bobber project

Offline Freaky1

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Re: The Beast transformed into...
« Reply #121 on: September 25, 2012, 11:46:27 PM »
Thanks, it has been a rough couple of months but things have been looking up lately. Poking along doing this little thing and that little thing and turn around the other day and I'm almost ready to fire this thing up!! I got the oil tank put in, rear fender done and in, battery box in and wrapped up the wiring.







If you can imagine, the ignition switch is mounted on the left side just to the back of the battery box, right behind where the positive terminal is on the battery. Well to make it less noticeable and give it some protection from the elements, I took one of the odd wiring boots and worked it on to the ignition switch. I think these were on my bike because they came with the farring that was on it but I could very easily be wrong.



In a attempt to prevent some chain scum flinging all over me and the bike I modified the chain guard that goes on the motor. I cut down the shifter cover so using this piece in its original configuration would have looked very odd.





Then I cut down the plug wires and hit the exhaust with some Scotchbright and mounted it up.





Before anyone asks, the line going into the top of the oil tank is the vent from the back of the motor. I assembled the tank and completely spaced putting in a bung for it. I drilled and tapped the cap and added the fitting, someday I might build a tank with it the correct way but not today. Besides I think looks pretty good and at this point I'm also in "whatever works" mode so there! :P

I did fire it up today and aside from a gas leak where the fuel line goes in between 3 and 4 all went pretty well. Oh it needs a good amount of fine tuning but at least it all sounded like everything was getting along inside the motor so I am calling it a major success at this point.

That which does not kill you leaves cool scabs which turn into awesome scars.

'77 CB750F Come on...were almost there!

maduncle

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Re: The Beast transformed into...
« Reply #122 on: September 26, 2012, 04:40:37 AM »

Love it!

The seat will make all the difference to the overall look, can't wait to see that on the bike.

That little rear fender is a winner.


Offline Freaky1

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Re: The Beast transformed into...
« Reply #123 on: September 26, 2012, 07:58:49 AM »
I've got the seat pan all done but I'm going to let professionals handle that because, like you said, it will make all the difference. I'm going to take the entire bike to a place here in town, #$%*en Stichen, and then we can design what's best for the seat & bike on site. Really the last things I have to do before it can go are fab up the shift linkage, color sand & rub out the gas tank. There are some other little things as well and those might get done before but if not it can go without them right now.
That which does not kill you leaves cool scabs which turn into awesome scars.

'77 CB750F Come on...were almost there!

Offline Freaky1

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Re: The Beast transformed into...
« Reply #124 on: February 11, 2013, 11:21:27 AM »
Ok, an update has been far too long in coming and I have actually been working on the bike. I had to do a bunch of work to my garage and finally got things organized...but maybe too much as now I have to remember what I did with some things. I have fired it up and it runs ok, it needs some tuning and that will come in time. I was just really happy that my first complete engine tear down actually went all back together, no leftover parts, started and nothing stuck or broke. The charging system works and no wires have caught fire so that's good too. I still need to get the seat done, sand the gas tank, and shoot it with one more clear coat then it gets it's first road test, now if the weather will just cooperate.
That which does not kill you leaves cool scabs which turn into awesome scars.

'77 CB750F Come on...were almost there!