Topic: New project for a first timer CB550 build - Slowly getting back to it!

[2strokeTrush]

Thanks, DCC told me they weren't LED though so i guess now i have to buy a LED relay like you did.  How does that hook up? And is that all I will need to make them work.  Im no electrician I don't want to blow something up!

So I double checked and sure enough that is a filament bulb in there. The led flasher will let you flash a led bulb directly. It wires in place of the existing flasher. If you were to run leds with the stock flasher you would need to either have a blinker that has a load resistor already or buy and install a separate inline load resistor so the LED bulb will flash correctly.

Thanks man, Glad i didn't order the relay yet!

[SOHC4 Cafe Racer Fan]

So when I got home from the business trip this week I had my new front tire and rim waiting for me! Tire is a Roadrider 100-90/18. Rim is a Sun 2.15 18".

Started lacing it up. Not the easiest thing to do in the world. Took me a few try's but after looking at an old picture I was able to get it all laced up. Next up is to true it and seal it so I can get the tire mounted.

Inner spokes on:



One side of outers added:



And all of them on hand tightened:

What Cal said.  The brushed satin finish of the Sun rims looks great.

[calj737]

I keep coming back to this thread just to admire those darn rims :-(

I'm so taken with their finish I may order a set to replace my factory BMW rims on my R90. And they're already alloy! Just love the look of your work, Bambu. My checkbook is haunted by your name...

[bambuhiphop]

I keep coming back to this thread just to admire those darn rims :-(

I'm so taken with their finish I may order a set to replace my factory BMW rims on my R90. And they're already alloy! Just love the look of your work, Bambu. My checkbook is haunted by your name...

You are very kind sir. My checkbook is haunted cause its constantly empty 

Its funny, I keep a spreadsheet to help myself navigate what parts I need to get when. It currently has 170 parts listed. To date I have purchased 71% of those parts but only spent 44% of the projected budget 

[bambuhiphop]

Playing with some Rearset bracket ideas



Opinions and thoughts more than welcome. Not sure I'm totally sold on what I have so far.

[calj737]

Layout looks good. As long as you construct the mounting bracket of thick enough metal, you should be good.

[bambuhiphop]

The reason I started playing with rearset bracket ideas is that I picked up a set from CognitoMoto. The quality is great. They do however require some cutting of the frame. Not really a big deal unless you have an already powder coated frame, say like me 

So after a few days of research and soul searching I decided to cut! So nerve racking



I didn't fully remove the stock rear brake setup. My plan is to reuse it as a mount point for an exhaust hanger.

I masked up everything up and painted with a ceramic that matches almost perfectly.







Now, I could have trimmed more done and smoothed out bu the brackets as is really cover 95% of the cuts. If I design my own then they will be 100% covered. I also really did not want to have the frame redone.

Bracket on the left side. Haven't decided on color yet. Think I am going to wait until the engine is in.



Also got some other parts in.

Caliper pipe from Slingshot.


Spring for the side stand. Not installed yet because man, is that thing a bear! Think I need to get the wheels on the bike so I can apply more force before it is on.


A slew of headlight parts


Couldn't resist trying the trim on the bike. It is a little too shinny so it will be going off to the chrome shop to have a new brushed finish applied.


And finally go more of the front wheel together.

[RobbyD]

Those wheels look amazing!  Can't wait to see some tires mounted on them to get the full affect

[bambuhiphop]

Those wheels look amazing!  Can't wait to see some tires mounted on them to get the full affect

Thanks Man, Front wheel should be done real soon. Just need to pick up the seal kit for the tubeless tire. I need to send my rear hub and spoke kit down to Buchanan's to make sure it fits the new rim. I am going with a wider rim than originally planned which requires a different spoke kit than what I have so having them get it to a loose lace. Fingers crossed I should be sending all that down to them by the end of April. So by the end of May I should have a complete roller.

[bambuhiphop]

Jumping around a little but started to get into the wiring harness.

All the tape and terminals on the harness were not in good shape. Wires themselves look good.  Coupled with the fact that most of the electrical on this bike is new and not stock I am kind of starting anew. I had done some work on making a wring diagram a little while back. Still working on that but it has helped thus far.

Started by pulling everything apart and getting laid out:








These just feel right off. Putting aside for the time being:


Went through everything that runs up to the headlight, compared to the stock diagram and marked them all.


Then started getting everything recovered. Using Flexo PET, shrink tubing, and electrical tape. Not running everything in one loom though. Stuff is decent to work with. Would cut better with a hot knife but since the ends are being covered with the shrink wrap its all good. The stuff is resistant to most chemicals and UV so electrics should be well protected.





Got most everything that wires into the headlight bucket done. Need to source some new connectors and wire in the new stuff that will be installed back by the electrical panel. But a good start for today and I am liking how it is turning out so far.

[bambuhiphop]

Diagram isn't done just yet. Still some unknowns on it but thought I would share.

[bambuhiphop]

Quick Update, Got a few minutes out in the garage last night. Got new wires cut, stripped, terminals on, shrink tubed, and wrapped for the coils.

[Gman]

Bhop,
Love the tubing - super clean, classy look.  I'm enjoying watching the progress.

Cheers,
G

[jdtim]

aaaaand, subscribed.

Love this build thread and watching it progress over time. Everything looks great so far. Loving the colors too; I'm not a huge fan of "glossy" finishes either.

Where did you get that Flexo PET tubing? That's such a great idea to keep all the wires together.

Looking forward to more updates!

Cheers,
-tim

[bambuhiphop]

Gman and jdtim. Thanks for the kind words. Progress is going slowly at the moment but it is going forward non the less.

Flexo PET came from Wirecare

http://www.wirecare.com/braided-sleeving.asp

[Quietsrfer13]

I just found your thread yesterday while I was slow at work. I am addicted to it. I will be saving the thread for ideas to use on my bike next winter when I get around to doing a full tear-down. You're doing great with this thing.

[bambuhiphop]

Not to much to update on. Been busy with work and the family. In a holding pattern right now waiting for some parts also.

Did get out into the garage while the kiddo was sleeping and got this stubborn tappet removed. Took quite a bit of doing. Just happy to have it removed!

[SOHC4 Cafe Racer Fan]

That took some persuasion.

[bambuhiphop]

That took some persuasion.

Just a bit... And by a bit I mean a ton. Worked on it on and off for a few months when I had time.

-- Mini Update --

Just about everything on the left side of this bike has been a pita to take apart. I think that side was exposed to the elements more during the bikes time relaxing in a field. I rearranged my garage a bit and can actually get to my vice.

The oil pump had a stuck cap, two seized screws, and the oil pressure switch wasn't going anywhere. Got it into the vice and with a breaker bar, a pair of pliers, and an impact screw driver go everything apart. Looks pretty good inside. Some new seals and a general cleanup and I should be good to go.

[bambuhiphop]

Rear tire came in the mail last night.

Just a quick snapshot of it mocked up

[minimo]

Nice visualization, b! Coming along nicely.

[SOHC4 Cafe Racer Fan]

Ok, got some parts in last night and was able to get some work done.

New forks finally came in. They are a little longer than the stock ones but no biggie. They sure are pretty though


After that went right into the fork rebuild. Following the directions from RaceTech I drilled out the holes in the dampener rod to 5/16 and added 4 more. This is needed to "disable" the rods as the emulator will be handling this job from now on. After I drilled them out I went through the new holes with a grinding wheel and lightly smoothed everything out. Also removed the roll pin. I got that out with a circular grinding wheel and my dremel.

Here is a comparison of one I worked on and one I hadn't


Close up


Here is the roll-pin removed


Stack order of the emulator, adapter, dampener rod, and spring


Built it dry last night as I still need to figure out the correct spacer for the springs but they are looking good.


Here they are mounted on the bike


Close up of the new nut


Didn't like the headlight brackets I got so those will be going back and new ones will be ordered. Also started fitting the new bars. My bar clamps haven't made their way to me yet so I just used the stock dummy lights for the time being. Just test fitting everything. Going to drill out the bars so I can run the wires inside.

Can you tell me what the stock length is for the 550 tubes?  I'm shopping for replacements.

[bambuhiphop]

Sure, I will measure them when I get home tonight. Still have them in a bin.

[SOHC4 Cafe Racer Fan]

Sure, I will measure them when I get home tonight. Still have them in a bin.

That would be great.  THANKS!

[Gman]

Bambu -
You need a tappet cover for the one you destroyed?  Can't be bothered to reread the whole thread to see if you have a solution, but it just dawned on me that I have some in the garage...  They're rough cosmetically, but if you are planning on powdercoating or whatever, I could float you one at no cost.

Cheers,
G