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Author Topic: P38 Racer- 1974 CB550  (Read 29831 times)

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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #75 on: September 25, 2012, 08:28:05 AM »


Front brake setup. Caliper is a dual piston 36mm unit from a BMW bike. The brake disc is a Brembo race unit. This took some math to get everything to fit.
I was going to use the stock brake, so I built the triple clamps to stock width. I then decided to go with another system and had no room. I didn't want to make another set of clamps, so I made it fit.
This pic is just of the mockup, and I know I am missing some fasteners!

I also machined the caliper body for some cosmetic tweaks, mainly to get rid of the "ATE" logo on the body. I also made my own stainless pistons with a differential length. The outboard piston is longer than the inboard.
« Last Edit: September 25, 2012, 08:36:23 AM by Hannibal Smith »
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #76 on: September 25, 2012, 08:32:35 AM »


California blue plate bike! Registered every year since '74. The DMV asked if I wanted a new white plate, and I said "No way!"- I machined a clamp for the shock body and made a plate holder. I also have my little plate light for legality.
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #77 on: September 25, 2012, 08:45:20 AM »


CR carbs baby. I pity the guy that orders these carbs and think they will bolt right up to a CB550. You have to machine the spigots and modify the cable pulley. It barely fits!
When I test fired the bike, the throttle response was shockingly fast with the CR's. You just blip the throttle and it responds just as fast as you rotate the grip.

Never mind the wiring job- it's just temporary to check the system!
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Offline LesterPiglet

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Re: P38 Racer- 1974 CB550
« Reply #78 on: September 25, 2012, 08:47:57 AM »
Beautiful work. I wish I had those alloy rims.
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #79 on: September 25, 2012, 09:09:52 AM »


The gauge holder in the mill- You bolt a plate down, then machine the perimeter away-oldest trick in the book. I used a polished aluminum sheet.
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Offline SF

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Re: P38 Racer- 1974 CB550
« Reply #80 on: September 25, 2012, 11:11:07 AM »
nice work good to see ya still in the build.
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Offline Opposedsix

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Re: P38 Racer- 1974 CB550
« Reply #81 on: September 25, 2012, 11:26:25 AM »
Really outstanding workmanship, a pleasure to follow. I am sure you could easily sell members starter block off plugs in aluminum and rearsets...with orders to keep you busy until Christmas/New Years.

Cheers
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Faster, faster, until the thrill of speed overcomes the fear of death.

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1976 CB550 Project

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1986 VF1000R (2)
1987 Hurricane 1000F

Offline Tex

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Re: P38 Racer- 1974 CB550
« Reply #82 on: September 25, 2012, 11:46:42 AM »
This build is amazing ;D
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #83 on: September 26, 2012, 07:25:49 AM »


Just about ready for final assembly! Have to make a battery box and run all the wires, then put on the tank and seat.
She runs super strong. It's loud, but not obnoxious, and has a great sound.

I was going to run a gel battery, but I couldn't get it to fit and still look good. I changed the plan and got an Anti-Gravity battery that can be stashed under my CR style tail section.

I will take a bunch of pics before I button it up. I made a piggyback mount for my coils and reg/rect and it is stashed under the tank.

I used the stock front fender bracket. I chopped off the old fender, then powdercoated the bracket. The new aluminum fender is installed with low profile aluminum rivets, they basically just vanish.
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Offline brandEn

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Re: P38 Racer- 1974 CB550
« Reply #84 on: September 26, 2012, 07:57:07 PM »
This build is coming along nicely! What ignition are you using?
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Offline Opposedsix

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Re: P38 Racer- 1974 CB550
« Reply #85 on: September 27, 2012, 06:42:54 AM »
Can I ask what the total length measurement is on your front fender.  I like the balance/size you went with...

Thanks, great build.
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Faster, faster, until the thrill of speed overcomes the fear of death.

- Hunter S. Thompson

1976 CB550 Project

Gone but not forgotten:
1986 VF1000R (2)
1987 Hurricane 1000F

Offline FunJimmy

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Re: P38 Racer- 1974 CB550
« Reply #86 on: September 27, 2012, 07:11:26 AM »
Quote from: Opposedsix on September 27, 2012, 06:42:54 AM
Can I ask what the total length measurement is on your front fender.  I like the balance/size you went with...

Thanks, great build.

Where did you find the aluminum fender?
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Offline Bluegreen

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Re: P38 Racer- 1974 CB550
« Reply #87 on: September 27, 2012, 05:49:57 PM »
Quote from: FunJimmy on September 27, 2012, 07:11:26 AM
Quote from: Opposedsix on September 27, 2012, 06:42:54 AM
Can I ask what the total length measurement is on your front fender.  I like the balance/size you went with...

Thanks, great build.

Where did you find the aluminum fender?

Hannibal doesn't find fenders, he makes them, with his beard.
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #88 on: September 27, 2012, 08:11:00 PM »
Quote from: Opposedsix on September 27, 2012, 06:42:54 AM
Can I ask what the total length measurement is on your front fender.  I like the balance/size you went with...

Thanks, great build.

17" flat distance, I prefer odd numbers whenever possible. The fender is mounted in the center, with equal lengths front/rear.
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #89 on: September 27, 2012, 08:17:33 PM »
Quote from: FunJimmy on September 27, 2012, 07:11:26 AM
Quote from: Opposedsix on September 27, 2012, 06:42:54 AM
Can I ask what the total length measurement is on your front fender.  I like the balance/size you went with...

Thanks, great build.

Where did you find the aluminum fender?

I got it from Roccity (?) years ago, and trimmed/shaped to get the nose at the same angle relative to the front axle as the 2 front frame tubes. I wanted the length to follow the same lines as the frame so it wouldn't compete with the cool wheel ( I love the shouldered aluminum rims!).
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #90 on: September 27, 2012, 08:29:33 PM »
Quote from: brandEn on September 26, 2012, 07:57:07 PM
This build is coming along nicely! What ignition are you using?

Dyna S- When I first fired the bike, I just slapped the Dyna on, no timing light, nothing. It fired on the 3rd kick and ran perfect. Long story short, My buddy disconnected the battery (sitting on the ground) and arc'ed the positive and cooked something in the unit. Sent it to Dyna, admitted my mistake, and they are fixing it right now.
I then grabbed my old points assy. and slapped it on, and it fired again perfectly. I know, I know...............................But I still want to run the Dyna S once it gets back. It got messed on my account, so I am not going to write off the Dyna S yet.
The electronic ignition is just so much more elegant IMO.
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #91 on: September 28, 2012, 07:57:28 AM »






More front end stuff shots. Yes, I made everything. Clip-ons are 3 deg. drop, feels great with my stretched out tank. I usually make clip-ons at 7-10 deg. but this bike worked better with shallow bars.
All front end stuff is adjustable with one size wrench.
Head light ears use hidden fasteners and I made non-marring friction discs for the bucket.

Once again, never mind the wiring, just a test setup!

You will notice that not everything was polished, I bead blasted the ears and clipons to even things out. Too much polished stuff detracts frm the race look IMO, so I mixed it up to highlight the triple clamps.
« Last Edit: September 28, 2012, 08:00:48 AM by Hannibal Smith »
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Offline knowsnothing

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Re: P38 Racer- 1974 CB550
« Reply #92 on: September 28, 2012, 08:12:25 AM »
Simply awesome.....I wish i could make cool #$%* like that  :'(
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Offline Mugen_Stumpo

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Re: P38 Racer- 1974 CB550
« Reply #93 on: September 28, 2012, 08:18:40 AM »
just WOW!

what clutch control are you using?
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Offline brandEn

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Re: P38 Racer- 1974 CB550
« Reply #94 on: September 28, 2012, 08:22:31 AM »
Dude, make me some 37mm fork ears! Nobody makes them and yours are sweet!!!!!
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #95 on: September 28, 2012, 08:24:25 AM »
Quote from: Mugen_Stumpo on September 28, 2012, 08:18:40 AM
just WOW!

what clutch control are you using?

I got a matching set from new Triumph, so it is a Nissin setup. I machined off some stuff to clean the perch up.
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Offline srbakker

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Re: P38 Racer- 1974 CB550
« Reply #96 on: September 28, 2012, 08:30:58 AM »
This is so far and away my favorite ongoing build right now.  The quality of your work is spectacular - keep it up!  BOTM nominations to follow.  ;D
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #97 on: September 28, 2012, 10:04:59 AM »

Head light ears in the making.

Clip-ons in the making.

This is the rear drum vent from the backside, I machined a little pocket for the sceen. I cut the vents from the inside out.
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #98 on: September 28, 2012, 10:21:16 AM »


Older picture of the final buttoning up. I shot the Eastwood ceramic paint on the cases. Couldn't get the hardener (catalyst) in California, so I had to shoot the cases in another state........ ;)
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Offline Hannibal Smith

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Re: P38 Racer- 1974 CB550
« Reply #99 on: September 28, 2012, 10:41:30 AM »


Reg/Rec and coil piggyback setup. It's hidden and just fits! Never mind the wires, dry build.



Plate holder clamp system.



Old California blue plate! For you non Californians, the blue plate was 70's- our new plates are white. I didn't restore the plate, I love the patina. I machined the holder from a 3/16" plate.
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