Author Topic: 1972 CB500 "An Inherited Basket Case" (Read 33086 times)

fantino · « **Reply #150 on:** April 18, 2021, 01:31:04 AM »

Finished setting the megacycle cam tonight. Duration and open\close are a little different from the cam card, but the lobe centers are within 1/2 degree. I think this is close enough?

Documenting the numbers for future reference:

INTAKE EXHAUST
OPEN 23 BTC (337) 48.5 BBC (131.5)
CLOSE 52 ABC (232) 20.5 ATC (20.5)
DURATION 255 249
LOBE CENTER 104.5 ATC 104 BTC

So I can set this easier later on, gap between notch in cam and cylinder head @ TDC: .060"

Cam card for reference:

fantino · « **Reply #151 on:** April 30, 2021, 02:23:56 AM »

I'm finally nearing completion on all of the printing. I've got all the pieces mated together for the tank molds and am only missing one section of the seat mold at this point, which should be finished by the time I wake up tomorrow morning

Next step is to stiffen up the molds by glassing the backside surface, and then I'll get started with coating the mold surfaces in an epoxy fairing compound. After that it'll be a lot of sanding, polishing and waxing to get the surfaces ready to pull parts.

In other news, just more small progress on the rest of the bike. The motor is all buttoned up and now just needs a home. I've been picking up controls, switches, and other peripherals so I can get everything laid out on the frame.

I made up a preliminary planning template to work off as I start building a physical harness - I'll fill in lengths between junctions once I have more mounted up to the frame, added grounding locations, add wire colors, etc.

RAFster122s · « **Reply #152 on:** April 30, 2021, 04:03:23 AM »

Very nice. How many copies do you intend to pull from the molds?

fantino · « **Reply #153 on:** April 30, 2021, 04:23:09 AM »

Quote from: RAF122S on April 30, 2021, 04:03:23 AM

Very nice. How many copies do you intend to pull from the molds?

Ideally only two - a test part out of fiberglass and then the real deal, but that’s being a little optimistic. I suppose after that the molds will just go in storage in case I ever need to make a replacement.

SOHC4 Cafe Racer Fan · « **Reply #154 on:** April 30, 2021, 12:56:49 PM »

What price would you sell gas tanks for?

fantino · « **Reply #155 on:** April 30, 2021, 08:40:45 PM »

Quote from: SOHC4 Cafe Racer Fan on April 30, 2021, 12:56:49 PM

What price would you sell gas tanks for?

For the tank I'm building now, or a unique design? I haven't thought about it too much, I had always planned on this being a one off.

For reference - and in the interest of transparency for anyone interested in doing something like this, here's my costing spreadsheet for this project, including both seat and tank. It's definitely not a "cheap" DIY in materials or labor, and this cost breakdown doesn't factor in that I already own a large 3D printer, have access to an already well equipped shop for composites work, etc. The true materials cost is actually a bit less as I'll have some leftover fabric, epoxy and paint when I'm done, and the total labor cost is more than doubled by unattended printing time (I usually setup long prints before bed).

I think each additional set would cost another $300 in materials and 12–14 hours in labor.

By the time I'm done, I definitely could have bought a FG bodykit from Airtech or GFTP and saved a few hundred bucks at the end of the day (but that's not really the point, is it?

) On that note - I'm definitely going to buy a CR750 fairing from AirTech, because I don't have the energy or money to make a set of molds that big on my own, haha.

fantino · « **Reply #156 on:** May 16, 2021, 06:09:16 AM »

Had a pretty busy couple of weeks with work and needing to fix a few things on my daily driver, so I haven't had much time to get in the shop to work on molds, but I did get a little bit more planning work done for the harness.

This may seem like planning overkill - but I want to end up with a very clean, minimal and easy to follow harness by the time I'm done. Next step for wiring is to get the engine mounted with the frame and forks. I'll use lengths of rope taped together to figure out the section lengths for the harness, add appropriate excess and then I'll be able to fill in the cut-sheet and get started.

Sounds like my new exhaust went out for coating this week, so I expect to see some pictures of the finished product pretty soon before it ships out. Pretty excited for these.

gmoss · « **Reply #157 on:** May 16, 2021, 06:23:50 AM »

Been following what I can of your build and taking notes as to “things I might learn about eventually and come back to this thread to reread”

I’ll take the 5ohm coils and spark plug wires off of ya

don’t need the points plate though. DM incoming.

fantino · « **Reply #158 on:** May 20, 2021, 09:41:27 AM »

Enrique sent over some fit-up photos of the exhaust and so they are finally near to being completed and shipped to me. I am quite excited about this

SOHC4 Cafe Racer Fan · « **Reply #159 on:** May 20, 2021, 11:04:00 AM »

Beautiful.

fantino · « **Reply #160 on:** June 04, 2021, 02:04:05 AM »

I got a package in the mail today...

I think the cats approve. It'll be a little while before I can test fit, but I'm pretty excited to finally have my dream exhaust in hand.

In other news, making progress on the molds but I still have a lot of sanding in my future, I wouldn't expect to be pulling parts for at least a few more weeks at the current pace. I may speed up work on the tunnel section so I can pull a test part to help with wiring harness layout work.

All of my composite fabrics and resin arrived last week. I'm going to make a couple of small test swatches to make sure I'm happy with the layup schedule. I'll toss them in a bucket of gas for a few weeks after to see how they hold up.

The last of my deutsch connectors finally showed up too (so many supply shortages!), so I've got everything I need to start putting the harness together. I'll hopefully have the engine test fit into the frame next week so I can get started.

fantino · « **Reply #161 on:** June 17, 2021, 04:16:43 AM »

More harness work lately. Not the most exciting work to share, but I really do want to end up with a clean, reliable and professional looking wiring job at the end of the day.

Put the motor in frame and tossed some of the relevant parts on there and made a basic harness template out of some old cable I had laying around. This is the most assembled this bike has been in probably 30 years

This gave me a template to measure lengths off of. I did end up modifying some of the junctions from the original plan once I started laying it out on the frame. I updated my documentation for future use and also worked out the lengths for every piece of wire that needed to be cut into a nice tidy cut list.

Using the updated map and cut list, I was able to get all of my wire cut and the base harness built this evening

Everything is longer than it needs to be at this point. Next steps will be to get sleeving and heatshrink onto the base harness, then it'll be ready to mount back onto the frame for final terminations. I'll mostly be using Deutsch connectors with spade and ring terminals as appropriate.

I'm moving over the next week, so things will be a bit chaotic. I don't expect too much progress until July.

fantino · « **Reply #162 on:** July 15, 2021, 03:21:16 PM »

It's been about a month since I posted last! Between my move and a little heat wave here in the Northwest, I haven't been able to get much done. I am working on my molds when I have spare time after work, hopefully I can pull a test part or two in the next few weeks.

I also received the last electrical parts I needed for the build - a Chronoclassic tach and headlight. I actually ordered these quite awhile ago, but backorders being what they were only just received them now. I went with the sealed beam glass LED light from Revival because it's the only LED light I could find that wouldn't look super out of place on an older bike. I thought about putting an LED H4 bulb into a non-sealed assembly, but much like when folks add xenon bulbs to non-projector headlamps I presumed the light pattern would be awful, especially to oncoming traffic.

My garage is packed to the gills and a total mess until I have a chance to reorganize from the move, so in the meantime, I'm looking for some small, clean projects I can do at home while I get settled in to keep the project moving forward. Most likely that will be sheathing the harness and truing up my wheels so I can install the new BT46s.

On the plus side, the weather has been nice this last week, so I've been getting in lots of rides on my EX250

Godffery · « **Reply #163 on:** May 23, 2022, 08:59:45 AM »

Just checked out this build thread. Some Very impressive work here to say the least!

fantino · « **Reply #164 on:** May 23, 2022, 03:26:11 PM »

Quote from: Godffery on May 23, 2022, 08:59:45 AM

Just checked out this build thread. Some Very impressive work here to say the least!

Thank you kindly!

A running theme with this build is it getting shelved every other year, haha. I picked up another big house project that has been taking up all my time since last summer. I have started to pick things up with the bike again, however. I'm laid up at home with COVID right now, so I've been dressing the wiring harness to pass the time.

The molds are really close to being ready to go as well, I just need to spend a couple evenings sanding and prepping them for a test layup.

RAFster122s · « **Reply #165 on:** May 23, 2022, 05:18:29 PM »

Hope your CoVID experience is not too rough. It affects everyone a little differently. Drink plenty of water, too easy to get dehydrated when you are sick.

Looking forward to more on the build.

Gurp · « **Reply #166 on:** May 24, 2022, 07:30:21 AM »

Love the detail in planning. I wish I thought like that. I have a idea then I just do. If not I forget. Lol

rollypoli · « **Reply #167 on:** January 11, 2023, 02:26:14 AM »

Quote from: fantino on May 23, 2022, 03:26:11 PM

Quote from: Godffery on May 23, 2022, 08:59:45 AM
Just checked out this build thread. Some Very impressive work here to say the least!

Thank you kindly!

A running theme with this build is it getting shelved every other year, haha. I picked up another big house project that has been taking up all my time since last summer. I have started to pick things up with the bike again, however. I'm laid up at home with COVID right now, so I've been dressing the wiring harness to pass the time.

The molds are really close to being ready to go as well, I just need to spend a couple evenings sanding and prepping them for a test layup.

It’s been a while since we’ve heard from you. I hope you are alive and well Id love an update on this build. It’s been amazing to read through

Godffery · « **Reply #168 on:** January 12, 2023, 09:58:38 AM »

Quote from: rollypoli on January 11, 2023, 02:26:14 AM

Quote from: fantino on May 23, 2022, 03:26:11 PM
Quote from: Godffery on May 23, 2022, 08:59:45 AM
Just checked out this build thread. Some Very impressive work here to say the least!

Thank you kindly!

A running theme with this build is it getting shelved every other year, haha. I picked up another big house project that has been taking up all my time since last summer. I have started to pick things up with the bike again, however. I'm laid up at home with COVID right now, so I've been dressing the wiring harness to pass the time.

The molds are really close to being ready to go as well, I just need to spend a couple evenings sanding and prepping them for a test layup.

It’s been a while since we’ve heard from you. I hope you are alive and well Id love an update on this build. It’s been amazing to read through

I'll second that.

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Author Topic: 1972 CB500 "An Inherited Basket Case" (Read 33086 times)