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Author Topic: 76 CB550 Cafe build  (Read 85947 times)

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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #175 on: October 27, 2017, 12:55:52 PM »
Had an epiphany over lunch.  What is the slickest water-soluble thing you can think of?  Put KY on the tire bead that wasn't sealing, same hit of air at 70 psi and it popped right into place :)
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Offline calj737

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Re: 76 CB550 Cafe build
« Reply #176 on: October 27, 2017, 01:04:52 PM »
Glad you found an automotive use for it  ;D
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline RAFster122s

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Re: 76 CB550 Cafe build
« Reply #177 on: October 28, 2017, 02:31:59 AM »
Girlfriend or wife may not believe any explanation you might give as to why you have KY Jelly in your toolbox/tool. Thanks            David
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Offline SOHC4 Cafe Racer Fan

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Re: 76 CB550 Cafe build
« Reply #178 on: October 28, 2017, 03:37:25 PM »
Lots of reasons to have it in your tool box, I suppose if you're into that.
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1975 CB550K1 "Blue" Stockish Restomod (http://forums.sohc4.net/index.php?topic=135005.0)
1975 CB550F1 frame/CB650 engine hybrid "The Hot Mess" (http://forums.sohc4.net/index.php/topic,150220.0.html)
2008 Triumph Thruxton (http://forums.sohc4.net/index.php/topic,190956.0.html)
2014 MV Agusta Brutale Dragster 800
2015 Yamaha FZ-09 (http://forums.sohc4.net/index.php/topic,186861.0.html)

"There are some things nobody needs in this world, and a bright-red, hunch-back, warp-speed 900cc cafe racer is one of them — but I want one anyway, and on some days I actually believe I need one.... Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba." Hunter S. Thompson, Song of the Sausage Creature, Cycle World, March 1995.  (http://www.latexnet.org/~csmith/sausage.html and https://magazine.cycleworld.com/article/1995/3/1/song-of-the-sausage-creature)

Sold/Emeritus
1973 CB750K2 "Bionic Mongrel" (http://forums.sohc4.net/index.php?topic=132734.0) - Sold
1977 CB750K7 "Nine Lives" Restomod (http://forums.sohc4.net/index.php?topic=50490.0) - Sold
2005 RVT1000RR RC51-SP2 "El Diablo" - Sold
2016+ Triumph Thruxton 1200 R (http://forums.sohc4.net/index.php/topic,170198.0.html) - Sold

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #179 on: October 29, 2017, 02:41:56 PM »
You guys are all hilarious.  The KY was not in the toolbox (at least not the toolbox in the garage).

Mocking stuff up and simultaneously getting the welder ready for the rear hoop and cleaning up the tank.



Once the hoop is on I'm going to start serious work on getting the tail done.  It will be a standard cafe tail, flat seat section that kicks up in the back.  Will be black leather along the sides and the top surface will be black alcantara with a red diamond stitch.  The color we've settled on is from a Jeep...



Have to mock up a headlight and see what size I want to go with.  Definitely doing an LED headlight.
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #180 on: November 06, 2017, 06:34:07 AM »
I have the tank down to bare metal, ready to start dent repair.  Any hints on removing the cap and locking hardware? 
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Offline calj737

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Re: 76 CB550 Cafe build
« Reply #181 on: November 06, 2017, 06:42:20 AM »
There’s a small guide pin that needs to be driven out at the hinge. Go easy, and drive it from the correct side.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #182 on: November 06, 2017, 06:44:20 AM »
Thank you.

What you describe is on the cap side.  What about the latch side?  There is a small philips head screw, but that just turns.  On the far side is a little 'door' that is held in place with a pin - does that just get ground off to expose something behind the door?
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #183 on: November 06, 2017, 06:46:47 AM »
Nevermind Cal, just found a pic of a new assembly.  That little pin holding the door on looks like the tip of a screw that goes through the whole assembly.  I just I need to keep turning that screw :)
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Offline calj737

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Re: 76 CB550 Cafe build
« Reply #184 on: November 06, 2017, 07:16:32 AM »
By the way, it’s a JIS screw, not a Phillips.
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'74 550 Build http://forums.sohc4.net/index.php?topic=126401.0
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #185 on: November 06, 2017, 08:09:27 AM »
The whole assembly is rusted to hell and going to get binned.  In a few minutes it will be a drill bit screw if it doesn't come out :)
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Offline calj737

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Re: 76 CB550 Cafe build
« Reply #186 on: November 06, 2017, 08:41:55 AM »
Don’t get carried away and ream the screw hole in an effort to remove the screw. Then you’ll be sorry...
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'74 550 Build http://forums.sohc4.net/index.php?topic=126401.0
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #187 on: November 07, 2017, 06:53:02 AM »
Success



Hardware off and I removed what look to be the world's worst application of tank cream.
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Offline calj737

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Re: 76 CB550 Cafe build
« Reply #188 on: November 07, 2017, 07:04:52 AM »
Looks more like cement than tank liner?  :o
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #189 on: November 07, 2017, 07:15:16 AM »
It was a grey epoxy with a nice layer of rust on the top surface.

I'm guessing I should cream the interior before working on the exterior?  Preferred cream?
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Offline SOHC4 Cafe Racer Fan

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Re: 76 CB550 Cafe build
« Reply #190 on: November 07, 2017, 11:28:45 AM »
I would de-rust the tank, and then apply Caswell epoxy. 
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1975 CB550K1 "Blue" Stockish Restomod (http://forums.sohc4.net/index.php?topic=135005.0)
1975 CB550F1 frame/CB650 engine hybrid "The Hot Mess" (http://forums.sohc4.net/index.php/topic,150220.0.html)
2008 Triumph Thruxton (http://forums.sohc4.net/index.php/topic,190956.0.html)
2014 MV Agusta Brutale Dragster 800
2015 Yamaha FZ-09 (http://forums.sohc4.net/index.php/topic,186861.0.html)

"There are some things nobody needs in this world, and a bright-red, hunch-back, warp-speed 900cc cafe racer is one of them — but I want one anyway, and on some days I actually believe I need one.... Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba." Hunter S. Thompson, Song of the Sausage Creature, Cycle World, March 1995.  (http://www.latexnet.org/~csmith/sausage.html and https://magazine.cycleworld.com/article/1995/3/1/song-of-the-sausage-creature)

Sold/Emeritus
1973 CB750K2 "Bionic Mongrel" (http://forums.sohc4.net/index.php?topic=132734.0) - Sold
1977 CB750K7 "Nine Lives" Restomod (http://forums.sohc4.net/index.php?topic=50490.0) - Sold
2005 RVT1000RR RC51-SP2 "El Diablo" - Sold
2016+ Triumph Thruxton 1200 R (http://forums.sohc4.net/index.php/topic,170198.0.html) - Sold

Offline calj737

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Re: 76 CB550 Cafe build
« Reply #191 on: November 07, 2017, 11:53:10 AM »
How would an epoxy layer have rust form on top of it? Rust is oxidation of steel. Epoxy has nosteel in it.  ???

If you do line the tank, I’m a big fan of Caswell also.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #192 on: November 07, 2017, 11:59:03 AM »
Someone tried to epoxy the tank, did a poor job of it and it dried in a big chunk in the bottom.  In the years since that was done (bike was last registered in 1986) there is more surface rust in the tank and it coated the epoxy.  The rust color will come off the epoxy chunks if I wipe it.

How does one remove the rust from inside?  Metal rescue?
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Offline SOHC4 Cafe Racer Fan

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Re: 76 CB550 Cafe build
« Reply #193 on: November 07, 2017, 12:00:25 PM »
Quote from: tshrey on November 07, 2017, 11:59:03 AM
Someone tried to epoxy the tank, did a poor job of it and it dried in a big chunk in the bottom.  In the years since that was done (bike was last registered in 1986) there is more surface rust in the tank and it coated the epoxy.  The rust color will come off the epoxy chunks if I wipe it.

How does one remove the rust from inside?  Metal rescue?

Depends on the level of rust. EvapoRust and Metal Rescue if the rust is not too extensive.
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1975 CB550K1 "Blue" Stockish Restomod (http://forums.sohc4.net/index.php?topic=135005.0)
1975 CB550F1 frame/CB650 engine hybrid "The Hot Mess" (http://forums.sohc4.net/index.php/topic,150220.0.html)
2008 Triumph Thruxton (http://forums.sohc4.net/index.php/topic,190956.0.html)
2014 MV Agusta Brutale Dragster 800
2015 Yamaha FZ-09 (http://forums.sohc4.net/index.php/topic,186861.0.html)

"There are some things nobody needs in this world, and a bright-red, hunch-back, warp-speed 900cc cafe racer is one of them — but I want one anyway, and on some days I actually believe I need one.... Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba." Hunter S. Thompson, Song of the Sausage Creature, Cycle World, March 1995.  (http://www.latexnet.org/~csmith/sausage.html and https://magazine.cycleworld.com/article/1995/3/1/song-of-the-sausage-creature)

Sold/Emeritus
1973 CB750K2 "Bionic Mongrel" (http://forums.sohc4.net/index.php?topic=132734.0) - Sold
1977 CB750K7 "Nine Lives" Restomod (http://forums.sohc4.net/index.php?topic=50490.0) - Sold
2005 RVT1000RR RC51-SP2 "El Diablo" - Sold
2016+ Triumph Thruxton 1200 R (http://forums.sohc4.net/index.php/topic,170198.0.html) - Sold

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #194 on: February 19, 2018, 09:34:32 AM »
I just got a warning when I started this post that nothing new has been added in 90 days.  Ugh.

Got the tank all sealed, used the Dragon Blood red Caswell.  Coated the bottom of the tank (exterior) with rust converter and then primed it with 2 part epoxy primer.  Did all the body work on the top as well (several small dings and depressions) and primed that.  Left side where the emblem sat for some reason didn't come out as well as I thought, I could still see a slight depression in the badge area so I've been skim coating it and getting ready for another coat of primer.

Finally got a rear hoop; ordered the pre-formed one from Cognito.  It was 1/4" too wide for my frame so I clamped it and welded it to the frame rails, then had to go to the back and cut out about 3/8" from the center and weld that to keep it from being too bulbous.



Started with the foam yesterday to form a rear section.  Spent a lot of time on this - whenever I see a cafe that I don't like it almost always involves the proportions of the tail compared to the tank.  Pretty happy with what I've ended up with and I just finished the second layer of fiberglass.  Also realized that I should have brazed in a think piece of steel to cover the opening on the back of the tank before I epoxied it.  I figured doing it now would be a bad idea so I'm adding a lip on the front of the seat that will be color matched to the tank; I don't really like the look of the seat itself being flared up to cover this opening.

Before anyone asks, that is in fact a piece of wood :).  I was struggling with what to do for a seat pan when I came across this piece of scrap that might be the lightest piece of wood I've ever picked up.  Figured why not, it was easy to sculpt the bottom to sit nice and low on the frame rails.  My plan for a seat is to get a big piece of 3/8" thick hpde cutting board, heat it to bend the kick-up section and let my upholstery guy put foam on that and wrap the whole thing in leather and alcantara with a nice burgundy diamond stitch.




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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #195 on: February 22, 2018, 09:23:20 AM »
Pulled out the foam and tape, now working to make everything thicker so that I can sand down to make it smooth.


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Offline Marissa

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Re: 76 CB550 Cafe build
« Reply #196 on: February 26, 2018, 01:01:49 PM »
Subscribed!

Good stuff here.
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1984 Nissan 300zx - sold
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1972 Honda CB500 - infinite work in progress

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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #197 on: March 02, 2018, 11:48:28 AM »
Moving forward with adapting a CBR600rr alternator to this bike.  Because...

vs


3 pounds in rotational weight, yes please. Not to mention the increased output and reliability.  Since CR26 carbs are over a grand I might convert to EFI with a microsquirt.  At least that way I can tune the bike in a way I understand - you guys and your needle jets and float height, way too complicated.

I took as good of measurements as I could (getting measurements on a taper is not easy) and I'm drawing the adapter up in autoCAD to 3d print it at work.  If everything seats correctly I will turn the adapter on my lathe, if not I'll make adjustments and 3d print ad infinitum until it is right.  Once I get the right measurements I'll leave it here for others to use.

One thought I had - why are all these things taper interference fits?  Seems unnecessarily complicated machining for the manufacturers.  Why can't I turn the ID of the CB600rr rotor to have no taper and cut a keyway in it?  That would make turning the adapter easier.
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Offline SOHC4 Cafe Racer Fan

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Re: 76 CB550 Cafe build
« Reply #198 on: March 02, 2018, 03:59:41 PM »
Quote from: tshrey on March 02, 2018, 11:48:28 AM
Moving forward with adapting a CBR600rr alternator to this bike.  Because...

vs


3 pounds in rotational weight, yes please. Not to mention the increased output and reliability.  Since CR26 carbs are over a grand I might convert to EFI with a microsquirt.  At least that way I can tune the bike in a way I understand - you guys and your needle jets and float height, way too complicated.

I took as good of measurements as I could (getting measurements on a taper is not easy) and I'm drawing the adapter up in autoCAD to 3d print it at work.  If everything seats correctly I will turn the adapter on my lathe, if not I'll make adjustments and 3d print ad infinitum until it is right.  Once I get the right measurements I'll leave it here for others to use.

One thought I had - why are all these things taper interference fits?  Seems unnecessarily complicated machining for the manufacturers.  Why can't I turn the ID of the CB600rr rotor to have no taper and cut a keyway in it?  That would make turning the adapter easier.

Let us know if you get this upgrade sorted.  A bunch of us were hoping/waiting for Anders to develop a 32 amp upgrade for CB550 bikes but then he went silent.  If you get it working, I am sure there are others interested (including ME).
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1975 CB550K1 "Blue" Stockish Restomod (http://forums.sohc4.net/index.php?topic=135005.0)
1975 CB550F1 frame/CB650 engine hybrid "The Hot Mess" (http://forums.sohc4.net/index.php/topic,150220.0.html)
2008 Triumph Thruxton (http://forums.sohc4.net/index.php/topic,190956.0.html)
2014 MV Agusta Brutale Dragster 800
2015 Yamaha FZ-09 (http://forums.sohc4.net/index.php/topic,186861.0.html)

"There are some things nobody needs in this world, and a bright-red, hunch-back, warp-speed 900cc cafe racer is one of them — but I want one anyway, and on some days I actually believe I need one.... Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba." Hunter S. Thompson, Song of the Sausage Creature, Cycle World, March 1995.  (http://www.latexnet.org/~csmith/sausage.html and https://magazine.cycleworld.com/article/1995/3/1/song-of-the-sausage-creature)

Sold/Emeritus
1973 CB750K2 "Bionic Mongrel" (http://forums.sohc4.net/index.php?topic=132734.0) - Sold
1977 CB750K7 "Nine Lives" Restomod (http://forums.sohc4.net/index.php?topic=50490.0) - Sold
2005 RVT1000RR RC51-SP2 "El Diablo" - Sold
2016+ Triumph Thruxton 1200 R (http://forums.sohc4.net/index.php/topic,170198.0.html) - Sold

Offline bambuhiphop

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Re: 76 CB550 Cafe build
« Reply #199 on: March 02, 2018, 05:17:46 PM »
Quote from: SOHC4 Cafe Racer Fan on March 02, 2018, 03:59:41 PM
Let us know if you get this upgrade sorted.  A bunch of us were hoping/waiting for Anders to develop a 32 amp upgrade for CB550 bikes but then he went silent.  If you get it working, I am sure there are others interested (including ME).

Ditto
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75' CB550K -- Still in pieces but it rolls again!!!!
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