Topic: Project Elizabeth: The Tale of a CB 500/550

[rachet]

I've wrestled (with jimmy ) about posting my project for some time now.  Going over the Project Shop, there are plenty of "projects" that are in "Limbo" that may never escape and I really don't want this to be one of them.  However, it's fun to get feed back, support, criticism, free beers, and pointers from all you fine respectable "biker" types. 

For starters, Project Elizabeth started as a 300 dollar cb500 non-runner that I found tucked away in a barn.  I never planned on doing anything with it in all honesty, it was just an added bonus to the 400 dollar cb750 non-runner from the same barn.  After months of forum crawling, and reading up on all the cool 500/550 bikes it started to become clear this little lady had potential!  What sealed the deal really was Paulages post http://forums.sohc4.net/index.php?topic=40414.0 and a recently acquired cb650 motor.

My current Time line is to have a runner by the end of summer with a standard cb550 motor, and by next summer, have it completed with the Hybrid Motor using the 550 trans, 650 jugs/head, and as big of pistons as I can possibly Stuff into them!  (at least 836 pistons).

Enough Boring reading, Bring on the PICS! 



Here she is the day I got her.



Here Is the mock up with the Phat rear tire, modified seat pan, and a straight Bar for "steering".


I modified the seat pan with an old gas tank and then laid up a fiber glass "insert" that I'll put foam and leather on.  The reason for this is I want to Powder coat the Gas tank, seat cowl, and frame all the same color.  The actual FG seat will be black.





You can see in the picture how the Frame comes out straight, but the seat angles up.  This has been a point of contention for me because it doesn't "flow".  What should I do?  What do you guys think is a good idea? 




Doesn't matter, I broke out the sawzall and hacked it down!    




I have some clean up to do and will re-install the support brace.  This is "my bike" and I plan on making it very specific to me.  It will really be a single seat, but in the unlikely event I have to give some poor HD owner a ride, I want to make sure that back half will hold up their Fat bum!   

Some fun facts and tid-bits of info...

The white gas tank is from a 750.
I have a 5-1/2 inch Headlight for her.
She will get clip-ons (most likely homemade).
Dual-Disks up front are in the works.
the Rear tire is from the Same 750.
The Front Tire is not.
I have a 550 "parts bike", Hence, the title "The Tale of a CB 500/550".
I cut most of the brackets off... then had to weld the seat brackets back on...
My cats name is Nail.
I will relocate the electrics so as to hide them... Not sure what to do with the battery as of yet.
To lower her stance, 11 inch shocks are in order.
I would like to update the steering with a bearing kit.
She will start with a cheap-O 4 into 1 exhaust.  I have one floating around, and/or I might try building one.  I've always wanted to.
the 5-1/2 inch Headlight is from the same 750.
at some point I really want to pick up the 4 into 4 exhaust from Benji that run about 1200 bucks...
Rear sets are on the agenda.

A Rear Disk break would be sweet, Just need to figure out how swap out the Drum for disk after I steal PJ's Rear Disk setup from his spare bike.

Don't tell him I'm going to steal his rear disk setup, he thinks I'm going to "pay" for it. 

And that brings us all up to date.  This is a weekend/evening project, after work and family needs are met.  I have my 750f for riding while I build this baby, and once she's done we'll see what happens to the 750.

Thanks for reading/posting!

Rachet-

[papp101]

Love it man, nice work on the seat.. . i'm working through fiberglassing my seat pan as well - how many layers did you use to make your seat pan? Fiber mat glass or fiber cloth?

Thanks! Keep up the progress!

[Hush]

500 base with 650 cylinders and oversized pistons, sounds like a plan Ratchet, nice that you have a camera too...keep it handy.

[KB02]

As for the 4 into 1 exhaust, it loks like it came with a Kerker. Did it?

[rachet]

Papp, because I have a metal base there is only about 4 layers.  I started with a layer of Felt, then some FG Cloth.  From My experience, FG Mat is Great if you have a lot of bends, or areas you want to fill.  Cloth is a lot easier to cut and just lay down over whatever you are FG'ng.  There are a few extra layers in the areas over the Seat Cowl and Gas tank.  I have actually made up about 4 "seats" and this is the first one (and only one) that I'm actually going to use.  The others were great practice, but were solid FB.  Last time I checked, you can't really Powder Coat FB with out special Powder.

Thanks Hush!  I expect you to baby sit me as I do this build since your "Copper" bike turned out amazing!  The camera is actually my wife's new birthday present/toy.  I get in the heat of the moment and forget to click, but I'll do my best.

KB, I have no idea!  It has the shape and look of a Kerker, but no branding that I can see.  I can snap a few more pics of the exhaust if you would like.  It's pretty crunched on the bottom of the collector.

Thanks guys!

Rach-

[BlindJoe]

What's your plan for finishing off the rear of the frame?

[rachet]

What's your plan for finishing off the rear of the frame?

If you look on the inside of the frame, where the metal is stamped, it has a nice round look that I will follow with a grinder and then weld up.  Nothing to fancy, just clean and simple.

[FunJimmy]

Rachet

Great start to your cafe build. That looks like a real good find for $300 too.

Looking at the profile where you cut the frame off, you could also fab up a tapered steel section following the line of the seat.
Something like a modern subframe profile. Check out the Buell X1 rear frame detail. If you built a shape like that and welded it to
your frame it would finish off the back real nice.

[rachet]

Great start to your cafe build.

But this is a bobber...

Nah, it's totally a cafe.  I've considered framing the tail piece in, and now that I cut the existing frame out, it would be a lot easier to mock up.  I'm going to try and get some garage time today and see what happens.  I'll post some pics if anything changes.

I've been following your build, btw, Great inspiration!

[rachet]

All right, FunJimmy egged me on and I am susceptible to Peer pressure, so Here is the newly modified rear frame.  I of course have some touch up to do, but all in all it turned out all right.







and Here is a mock up of the Brake light I'm using.

[FunJimmy]

All right, FunJimmy egged me on and I am susceptible to Peer pressure, so Here is the newly modified rear frame.  I of course have some touch up to do, but all in all it turned out all right.

HeII no. It turned out great!
And in no time flat. I wish I could get results that fast.

Cheers
FJ

[rachet]

Thanks FJ!  I only have a cheap-o Harbor Freight Bender so The bends could be a little better.  The Rear bar isn't a bend at all, but a straight piece welded in, ground down, welded up, ground down again... welded... you get the idea.

I read your post around Noon PST, and by 3'ish I was taking the pics you see.  It was just a fun, productive day.

Since you are so full of great ideas, what do you think about the underside?  I want to tuck the electrics up in the seat hump, do you think forming some sheet metal and welding it up would be fine?  It would also act as a mud flap I suppose?

Anyone else have ideas/photos?

thanks!

Rach-

[FunJimmy]

Forming sheet metal and welding it in is permanent and probably difficult to fit completely.
Personally I'd try ABS sheet plastic. You could easily weld in mounting tabs to secure the ABS sheet once formed to your satisfaction.
1/8" ABS sheet is pretty cheap, can be formed with heat and comes black.
You can heat the whole piece up in the oven or just were you want to bend it with a paint strip heat gun.

Whatever you choose, I'm sure you'll do a fantastic job.

Cheers
FJ

[rachet]

ABS is a great idea!  Since the electrics will be up there, I'm concerned about water/moister.  We just had our one sunny weekend for the year here in Oregon, so I have to make this water tight.  I might bend up the sheet metal to fit inside the frame, then bolt that in place.  Not permanent, and with a little rubber stripping it should be pretty water proof.  I will still be able to access the electronics when I flip the seat up.

I'll have to ponder this.

[rachet]

I hope everyone is having a happy Easter!  After some grocery shopping with the Family, I was able to get out into the garage and do some damage.  Ever since last weekend, I've been mulling over how the Rear Seat pan had a gap between it and the newly added frame.  I knew there was no way I could live with this so Here is how I "fixed" it.

Before


I Really, Really, need a "break".  That is to say, that machine you use to bend angles in Sheet Metal.  A hammer and hard metal edge also works, And since that's what I have, that is what I used.  I say this because I hand formed everything including the little lip on the under side of the seat cowl.  Here's how it turned out.


Of course, the rest of the seat pan looks incomplete and I had to address that...


Cut out the old-


Replaced it with the new piece-


Here's a pic of the underside, for scientific purposes...


and Finally, here is what the FG Insert looks like in the newly modified seat Pan.  Just as an FYI, I've done everything to both sides so I just need to finish tack welding everything and grind'er down!


I need to cut the FG insert along the sides and redo them to allow for the Seat Material to be tucked between Insert and Seat Pan and when I do that, I'll shape the insert to follow the lines of the pan.

Stay tuned, Same Bat Channel, Same Bat Time...

[rachet]

forgot one little pic showing it from the rear.

[Mayor08]

Nice Weezer reference in the first post...how's the progress been since the last post?

[byfbo]

Yeah how about it?  That metal work is lookin pretty good.

[rachet]

Well just as I feared, as soon as I started a build thread, Life got in the way and The build ground to a halt.  I'm hoping to get back to it after the holidays.  It's a balancing act between family, work, and fun.  Thanks for reminding me it's here!

Rach-

[spatman]

Anything new??? I'm learning how to weld and have a 500 in need of a new seat pan. I need inspiration, man!

-joe

[RAFster122s]

Can you cut and shape some fill in pieces to more closely conform to the tail lamp and blend into your rear tail cowling? Then weld them in place? That seems to be the way to make it fit better. Just need to form it, tack it in place, weld it to the other metal, adjust fitment, and then grind the welds down to finish it. Leave room for a strip of rubber around the lamp to make it look even better when finished.

Just a thought...

[Little_Horse]

FWIW for those of you trying your hand at sheet metal work the small Harbor Freight English wheel and the air planishing hammer they have work great for small projects like cowls body work and tank mods, and they don't cost too much.