DO THE TON

Blood Sweat Tears and Grease => Projects => Trackers => Topic started by: Pete12 on Oct 17, 2017, 10:06:22

Title: CB450 Tracker
Post by: Pete12 on Oct 17, 2017, 10:06:22
Long time lurker, first time poster...

Picked up a CB450 from a mate for free with the idea of turning it into a street tracker. I built an RD350 racer last year that turned out OK, so this is being built for my brother. His only request was that it be fitted with pillion footrests and a long enough seat to fit his girlfriend's behind on behind...

https://i.imgur.com/HhKoLA0.jpg[/img]](https://i.imgur.com/HhKoLA0.jpg) (http://[img width=770 height=433)

It was pretty weathered externally, but turned over freely with good compression.

https://i.imgur.com/lwiwtJN.jpg[/img]](https://i.imgur.com/lwiwtJN.jpg) (http://[img)

The outer covers were a bit knocked around so we found another CB450 on Gumtree for $210 that was incomplete and had been seized at some stage. The frame was in good condition so we decided to use that and keep the other one complete for the mock-up stage.

I had a set of YZ250 Excel hubs that I bought for my race bike years ago, so they have been donated to the project. I ordered 19"x2.75" Sun rims and S/S spoke from Buchanan's and laced them onto the hubs...

https://i.imgur.com/q98Cbx8.jpg[/img]](https://i.imgur.com/q98Cbx8.jpg) (http://[img)

https://i.imgur.com/xxGXl3v.jpg[/img]](https://i.imgur.com/xxGXl3v.jpg) (http://[img)

..and fitted them up with some DOT approved Shinko flat track tyres.

https://i.imgur.com/y3Z4T5n.jpg[/img]](https://i.imgur.com/y3Z4T5n.jpg) (http://[img)

I started the frame mods by pulling the steering head back a couple of degrees to 25 to give it a tracker stance.

https://i.imgur.com/WBB02j3.jpg[/img]](https://i.imgur.com/WBB02j3.jpg) (http://[img)

Obviously the bigger diameter wheels and pulling the steering head back has affected the trail and the wheelbase, so I plotted it out on AutoCAD to work out the new values for swinging arm length and fork offset. I made a new square section swinging arm that will bring the wheelbase to 55"-56". It still needs to be gusseted at the front and the shock mounts installed but it is OK for the mock-up.

https://i.imgur.com/HHxYYCV.jpg[/img]](https://i.imgur.com/HHxYYCV.jpg) (http://[img width=770 height=433)

I also made all the hardware for the back wheel adjusters but still have to make an axle for it.

https://i.imgur.com/GDMEZAb.jpg[/img]](https://i.imgur.com/GDMEZAb.jpg) (http://[img width=770 height=433)

I ordered a big hunk of 6160 aluminium that arrived a couple of days ago so I will start making the triple trees tomorrow night.

Please excuse the photo's, they are a mix of camera and phone and I have had a hell of a time trying to post them on here, so I will try and correct that for any future shots.
Title: Re: CB450 Tracker
Post by: Rat_ranger on Oct 17, 2017, 10:30:09
Good start, I'll be watching this to see how it ends up.
Title: Re: CB450 Tracker
Post by: Pete12 on Oct 18, 2017, 07:05:48
Made some progress today. I finished making the back axle out of 4140, but still need to mill a couple of flats on the end for the wrench. I have a really old indexing head that weighs a ton, so I'll wait until I have a few jobs to do before I wrestle it up onto the mill bed.

https://i.imgur.com/jyPMwG9.jpg[/img]](https://i.imgur.com/jyPMwG9.jpg) (http://[img width=770 height=433)

Started boring the holes for the triple trees on the mill,

https://i.imgur.com/V0qbOky.jpg[/img]](https://i.imgur.com/V0qbOky.jpg) (http://[img width=770 height=438)

got them to size and then cut the bar in half (which turned out to be a big job), and tried them for size - all good. I'll set them back up in the mill and finish the thickness, profile, slots and retaining screw holes.

https://i.imgur.com/0Z4GEcZ.jpg[/img]](https://i.imgur.com/0Z4GEcZ.jpg) (http://[img)

I'm using the original CB450 stem with All Balls tapered roller races, just have to make a threaded insert and weld it in the top as I will make a S/S bolt instead of using the existing chrome nut. I'm giving it 0.0015" of interference so that it fits up nice and tight with the aid of my press and judicious application of heat.

After looking for a long time I picked up a perfect set of R6 forks from eBay for $150, pretty happy about that. They came with an axle which I will be able to modify to suit the YZ wheel.

I'm still trying to decide whether to use an R6 or YZ caliper on the front. The rear will be YZ and in the interests of uniformity, I will probably use the YZ one. Either way I have to make up fork or disc adaptors, so that's not really a deciding factor. The bike will be considerably lighter than it was from the factory, and I don't plan on doing anything to the motor aside from a rebuild, Mikuni carbs and a free flowing exhaust, so it shouldn't be too hard to pull up. I'd appreciate any thoughts on why I should pick one over the other.

Title: Re: CB450 Tracker
Post by: Rat_ranger on Oct 18, 2017, 09:36:51
Make an adapter for a 320mm rotor and use the r6 caliper.  Reasoning: supermoto guys upgrade to a larger rotor and 4 pot calipers to improve brake feel and fade.  Although if you already have the yz caliper it would do fine, just might not "feel" as good, which is subjective.
Title: Re: CB450 Tracker
Post by: Pete12 on Oct 18, 2017, 17:17:38
Make an adapter for a 320mm rotor and use the r6 caliper.  Reasoning: supermoto guys upgrade to a larger rotor and 4 pot calipers to improve brake feel and fade.  Although if you already have the yz caliper it would do fine, just might not "feel" as good, which is subjective.

Good advice, thank you.
Title: Re: CB450 Tracker
Post by: JadusMotorcycleParts on Oct 19, 2017, 15:40:17
Wow this looks awesome!  Sign me up  :D
Title: Re: CB450 Tracker
Post by: canyoncarver on Oct 19, 2017, 16:41:28
Cool build!
Title: Re: CB450 Tracker
Post by: Pete12 on Oct 20, 2017, 01:02:12
Thanks Guys...

Got the triples profiled finally. I ended up with 55mm of offset which equates to around 95mm of trail when it's all assembled, which should be pretty good I think.

This is the lower one and the two holes in the bottom are for the steering stops which will just be a couple of cap screws that will locate against the existing frame lug.

https://i.imgur.com/1SpICl8.jpg[/img]](https://i.imgur.com/1SpICl8.jpg) (http://[img width=770 height=700)

This is the upper one and the two holes in it are for the handlebar clamps. I am going to use Maico rubbers on the clamps to try and reduce the vibration that these CB450's are rumoured to have...

https://i.imgur.com/mcTxuTS.jpg[/img]](https://i.imgur.com/mcTxuTS.jpg) (http://[img)

The forks assembled to check the fit. The steering stem will get pressed in and then I can install them and get on with making the handlebar clamps.

https://i.imgur.com/sQpLJCP.jpg[/img]](https://i.imgur.com/sQpLJCP.jpg) (http://[img)

I bought an Acewell tacho from Dime City Cycles (what a great bunch of guys to deal with there) so I'll make up a mounting bracket for it once the handlebar clamps are finished - it will attach to the front of the top tree

https://i.imgur.com/GY5CVAu.jpg[/img]](https://i.imgur.com/GY5CVAu.jpg) (http://[img)

Apologies again for the varying size and quality of the photos - not too sure what's going on there but I'll try and get some uniformity with them (I hope)...
Title: Re: CB450 Tracker
Post by: Pete12 on Oct 21, 2017, 06:57:24
Well, spent the whole day in the shed today as it was drizzling outside. Good way to spend a Saturday in my book.
I got the handlebar clamps and the tacho bracket all finished. Both fiddly jobs but turned out OK I think.

https://i.imgur.com/mTyBY5Q.jpg[/img]](https://i.imgur.com/mTyBY5Q.jpg) (http://[img width=770 height=425)

https://i.imgur.com/VYUk8eQ.jpg[/img]](https://i.imgur.com/VYUk8eQ.jpg) (http://[img width=770 height=598)

https://i.imgur.com/TiWRVnr.jpg[/img]](https://i.imgur.com/TiWRVnr.jpg) (http://[img width=770 height=574)

https://i.imgur.com/So1YQgE.jpg[/img]](https://i.imgur.com/So1YQgE.jpg) (http://[img width=770 height=631)

Starting to look almost like a bike now.

https://i.imgur.com/YkQJAnB.jpg[/img]](https://i.imgur.com/YkQJAnB.jpg) (http://[img width=770 height=433)

The next thing will be to get the bottom end of the engine in so I can set the back wheel spacing to get the chain line right. Once that's done I can offset the rim if it needs it and then make a rear caliper bracket. I bought some Cannondale calipers at Mid Ohio a few years ago for $5 each, so I'll probably fit one of them up. I bought a WR250 rear brake complete but the caliper is a bit ratty so I'll probably just end up using the master cylinder and brake pedal linkage. All good fun....

Title: Re: CB450 Tracker
Post by: Pete12 on Oct 24, 2017, 04:29:51
Made some new aluminium rear footrest brackets to replace the pressed steel ones that are standard.
https://i.imgur.com/fTnblUR.jpg[/img]](https://i.imgur.com/fTnblUR.jpg) (http://[img width=770 height=433)
https://i.imgur.com/2JyiOsk.jpg[/img]](https://i.imgur.com/2JyiOsk.jpg) (http://[img width=770 height=433)
Cut the old ones off and cleaned up the welds.
https://i.imgur.com/O5dQsF1.jpg[/img]](https://i.imgur.com/O5dQsF1.jpg) (http://[img width=770 height=433)
Made up some little brackets and tacked them in place on the frame
https://i.imgur.com/H0aCrVC.jpg[/img]](https://i.imgur.com/H0aCrVC.jpg) (http://[img width=770 height=433)

Started going through all the parts to see what else I needed and out of the three alternator covers I have there is not a single good one. All of them have gear lever scrapes on them - I honestly don't know what is wrong with someone that doesn't notice (or care) about the gear lever gouging the cover.
https://i.imgur.com/wWg5ybg.jpg[/img]](https://i.imgur.com/wWg5ybg.jpg) (http://[img width=770 height=433)
In fear of buying another one with the same problem I made a new one out of some spare alloy plate I had laying around. It was only 10mm thick so I made a removable outer cover which fixed the width problem and also allows the timing marks to be accessed without removing the whole cover. Removing the whole cover with the bike on the sidestand usually results in oil dripping out, so I won't have that problem any more. One advantage of it being thinner is less chance of the gear lever going anywhere near it lol..
https://i.imgur.com/M8kdcKr.jpg[/img]](https://i.imgur.com/M8kdcKr.jpg) (http://[img width=770 height=433)
https://i.imgur.com/nbwtgMF.jpg[/img]](https://i.imgur.com/nbwtgMF.jpg) (http://[img width=770 height=433)

Making a rod for my own back with all these alloy bits and pieces that will all require a lot of rubbing, buffing and polishing  ::)
Title: Re: CB450 Tracker
Post by: 1fasgsxr on Oct 24, 2017, 13:38:26
 :o
Title: Re: CB450 Tracker
Post by: Pete12 on Oct 24, 2017, 18:12:48
:o
Why are you shocked??
Title: Re: CB450 Tracker
Post by: 1fasgsxr on Oct 25, 2017, 10:14:43
Closest I could find to a WOW !
Title: Re: CB450 Tracker
Post by: Pete12 on Oct 25, 2017, 18:12:03
Closest I could find to a WOW !

Haha, thanks.

Made some alloy front and rear engine plates and roughly bolted the bottom half of the engine in to sort out the chain alignment.
https://i.imgur.com/IEN2iFg.jpg[/img]](https://i.imgur.com/IEN2iFg.jpg) (http://[img width=770 height=433)
https://i.imgur.com/Klp6ytj.jpg[/img]](https://i.imgur.com/Klp6ytj.jpg) (http://[img width=770 height=433)
I had an old sprocket and chain laying around so I fitted them up. With the chain lined up and the left hand spacer in place the wheel is offset around 8mm to the right hand side so I just adjusted the spokes and pulled it over into the centre, so all good now. I don't think it will be an issue but I will pull the tyre off and make sure that there are no spoke ends poking out through the nipples.
https://i.imgur.com/QJz1mMY.jpg[/img]](https://i.imgur.com/QJz1mMY.jpg) (http://[img width=770 height=433)
I'm having trouble sourcing a 520 16T countershaft sprocket for this motor. XL500 sprockets are very close but the spline minor diameter is 22mm as opposed to the CB450's 21mm. Not sure it would be a problem but I would like to get the correct fitting one. Anyone have any experience with this?
Title: Re: CB450 Tracker
Post by: JB56 on Oct 26, 2017, 01:32:21
Thats one helluva lucky brother!!! If the intitial work is anything to go buy it will be an absolute weapon when finished....
Title: Re: CB450 Tracker
Post by: JB56 on Oct 26, 2017, 01:36:35
and could you post a picture of the RD you did last year if that's OK?
Title: Re: CB450 Tracker
Post by: Pete12 on Oct 26, 2017, 02:24:58
Thats one helluva lucky brother!!! If the intitial work is anything to go buy it will be an absolute weapon when finished....

Oh, don't you worry, he'll pay.. :)
Title: Re: CB450 Tracker
Post by: Pete12 on Oct 26, 2017, 02:35:27
and could you post a picture of the RD you did last year if that's OK?

Thanks for your interest. Here's the RD350:
https://i.imgur.com/8barr6q.jpg[/img]](https://i.imgur.com/8barr6q.jpg) (http://[img width=770 height=482)
https://i.imgur.com/2UDatGk.jpg[/img]](https://i.imgur.com/2UDatGk.jpg) (http://[img width=770 height=513)
Title: Re: CB450 Tracker
Post by: 1fasgsxr on Oct 26, 2017, 07:59:28
I had my 520 sprockets made at Rebel Gears.  I don't know if you are in the states, but if so I would give them a try.
Title: Re: CB450 Tracker
Post by: Pete12 on Oct 26, 2017, 10:02:50
I had my 520 sprockets made at Rebel Gears.  I don't know if you are in the states, but if so I would give them a try.

Thanks for the tip. I'm in Australia but heading to NC soon for work so I'll follow that up.
Title: Re: CB450 Tracker
Post by: 1fasgsxr on Oct 26, 2017, 13:13:32
From what I can tell that will make you anything you want.
Title: Re: CB450 Tracker
Post by: jag767 on Oct 26, 2017, 22:44:06
From what I can tell that will make you anything you want.

For the right price they make anything. I needed a custom 520 offset 44 tooth sprocket for a cb350f rear wheel with a 7mm offset and bingo. $130 later I have it.
Title: Re: CB450 Tracker
Post by: Pete12 on Oct 27, 2017, 08:07:36
Thanks guys, I'll give them a try.
Got my rear caliper bracket made up with the new Nisin caliper.
https://i.imgur.com/3KipL0E.jpg[/img]](https://i.imgur.com/3KipL0E.jpg) (http://[img width=770 height=433)
Made up a locating slot and welded it in position on the swingarm, all ready to go, back wheel finally finished...
https://i.imgur.com/2hUVQ5W.jpg[/img]](https://i.imgur.com/2hUVQ5W.jpg) (http://[img width=770 height=433)
I bought an R6 front caliper but had all sorts of trouble fitting it up as it's very wide and fouls the spokes without a really wide disc adaptor, so I've gone ahead and found a good second hand 08 WR250 caliper and master cylinder. It comes complete with hose and brake light switch and although the four pot caliper from the R6 would have been good, this one should still work well, particularly with the increased diameter of the R6 disc. The next project will be to make a disc adaptor and then a caliper bracket once it arrives next week.
Title: Re: CB450 Tracker
Post by: 3DogNate on Oct 27, 2017, 11:12:01
Excellent work... continue.
Title: Re: CB450 Tracker
Post by: Pete12 on Oct 28, 2017, 22:02:33
Made up an adaptor for the R6 disc to fit the YZ hub

https://i.imgur.com/kqIvpBB.jpg[/img]](https://i.imgur.com/kqIvpBB.jpg) (http://[img width=770 height=433)
https://i.imgur.com/Z6NNemW.jpg[/img]](https://i.imgur.com/Z6NNemW.jpg) (http://[img width=770 height=433)
https://i.imgur.com/gsfr1z0.jpg[/img]](https://i.imgur.com/gsfr1z0.jpg) (http://[img width=770 height=433)

The WR caliper should arrive tomorrow so I can make up the adaptor bracket for it and then the wheel spacers and I should have a rolling chassis. I need to start thinking about the exhaust pipes next, and then start on the tank and seat. The fun is about to start...
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 01, 2017, 04:14:20
I made the front caliper bracket this afternoon, which was quite fiddly but worked out OK
https://i.imgur.com/oHafBZq.jpg[/img]](https://i.imgur.com/oHafBZq.jpg) (http://[img width=770 height=433)

It looks like a bit of an afterthought, but I really didn't have any choice and it fits up and works fine. I still need to make up the front wheel spacers and then centre the wheel between the forks.
https://i.imgur.com/AS3G6lf.jpg[/img]](https://i.imgur.com/AS3G6lf.jpg) (http://[img width=770 height=433)

I'll order the bends for the pipes tomorrow. I was going to go with two up one side, but as this bike is going to carry a pillion I'll build a two into one system and exit it on the lower right hand side, which still should look OK I think.
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 03, 2017, 01:43:05
Hit a bit of a snag with the front end. Started making up the wheel spacers and noticed that the axle was binding in the clamp hole in the forks. I loosened the forks in the triples and rotated them and saw that the fork lower was moving in and out on the axle. My worst fears were confirmed when I put a straight edge on the fork tubes and saw that they were both bent - no wonder they were cheap. The seller had assured me that they were flawless and had come off a bike that had never been crashed. They're 43mm forks, they certainly didn't get bent falling off the side stand. Too late to do anything now, just need to remember the Latin phrase "caveat emptor" in the future...

They had about 4mm of bend in them so I quickly machined up 3 cradles in the mill and very carefully straightened them.
https://i.imgur.com/Aj0BcKg.jpg[/img]](https://i.imgur.com/Aj0BcKg.jpg) (http://[img width=770 height=433)

They are now within about 0.005" (sorry, always talk small values in inches), so no problem. They needed to come apart for seals and oil anyway, but I just wasn't prepared for a trial run.

Once that was out of the way I made up the wheel spacers which turned out OK. The disc is in the centre of the caliper and the wheel is in the centre of the forks, so nothing more required there.
https://i.imgur.com/L0vuTqY.jpg[/img]](https://i.imgur.com/L0vuTqY.jpg) (http://[img width=770 height=433)

Aside from the rear shock mounts (waiting on the shocks to arrive) I now have a rolling chassis with both wheels in tight and aligned.
https://i.imgur.com/TcCrQ45.jpg[/img]](https://i.imgur.com/TcCrQ45.jpg) (http://[img width=770 height=433)

I'll build the exhaust next because I can do it on the original bike that is still together, as I want to pull the engine out and rebuild it. The footrests and brake can wait until I have the seat and tank made and in place so that I can find the optimum mounting position.
Title: Re: CB450 Tracker
Post by: JB56 on Nov 03, 2017, 03:23:25
Thanks for the pics of the RD.  That is just awesome.  The build is coming along very nicely.  Do you do this for a living or is it just a hobby and where are you located? In the US?
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 03, 2017, 05:33:05
Thanks for the pics of the RD.  That is just awesome.  The build is coming along very nicely.  Do you do this for a living or is it just a hobby and where are you located? In the US?

Thanks for the reply JB56. This is only a hobby, I just like fiddling with old bikes. I am in Australia.
Title: Re: CB450 Tracker
Post by: SONIC. on Nov 03, 2017, 10:52:51
Very nice!
Are you CNC milling parts or manually?
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 03, 2017, 19:57:44
Very nice!
Are you CNC milling parts or manually?

Thanks Sonic.
I appreciate your confidence but I am nowhere near a good enough machinist to be able to make those parts on a manual mill. I bought this used Delta turret mill with a ProtoTRAK 3 axis controller about 4 years ago, but had it in storage until recently as I have just built a new house.
https://i.imgur.com/siZmerb.jpg[/img]](https://i.imgur.com/siZmerb.jpg) (http://[img width=770 height=433)

I am just getting used to running it and have only used it in two axis mode as that mode is conversational programming and really quite easy. I do plan on learning how to program it in three axis mode, but that will be when I have finished this current project. Up until getting this mill running I made all my parts with the bandsaw, hacksaw, drill press and files, but wow, this is so much quicker and easier
It was a little hard to justify buying this machine just for hobbies, but I have a great wife who really doesn't mind what I buy for the workshop, which makes life easy.
Title: Re: CB450 Tracker
Post by: Rat_ranger on Nov 04, 2017, 11:52:32
Nice, no need for CAD/CAM.  Even if you are good at manual machining a conversational is so much easier. 
Title: Re: CB450 Tracker
Post by: djmaynard on Nov 05, 2017, 15:31:43

It was a little hard to justify buying this machine just for hobbies, but I have a great wife who really doesn't mind what I buy for the workshop, which makes life easy.

That would be nice. Mine always wonders why I get so many packages a few times a week.


Sent from my iPhone using DO THE TON (http://r.tapatalk.com/byo?rid=89466)
Title: Re: CB450 Tracker
Post by: SONIC. on Nov 05, 2017, 16:51:30
Thanks Sonic.
I appreciate your confidence but I am nowhere near a good enough machinist to be able to make those parts on a manual mill. I bought this used Delta turret mill with a ProtoTRAK 3 axis controller about 4 years ago, but had it in storage until recently as I have just built a new house.
https://i.imgur.com/siZmerb.jpg[/img]](https://i.imgur.com/siZmerb.jpg) (http://[img width=770 height=433)

I am just getting used to running it and have only used it in two axis mode as that mode is conversational programming and really quite easy. I do plan on learning how to program it in three axis mode, but that will be when I have finished this current project. Up until getting this mill running I made all my parts with the bandsaw, hacksaw, drill press and files, but wow, this is so much quicker and easier
It was a little hard to justify buying this machine just for hobbies, but I have a great wife who really doesn't mind what I buy for the workshop, which makes life easy.

That's what I figured but wasn't 100%.
Very nice work and machine. I'm looking for one but haven't found one I like yet.
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 05, 2017, 20:33:38
Quote from: SONIC.

I'm looking for one but haven't found one I like yet.

The ProtoTRAK seems quite good but I also looked at the Millpwr Acu-rite controller which has just about the same functions but includes an alpha-numeric engraving option which I really would have liked. I put my brother's initials in the new alternator cover that I made but I had to program the coordinates for it. Not a big deal for just two letters, but words would take a while.
https://i.imgur.com/oMrPuKR.jpg[/img]](https://i.imgur.com/oMrPuKR.jpg) (http://[img width=770 height=433)

Having said that, I'm very happy with the machine that I have as it's in really good condition and hasn't seen a lot of use.
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 05, 2017, 20:35:16
Quote from: djmaynard
That would be nice. Mine always wonders why I get so many packages a few times a week.

 ;D ;D
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 08, 2017, 00:09:34
Still waiting for my exhaust pipe bends and pipe to arrive which will hopefully be in the next couple of days. In the meantime I made up the pipe ends, collets and flanges. The collets still need to be cut in half but I want to check the fit on the pipe first.
https://i.imgur.com/afmOVYa.jpg[/img]](https://i.imgur.com/afmOVYa.jpg) (http://[img width=770 height=433)

I'm not sure if I like the design or not, I'll see what it looks like when the motor is all together.
https://i.imgur.com/uDitsXE.jpg[/img]](https://i.imgur.com/uDitsXE.jpg) (http://[img width=770 height=433)

They are about half the weight of the original steel flanges, so that's a good thing..
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 10, 2017, 21:10:53
Still waiting on the elusive exhaust components, which are scheduled for delivery Monday, so I made up some headlight brackets. Getting pretty crowded with aluminium on the front end so I may powdercoat these, but I'll wait until it's fully mocked up before deciding. The headlight is a NOS one that I had laying around and I like the shape of it. It just needs a coat of paint and it'll be good to go.

https://i.imgur.com/5wqSuky.jpg[/img]](https://i.imgur.com/5wqSuky.jpg) (http://[img width=770 height=433)
https://i.imgur.com/jMipRhn.jpg[/img]](https://i.imgur.com/jMipRhn.jpg) (http://[img width=770 height=433)

The hole in the back is for the blinkers so I machined up a couple of sleeves to space them out a bit further and fitted them up. They are from DCC and are neat little units.

https://i.imgur.com/tMZRzFt.jpg[/img]](https://i.imgur.com/tMZRzFt.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 14, 2017, 04:48:37
Exhaust pipe parts turned up yesterday. They look pretty good, the mandrel  bends don't have much deformation and have only necked a very small amount, which I will be able to get out with some filing.
https://i.imgur.com/1BDrSgk.jpg[/img]](https://i.imgur.com/1BDrSgk.jpg) (http://[img width=770 height=433)

Got started with the first pipe.
https://i.imgur.com/KhapLP0.jpg[/img]](https://i.imgur.com/KhapLP0.jpg) (http://[img width=770 height=433)
I'm going to keep the pipes in line with the front downtube, I think they look good that way.

Hopefully I can get these finished in the next few days and then get started on the tank.
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 15, 2017, 03:34:41
Got the pipes tacked together now. Tacked a plate across them to hold them steady until they're all finished. Need to make the collector next which I'll develop on paper and then make a template and cut it out of sheetmetal - pattern development is always fiddly but the result is good. Once the collector is built I can then make the rest of the pipe and muffled (slightly) reverse cone megaphone.

Title: Re: CB450 Tracker
Post by: 1fasgsxr on Nov 15, 2017, 10:24:15
Looking good.. perfect lines on the exhaust
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 17, 2017, 00:51:43
Looking good.. perfect lines on the exhaust

Thank you and thanks for following along.

As I am building a 2 into 1 system I need to make a collector to transition between the two. Bell's book suggests a collector taper of 7-8 degrees (not that it's going to be a race bike, but it may as well be done somewhere near right), so I developed the pattern in AutoCAD. Even though it takes time it's still a whole lot better than taking to the bare metal with the marking blue, divider, ruler and scriber, imho.
https://i.imgur.com/nYmTlhG.jpg[/img]](https://i.imgur.com/nYmTlhG.jpg) (http://[img width=770 height=433)
Once that was done I isolated the pattern outline and converted it to a BMP file. I then imported that into my sticker cutter (another great toy that I was lucky enough to buy, without any possible hope of payback), and cut the pattern.
https://i.imgur.com/WAjT4bj.jpg[/img]](https://i.imgur.com/WAjT4bj.jpg) (http://[img width=770 height=433)
I then stuck the pattern onto a bit of old body steel, and cut around it with the snips.
https://i.imgur.com/mWmgxWm.jpg[/img]](https://i.imgur.com/mWmgxWm.jpg) (http://[img width=770 height=433)
https://i.imgur.com/BiZST2p.jpg[/img]](https://i.imgur.com/BiZST2p.jpg) (http://[img width=770 height=433)
I then welded the seam and rolled it up around a bit of pipe in the vice, and it fits pretty good.The steel I used is quite rusty so I'll get a new sheet next week as I still have the rest of the megaphone to manufacture.
Title: Re: CB450 Tracker
Post by: cxman on Nov 17, 2017, 08:51:47
what size is your main pipe and mandrel bends
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 17, 2017, 10:45:16
what size is your main pipe and mandrel bends

Pipe ID about 38mm.
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 18, 2017, 20:23:13
Can't do much until I get some body steel so I milled some slots in the two countershaft sprocket covers. I'll let my brother decide which one he wants to go with and he if he doesn't like either then new s/h covers are plentiful and cheap  :D
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 23, 2017, 22:40:50
Finally got around to making the new collector and fitted it up. I also dressed all the welds on the joins and it came up OK.
https://i.imgur.com/JmEFoDx.jpg[/img]](https://i.imgur.com/JmEFoDx.jpg) (http://[img width=770 height=433)

Cut some more body steel and welded and rolled up a 50mm tube for the next part of the exhaust.
https://i.imgur.com/YSGyLLn.jpg[/img]](https://i.imgur.com/YSGyLLn.jpg) (http://[img width=770 height=433)
https://i.imgur.com/RCzhmfp.jpg[/img]](https://i.imgur.com/RCzhmfp.jpg) (http://[img width=770 height=433)

I then cut and tacked some segments for the bends
https://i.imgur.com/QUSYjrT.jpg[/img]](https://i.imgur.com/QUSYjrT.jpg) (http://[img width=770 height=433)

Once that was done I fitted the pipes and taped the joins together to ensure the fit was OK.
https://i.imgur.com/ZzvFJtC.jpg[/img]](https://i.imgur.com/ZzvFJtC.jpg) (http://[img width=770 height=433)

I will make the megaphone next, mock it all up and once I'm happy with the fit, weld it all together. When that's finished I'll make and install the baffle and then move on to the tank.
Title: Re: CB450 Tracker
Post by: JadusMotorcycleParts on Nov 26, 2017, 16:05:54
Looking awesome!  That rolled collector came up amazing.  Cool technique.
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 27, 2017, 03:18:59
Looking awesome!  That rolled collector came up amazing.  Cool technique.

Thanks very much for the positive feedback.

Printed up some sticker templates today for the megaphone and reverse cone so I should be able to get that done in the next couple of days. Even without the sticker maker it's very easy to draw the pattern for a cone directly onto the body steel, this just makes it a little easier and quicker
https://i.imgur.com/Z36deQr.jpg[/img]](https://i.imgur.com/Z36deQr.jpg) (http://[img width=770 height=433)

Also made a couple of stickers to be placed discreetly on the swing arm  ;D ;D

Title: Re: CB450 Tracker
Post by: Pete12 on Nov 28, 2017, 05:49:36
Put the stickers on the body steel and cut around them ready for rolling and welding.
https://i.imgur.com/6kLxzp3.jpg[/img]](https://i.imgur.com/6kLxzp3.jpg) (http://[img width=770 height=433)
Before I get onto that I want to finish the headers so I finished welding the sections together, which are just fuse welded with the oxy/acetylene.
https://i.imgur.com/Ks3bHcw.jpg[/img]](https://i.imgur.com/Ks3bHcw.jpg) (http://[img width=770 height=433)
There is a bit of undercut but the penetration is really good and it just leaves a nice neat bead around the inside of the weld.
https://i.imgur.com/IuXewPe.jpg[/img]](https://i.imgur.com/IuXewPe.jpg) (http://[img width=770 height=433)
I've been building two stroke pipes for a long time now and never had one so much as crack, so it works for me. :o
Title: Re: CB450 Tracker
Post by: Luugo86 on Nov 28, 2017, 12:24:28
Nice welds, I like using the oxy/fuel rig for stuff like this. I like where this project is heading.
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 29, 2017, 09:36:37
Nice welds, I like using the oxy/fuel rig for stuff like this. I like where this project is heading.

Thanks very much for the comment. I have tig which I use for most things but have always used the O/A set for pipes. Very easy to control and direct the weld puddle. Someday I'll make a little speed controlled chuck so I can get a continuous weld around the butt joins.

Rolled up the cones around a length of pipe in the vice and welded the seams.
https://i.imgur.com/YaWVSBo.jpg[/img]](https://i.imgur.com/YaWVSBo.jpg) (http://[img width=770 height=433)

Welded the reverse cone onto the megaphone and then tacked it onto the pipe.
https://i.imgur.com/F7XbXWR.jpg[/img]](https://i.imgur.com/F7XbXWR.jpg) (http://[img width=770 height=433)

It's only tacked at this stage as it is on the mock-up bike with the rear end on the actual bike a bit different. As the actual bike doesn't have a head on it at this stage I will wait until its final assembly stage to finish welding the pipe completely. I'll also run a second pass around the join between the megaphone and the reverse cone and dress it back for a seamless finish. I will wait to install the baffle until I can actually run the bike with different baffles to see which type performs (and sounds) the best.

The exhaust looks a little out of place on the mock-up bike but I think once it's all finished and painted it will look OK. Next project, the fuel tank...
Title: Re: CB450 Tracker
Post by: Aussie Steve on Nov 29, 2017, 11:09:52
This is really very interesting. If you ever feel the urge to post a video on YouTube about your exhaust making technique, I'd watch for sure. No doubt a lot could be learnt. Keep up the nice work.

Sent from my Lenovo A6020a40 using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)

Title: Re: CB450 Tracker
Post by: Pete12 on Nov 30, 2017, 00:41:46
This is really very interesting. If you ever feel the urge to post a video on YouTube about your exhaust making technique, I'd watch for sure. No doubt a lot could be learnt. Keep up the nice work.

Thanks Steve. What are you interested in particularly? Megaphone design, pattern development, material selection, shape forming or welding? Not too sure about a YouTube video but happy to share some advice, for what it's worth.
Title: Re: CB450 Tracker
Post by: jag767 on Nov 30, 2017, 07:14:36
That's very impressive. I'll be interested to see your process doing that as well.
Title: Re: CB450 Tracker
Post by: Pete12 on Dec 01, 2017, 00:41:26
That's very impressive. I'll be interested to see your process doing that as well.

Thanks Jag, haven't seen anything from Steve yet so not really sure what you want to see. No problem with any of it, I just don't want to tell you things you already know...

Sat the head on the good bike today to see how the exhaust fitted up and it clashes with the rear caliper hydraulic hose - good thing I only tacked it together.
https://i.imgur.com/ScPYIHc.jpg[/img]](https://i.imgur.com/ScPYIHc.jpg) (http://[img width=770 height=433)

Also put the seat on off my race bike so that I can get started on building the tank. The seat has to come down about 25mm which will happen when I make up the new rear loop. This will put the seat height at just over 800mm from the ground, which should be a good height. I'm going to buy a seat, as the Knight shape is quite complex and not so easy to make from scratch out of aluminium, and they are not expensive.
https://i.imgur.com/wpJxgA9.jpg[/img]](https://i.imgur.com/wpJxgA9.jpg) (http://[img width=770 height=433)

I also took the rear right hand cam bearing off my spare head and put it on the front right hand side of the new motor so I don't have that ugly obsolete tacho drive sitting there.
https://i.imgur.com/CJIVwx7.jpg[/img]](https://i.imgur.com/CJIVwx7.jpg) (http://[img width=770 height=433)

Getting closer now, I'll be happy once I've got the tank made and positioned correctly. I can then make the seat loop, battery tray and front mudguard.
Title: Re: CB450 Tracker
Post by: Pete12 on Dec 06, 2017, 00:08:54
I bought some cardboard to get started on the tank template but before I started I sat the old tank on to see how it would go lengthwise with regards to the seat position. Funnily enough, the original didn't look too bad on there...
https://i.imgur.com/LVshn1Z.jpg[/img]](https://i.imgur.com/LVshn1Z.jpg) (http://[img width=770 height=433)

It looked a little too wide so I decided to narrow it up by 25mm. Firstly, I cut the filler cap out with a holesaw.
https://i.imgur.com/28K3El0.jpg[/img]](https://i.imgur.com/28K3El0.jpg) (http://[img width=770 height=433)

I then cut a 25mm strip out of the centre and then cut the flanges off all the way around, so the tank is now in four pieces.
https://i.imgur.com/bDjf6jK.jpg[/img]](https://i.imgur.com/bDjf6jK.jpg) (http://[img width=770 height=433)

The next thing will be to knock all the dents out, (and there are many of them :(), then make a new tunnel and weld it all back together again. Once that's done I can make the new rear loop then align the tank and seat properly before finalising the tank mounts.
I taped the tank back together and these are before and after photos.
https://i.imgur.com/808Fw6J.jpg[/img]](https://i.imgur.com/808Fw6J.jpg) (http://[img)
https://i.imgur.com/iTFH82L.jpg[/img]](https://i.imgur.com/iTFH82L.jpg) (http://[img width=770 height=433)

I sort of like the idea of using the original tank as it will retain some of the bike's character. If it doesn't look good when it's all fitted up then I will just revert to plan A, and make a new tank.
Title: Re: CB450 Tracker
Post by: SONIC. on Dec 06, 2017, 09:40:07
I like it.
I think I'd take it down another inch or so in width and it will be killer.
Title: Re: CB450 Tracker
Post by: Luugo86 on Dec 06, 2017, 16:48:26
I like it.
I think I'd take it down another inch or so in width and it will be killer.

 +1 
  Also, is the tailpiece a unit that you ordered up or fabricated? I like it.
Title: Re: CB450 Tracker
Post by: Pete12 on Dec 07, 2017, 01:52:13
+1 
  Also, is the tailpiece a unit that you ordered up or fabricated? I like it.
I like it.
I think I'd take it down another inch or so in width and it will be killer.

Thanks for the feedback guys. I can't really narrow it any more at the back as it is now the correct width for the seat, which is important in my opinion. I'm also struggling to get the fuel tap in to clear the carbs, but I should be able to find a way around that. I will, however, narrow it up more at the front which I believe will still have the desired effect. I'll finish knocking all the dents out then tack it together and see how it looks.

Luugo86 - the seat is a Knight type off my race bike and I'm just using it for the mock-up but will be getting one the same for this bike. Depending on where you live you can buy them in England or the States, possibly Europe as well.
Title: Re: CB450 Tracker
Post by: Pete12 on Dec 12, 2017, 06:37:56
I ended up cutting nearly 40mm out of the tank and I think it looks OK. I tried overlapping it a bit more to see how it looked but it was starting to get a little skinny for the height so I've gone with what I had. I knocked all the dents out and then welded the seam together and will make the tunnel next and then weld that in. I can then position it correctly and make the front and rear mounts. It's certainly recognisable as a CB450 tank, just looks like it has been on a diet, which is pretty much the look I was aiming for. It matches the seat where they meet, so once the two are lined up correctly height wise they should both look like they are meant to be there. We haven't decided on a colour yet, but my brother is pretty keen to use the original striping design, carried through to the seat tail. Sounds OK to me..

https://i.imgur.com/OQ5Z8tw.jpg[/img]](https://i.imgur.com/OQ5Z8tw.jpg) (http://[img width=770 height=433)

I'm undecided at this stage whether to buy a pop-up cap or just make a regular screw-on cap, but no hurry with that at this stage.

The manifold that was supplied with the new Mikuni carbs is a universal type and doesn't match up to the head too well,

https://i.imgur.com/3u7hqUq.jpg[/img]](https://i.imgur.com/3u7hqUq.jpg) (http://[img width=770 height=433)

so I milled up a transition piece that matches both sides.

https://i.imgur.com/OxkWEaM.jpg[/img]](https://i.imgur.com/OxkWEaM.jpg) (http://[img width=770 height=433)
https://i.imgur.com/MzNko8n.jpg[/img]](https://i.imgur.com/MzNko8n.jpg) (http://[img width=770 height=433)

I think it looks better aesthetically, and it will also give fuel tap a little more clearance, so I'm pretty happy with that. The increased inlet tract length may even give it a bit more low down torque which will be a good result if that is the case.

Title: Re: CB450 Tracker
Post by: 1fasgsxr on Dec 12, 2017, 09:41:58
We need a drooling emoji !!
Title: Re: CB450 Tracker
Post by: Pete12 on Dec 16, 2017, 06:06:58
We need a drooling emoji !!
Haha, thanks very much.

I bought an English Wheel a while ago (well, actually Chinese Wheel if the truth be known), and gave it its maiden run today for the front mudguard. I had a bit of scrap aluminium so, after a fairly steep learning curve, ended up with this:

https://i.imgur.com/A9u4nRt.jpg[/img]](https://i.imgur.com/A9u4nRt.jpg) (http://[img width=770 height=433)

It's not the final piece as it's neither long enough or wide enough, so I will start on that next. The wheel seems to work OK but as it's manufactured and not forged it flexes quite a bit. Seeing that I will probably be only doing small parts on it (no E type Jag bonnets for this boy) I will put some stiffening braces in so that the wheel gap remains more constant which should make it easier to use. Unexpectedly, it bit me a number of times, so I need to treat it with the respect it deserves.

I tried all sorts of different things and somehow managed to get the curve to match the tyre OK (very important IMO) so I'm hoping I can reproduce the result on the final article.
Title: Re: CB450 Tracker
Post by: Pete12 on Dec 19, 2017, 01:55:10
Far too hot to even think about making a mudguard or tank tunnel here today so I decided to make a new points cover, a nice easy job on the milling machine. I traced around the original cover and then scanned the sketch, converted it into a .dwg file and picked up all the coordinates in AutoCAD. Then it was just write the program on the mill and machine it up.

https://i.imgur.com/q21Hdlf.jpg[/img]](https://i.imgur.com/q21Hdlf.jpg) (http://[img width=770 height=433)

I left the end open and rebated so that I can fit a perspex disc to it and watch the points arcin' and a sparkin'....

https://i.imgur.com/1WrGoj4.jpg[/img]](https://i.imgur.com/1WrGoj4.jpg) (http://[img width=770 height=433)

https://i.imgur.com/XdINDJ3.jpg[/img]](https://i.imgur.com/XdINDJ3.jpg) (http://[img width=770 height=433)



Title: Re: CB450 Tracker
Post by: JB56 on Dec 19, 2017, 21:13:38
 Wow, I haven't seen this for a while.  Amazing build!!
The points cover is a work of art..  Should be in the Guggenheim...
Title: Re: CB450 Tracker
Post by: JB56 on Dec 19, 2017, 21:17:47
On the subject of the points cover what are your plans for the motor finish??
Black barrel with filed fins? Bead blasted cylinder head or black head? Black motor or polished alloy??
Have you made a decision on that yet??
Amazing work so far.  I think we would all like to know more how you converted a scanned piece of paper into a goddam points cover??
Title: Re: CB450 Tracker
Post by: Pete12 on Dec 20, 2017, 18:11:35
Thanks JB56.

Haha, points cover in the Guggenheim. If you haven't already, check out the current bike of the month. Now there's a work of art.

The plan for the motor at this stage is black with all the small covers polished and s/s retaining screws, and the end of the fins sanded. I've seen a few like this and they look really good. This of course, is subject to change as we really haven't finished the final colour plan yet.



Title: Re: CB450 Tracker
Post by: irk miller on Dec 20, 2017, 19:25:15
Late to the party, but very happy to join in. 
Title: Re: CB450 Tracker
Post by: Pete12 on Jan 15, 2018, 05:46:48
Late to the party, but very happy to join in.
Thanks Irk, welcome aboard..

I'm waiting on the seat to arrive from the US, which I need before I can do the rear loop or the tank mounts, so I made the first part of the gear lever. I got a short length of aluminium round bar and set it up in the mill and machined the shape into it,
https://i.imgur.com/JB91Z2k.jpg[/img]](https://i.imgur.com/JB91Z2k.jpg) (http://[img width=770 height=433)

I then bored a hole in it with the diameter of the hole being equivalent to the spline minor diameter,
https://i.imgur.com/Klg2dIX.jpg[/img]](https://i.imgur.com/Klg2dIX.jpg) (http://[img width=770 height=433)

and then found a brake cam shaft with the same spline as the gear lever and pressed it in until it bottomed out in the hole.
https://i.imgur.com/nyGyvHQ.jpg[/img]](https://i.imgur.com/nyGyvHQ.jpg) (http://[img width=770 height=433)

Once I pushed it back out I ended up with a nice clean spline.
https://i.imgur.com/UsIqujd.jpg[/img]](https://i.imgur.com/UsIqujd.jpg) (http://[img width=770 height=433)

Then it was a matter of cutting the slot using a slotting saw,
https://i.imgur.com/RtZw8aQ.jpg[/img]](https://i.imgur.com/RtZw8aQ.jpg) (http://[img width=770 height=433)

and then drilling and tapping the clamp bolt hole.
https://i.imgur.com/Lr30IV8.jpg[/img]](https://i.imgur.com/Lr30IV8.jpg) (http://[img width=770 height=433)

Once I have positioned the footrests I can make the arm the correct length and weld it onto this piece. I will make the toe part the same size as the original so I can install an original rubber.


Title: Re: CB450 Tracker
Post by: LiamG6 on Jan 15, 2018, 08:41:00
Really nice work mate, living the dream by the way with the mill etc. Good setup. I'm in oz and building a CB450 too. Bike looks fantastic so far and can't wait to see what else you do with it.

I noticed you used the left rear cam cover on the front right to remove the tacho drive, did you drill an oil hole in it to transfer oil from the cover to the cam itself? You'll need to do that unless you are moving to external oil lines like capellini stuff etc. I'm going with a digital acewell speedo/tacho so I'm making the same change. Was just going to size the oil hole the same as the combined area of the 2 holes in the old tacho drive cover. Was also going to make a jig to transfer the cam timing mark onto the new cover. Getting the angle of the oil hole right is the tricky part, to make sure the oil comes out right at the end of the cam journal. I'm ignoring the fact that the oil spiral inside the cam cover journal is now rotating in the wrong direction, time will tell if that causes issues.

Anyways, I'll be following along admiring your work, very impressed so far!
Title: Re: CB450 Tracker
Post by: Pete12 on Jan 15, 2018, 19:27:30
Hi Liam,
I have only got up to the stage of seeing if the cover would physically fit, but I'd had a look at the lubrication diagram for the top end and appreciate the need for the oil hole and also the mark for the valve timing, but hadn't given any thought at all to the helical groove inside the journal, which may well be a showstopper. I have a tiny little right angle porting die grinder so I will have a go at doing one by hand on one of my spare covers and go from there. Obviously there will be crossovers between the two paths but the direction of rotation should take care of that.
Thanks very much for taking the time to comment, you've quite possibly saved me a cam and journal.
Title: Re: CB450 Tracker
Post by: LiamG6 on Jan 24, 2018, 21:53:24
I don't think it would be a showstopper, but it may accelerate wear in the long run. Provided the oil pressure is enough to force oil through the helical spiral despite the rotation of the cam sort of pushing oil in the wrong direction I think it would actually work fine, just something to keep an eye on. I think trying to mess around in there with a dremel might lead to worse problems. The people who normally make this switch convert to needle bearings so it isn't an issue for them but that is a costly and unnecessary change for a street bike.

Look forward to any updates mate.
Title: Re: CB450 Tracker
Post by: Pete12 on Feb 05, 2018, 03:51:11
I don't think it would be a showstopper, but it may accelerate wear in the long run. Provided the oil pressure is enough to force oil through the helical spiral despite the rotation of the cam sort of pushing oil in the wrong direction I think it would actually work fine, just something to keep an eye on. I think trying to mess around in there with a dremel might lead to worse problems. The people who normally make this switch convert to needle bearings so it isn't an issue for them but that is a costly and unnecessary change for a street bike.

Look forward to any updates mate.

Thanks for the comments Liam, I'd probably set the die grinder up in the lathe and do it that way, but as I'm a while away from building the engine I'll just give it some thought in the meantime

The Christmas hiatus is well and truly over and my seat arrived last week so it's time to get cracking again. The seat is well made and just the right size so I will cut the rear loop off next. I will position the seat and tank so that they match up properly, and then go ahead and make the new loop, incorporating the top shock mounts at the same time.
https://i.imgur.com/Y1IxRtW.jpg[/img]](https://i.imgur.com/Y1IxRtW.jpg) (http://[img width=770 height=433)

I wasn't happy with the exhaust pipe between the collector and the megaphone, the bend wasn't too good and the seam in the straight pipe was facing the outside, so I made up a new one and it looks a lot better, IMO.
https://i.imgur.com/UDsMNY2.jpg[/img]](https://i.imgur.com/UDsMNY2.jpg) (http://[img width=770 height=433)

I made a S/S endcap for the megaphone and a baffle for inside. I'll pack it with fibreglass which should result in a nice throaty exhaust note when it's finished.
https://i.imgur.com/cYNcyGL.jpg[/img]](https://i.imgur.com/cYNcyGL.jpg) (http://[img width=770 height=433)
https://i.imgur.com/2HEyU0f.jpg[/img]](https://i.imgur.com/2HEyU0f.jpg) (http://[img width=770 height=433)
https://i.imgur.com/HxOlrk8.jpg[/img]](https://i.imgur.com/HxOlrk8.jpg) (http://[img width=770 height=433)

Just need to buff the endcap and make a rear mounting bracket for the pipe and give it a coat of pot belly black and it'll be ready to go.
Title: Re: CB450 Tracker
Post by: Pete12 on Feb 08, 2018, 16:54:13
Waiting to get the tube for the rear loop so I made the bung and cap for the tank. The bung needs to go in before the tank tunnel is fitted up as I'm going to braze it from underneath.

Title: Re: CB450 Tracker
Post by: Pete12 on Feb 08, 2018, 22:39:09
Cut off the rear of the frame today, ready to make the new rear loop. First, though, I will get the tank tunnel and mounts fabricated and installed. Once the tank is at the correct height I can then fabricate and position the loop so the tank and seat flow together nicely. Once that's finished I can fabricate and install upper and lower shock mounts and then chase up some new shocks. Thinking about going with Ikons, they are reasonably priced with plenty of adjustment and look well manufactured. Anyone have any experience with them, good or otherwise?
Title: Re: CB450 Tracker
Post by: irk miller on Feb 09, 2018, 07:18:09
My experience is with Kona, which are excellent shocks I have on my R100/7.  Kona is now Ikon. 
Title: Re: CB450 Tracker
Post by: Pete12 on Feb 09, 2018, 08:10:57
That's a good recommendation coming from you Irk, that'll do me, thanks.
Title: Re: CB450 Tracker
Post by: Pete12 on Feb 12, 2018, 04:32:30
Salvaged the rear tubes out of the old back end. They originally turned in a small amount to end up inside the top shock mounts.
https://i.imgur.com/OIRxkCt.jpg[/img]](https://i.imgur.com/OIRxkCt.jpg) (http://[img)

I drilled out the spot welds and ground off two small tack welds to release the tubes from the junction with the seat loop and the shock mounts.
https://i.imgur.com/z2RoJWn.jpg[/img]](https://i.imgur.com/z2RoJWn.jpg) (http://[img width=770 height=433)

I then machined two adaptors that will eventually be plug and joint welded.
https://i.imgur.com/n55YEYK.jpg[/img]](https://i.imgur.com/n55YEYK.jpg) (http://[img width=770 height=433)

The tubes will now  be rotated 45o forward and will meet up with the new seat loop. The top shock mounts will now be in line with the seat loop in the conventional manner.
Title: Re: CB450 Tracker
Post by: Pete12 on Feb 13, 2018, 04:54:24
My new Bridgestone 350 fuel tap arrived today. The quality looks good and it operates nice and smoothly so it should be good
https://i.imgur.com/OZLPrRp.jpg[/img]](https://i.imgur.com/OZLPrRp.jpg) (http://[img width=770 height=433)

I got this one because, after narrowing the tank, I have fairly limited room available. This one is good because it's fairly squat and both the discharge pipes are in the horizontal plane which will make it easy to thread the fuel lines.
https://i.imgur.com/xUNBHki.jpg[/img]](https://i.imgur.com/xUNBHki.jpg) (http://[img width=770 height=433)

The mounting thread is M22 x 1.0 so I had to machine and thread a new stub for the tank. I'll braze this in at the same time I do the filler bung and then I can go ahead and finish the tank tunnel.
https://i.imgur.com/FIMnnrh.jpg[/img]](https://i.imgur.com/FIMnnrh.jpg) (http://[img width=770 height=433)

https://i.imgur.com/jLp2prj.jpg[/img]](https://i.imgur.com/jLp2prj.jpg) (http://[img width=770 height=433)

Title: Re: CB450 Tracker
Post by: Pete12 on Feb 15, 2018, 03:54:58
Brazed in the tank filler neck and filled the holes for the tap and balance pipes. The tap will go back in the same place but with a bigger stub and I've relocated the balance pipes to the front of the tank. This is all a result of narrowing the tank but it should all work out fine. The tank sits level so the balance pipes at the front won't have any adverse affect at all.
https://i.imgur.com/Qhc9T9I.jpg[/img]](https://i.imgur.com/Qhc9T9I.jpg) (http://[img width=770 height=433)
https://i.imgur.com/totchQX.jpg[/img]](https://i.imgur.com/totchQX.jpg) (http://[img width=770 height=433)

I made the tunnel and tacked it into position and will finish welding it tomorrow. It will be interesting to see how much fuel it now holds. Standard is around 4.5 US gallons, if I end up with three I think it will be OK. I still have to make a couple of patch panels, but once that's done I can mount it up.
(The tunnel is in the centre, it's just the photo angle that makes it look like it's not)
Title: Re: CB450 Tracker
Post by: teazer on Feb 15, 2018, 10:56:50
My experience is with Kona, which are excellent shocks I have on my R100/7.  Kona is now Ikon. 

Perfect for a cafe racer......   :-)


I suspect autocorrect changed Koni into Kona .
Title: Re: CB450 Tracker
Post by: irk miller on Feb 15, 2018, 14:40:17
Perfect for a cafe racer......   :-)


I suspect autocorrect changed Koni into Kona .
Hahaha.  I didn't even notice that. 
Title: Re: CB450 Tracker
Post by: Pete12 on Feb 16, 2018, 04:51:50
Got the tunnel and all the patch panels welded in today, also tacked the front mounts in place. Still need to weld in the fuel tap spigot and the balance pipes, but I've run out of Argon so that will have to wait until next week.
https://i.imgur.com/8UTHwft.jpg[/img]](https://i.imgur.com/8UTHwft.jpg) (http://[img width=770 height=433)

It's pretty much sitting where I want it so the next thing is make the rear loop and then the seat mounts. When that's finished I can make the rear tank mount, which I will use in conjunction with a standard old Yamaha DT/MX rubber grommet. I will need to make a master list of all the different bits and pieces I have used to facilitate replacement in the future, should the need arise.
Title: Re: CB450 Tracker
Post by: Pete12 on Mar 27, 2018, 01:33:27
Back home from work again and finally finished the rear loop. I have to make up the rear taillight mounts, the rear blinker mounts and the shock mounts and it will all be good. I then need to manufacture the battery box and mount it in place and then get on with the main footrests.

https://i.imgur.com/J5jA0Uy.jpg[/img]](https://i.imgur.com/J5jA0Uy.jpg) (http://[img width=770 height=433)

Title: Re: CB450 Tracker
Post by: paddyshepherd on Apr 02, 2018, 08:33:47
Have to say this is a fantastic looking build. If I had half the skills (and equipment for that matter!) that you have I'd be a very happy bloke.
Keep at it.
Title: Re: CB450 Tracker
Post by: Pete12 on Apr 02, 2018, 20:29:13
Thanks Paddy.
Unfortunately I work overseas, which is why it takes so long, but looking forward to getting it finished and on the road.
Title: Re: CB450 Tracker
Post by: Pete12 on Apr 03, 2018, 06:25:46
Whoo-hoo, got my Kona (Koni, haha) shocks today, and they look great. Going away for work but they'll be waiting for when I get back...
Title: Re: CB450 Tracker
Post by: irk miller on Apr 03, 2018, 09:00:32
Whoo-hoo, got my Kona (Koni, haha) shocks today, and they look great. Going away for work but they'll be waiting for when I get back...
Haha.  I'm drinking some right now.
Title: Re: CB450 Tracker
Post by: Pete12 on Apr 26, 2018, 05:19:54
Made the top shock mounts today. Tomorrow I can do the bottom mounts and check out the ride height - I think it will be OK but it's always good to check first. Everything is just tacked together at the moment, when everything is all good I can weld it all together.
https://i.imgur.com/NZhwsj5.jpg[/img]](https://i.imgur.com/NZhwsj5.jpg) (http://[img width=770 height=433)
https://i.imgur.com/jQhnJRC.jpg[/img]](https://i.imgur.com/jQhnJRC.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: Pete12 on Apr 27, 2018, 05:59:41
The digital speedo has a pickup so I made a new front brake bracket and incorporated it into it so it doesn't look like an add-on. I'll mount the magnetic sensor on the hub and it should work fine.
Tomorrow I'll hopefully get the lower rear shock mounts made and installed.
https://i.imgur.com/jmkqnwN.jpg[/img]](https://i.imgur.com/jmkqnwN.jpg) (http://[img width=770 height=433)
https://i.imgur.com/VivyCvA.jpg[/img]](https://i.imgur.com/VivyCvA.jpg) (http://[img width=770 height=433)
https://i.imgur.com/d5fVMhZ.jpg[/img]](https://i.imgur.com/d5fVMhZ.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: Pete12 on Apr 28, 2018, 21:18:28
Made the lower shock mounts today. I fabricated them from two pieces and then welded them together. I made up a nut, sleeved it down to fit and then welded it into place.
https://i.imgur.com/kNsTr6p.jpg[/img]](https://i.imgur.com/kNsTr6p.jpg) (http://[img width=770 height=433)
https://i.imgur.com/CTbUi3O.jpg[/img]](https://i.imgur.com/CTbUi3O.jpg) (http://[img width=770 height=433)

I set the shock angle the same as the rear engine downtube. Those Ikon shocks sure look the goods and are fully adjustable, money well spent there.
https://i.imgur.com/h38rXCQ.jpg[/img]](https://i.imgur.com/h38rXCQ.jpg) (http://[img width=770 height=433)

The next thing to do is the footrests and side stand, which will be a bit tricky but hopefully will turn out OK.
Title: Re: CB450 Tracker
Post by: SONIC. on Apr 28, 2018, 22:17:25
Love it.
Especially the brake caliper mount with the speed sensor mount built in, well done.

I finally got my cnc mill up and running so hopefully whenever I get back to playing with bikes I'll put it to as good a use as you have for this build!
Title: Re: CB450 Tracker
Post by: Pete12 on Apr 29, 2018, 06:13:53
Thanks very much Sonic.
I'm sure you'll turn out some great gear with your CNC mill. I just draw up my pieces full scale in AutoCAD and then do a "list" for all the co-ordinates and program these into the mill. I'm sure that there are easier ways, but I haven't learnt them yet!!
Good luck with yours...
Title: Re: CB450 Tracker
Post by: Pete12 on May 02, 2018, 04:41:23
I got the footrest mounts made today, I had to make the right hand side twice as my measurements were a little bit out on the brake pedal pivot point. Anyway, all good now, tomorrow I can make the brake pedal and fit up the sidestand. Friday I have to go O/S for work for two weeks so nothing will happen until I get home. It's getting closer now, but I have to have it finished for the Distinguished Gentlemen's Ride in September, so I need to get cracking...
https://i.imgur.com/cuQipIQ.jpg[/img]](https://i.imgur.com/cuQipIQ.jpg) (http://[img width=770 height=433)
https://i.imgur.com/eqPjGTJ.jpg[/img]](https://i.imgur.com/eqPjGTJ.jpg) (http://[img width=770 height=433)
https://i.imgur.com/Xqa8tHz.jpg[/img]](https://i.imgur.com/Xqa8tHz.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: Pete12 on May 18, 2018, 23:38:00
Just got back from overseas this morning and opened a couple of parcels that were waiting for me. The first one is a new R6 front disc and YZ250 rear disc,
https://i.imgur.com/x2h8IQL.jpg[/img]](https://i.imgur.com/x2h8IQL.jpg) (http://[img width=770 height=433)


The next one was a set of manual chokes for the Mikuni carbs that I can operate with a hot start lever (thanks Irk),
https://i.imgur.com/Xh4qpfA.jpg[/img]](https://i.imgur.com/Xh4qpfA.jpg) (http://[img width=770 height=433)

I have a bunch of NOS cables that I got from a shop a while ago and there are a heap of Yamaha accelerator cables in there, so I just need to hit the pushbike shop and get some black cable and I can make up the choke actuator assembly.
Title: Re: CB450 Tracker
Post by: Pete12 on May 22, 2018, 05:58:05
Made up the rear brake pedal today. I set it up the same length as my Rotax, and it feels good. Tomorrow I will get some new bolts and assemble both footrests, so I can then set up the sidestand. I'm almost at the point of finishing the mock-up, once that's all done I can pull it down and weld it all together then start painting and assembly. This bike should go OK when it's finished as it will be a lot lighter than it was originally as I've made all this gear out of aluminium. I will have a heap of polishing to do, might get my brother onto that little job lol.
https://i.imgur.com/SQHu9i5.jpg[/img]](https://i.imgur.com/SQHu9i5.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: Pete12 on May 23, 2018, 05:01:08
Today I got the sidestand mounted up to the LHS footrest bracket. It was around 20mm too short so I added a piece in and it's good now. I purchased some new lower engine mounting bolts from the fastener shop which fit well, but just need to be cut down to length. Tomorrow I'll get the rear tank mount made up and hopefully the seat mounts as well.
https://i.imgur.com/xHKRtV2.jpg[/img]](https://i.imgur.com/xHKRtV2.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: Pete12 on May 25, 2018, 06:25:02
I didn't do much in the shed today but managed to make up an actuator for the choke which fits on top of the clutch lever. I made an adaptor to go in the old mirror mount and then used a threaded rod joiner to extend the pivot pin, which seems to work fine. I used this type of clutch lever as the switch block needs to fit underneath it and it only has a single clamp bolt at the back. I still need to fit up the cable but that will have to wait as I have to go away again for a couple of weeks.
https://i.imgur.com/pWeyOzm.jpg[/img]](https://i.imgur.com/pWeyOzm.jpg) (http://[img width=770 height=433)
https://i.imgur.com/iWhqPff.jpg[/img]](https://i.imgur.com/iWhqPff.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: doc_rot on May 25, 2018, 06:58:28
Just caught up with your project. Its looking great. I know how much time all those custom parts take. 
Title: Re: CB450 Tracker
Post by: Pete12 on May 25, 2018, 08:53:04
Thanks doc, yes they sure do. Only a few trinkets left now though...
Title: Re: CB450 Tracker
Post by: Pete12 on Jun 18, 2018, 05:35:35
Today I finished the swingarm. I added the front stiffener, the chain guard brackets and the shock mounts. I also made up some new bushes out of nolathane and fitted them up. They are much bigger diameter than the original Honda bushes, which were a very poor design, IMO.
https://i.imgur.com/OksJ34l.jpg[/img]](https://i.imgur.com/OksJ34l.jpg) (http://[img width=770 height=433)

Next I need to make up the rear taillight mount and battery box mounts and weld them both into place. Once that is finished the whole bike can be pulled apart and all the frame mods can be finish welded.
Title: Re: CB450 Tracker
Post by: LiamG6 on Jun 18, 2018, 06:46:20
coming along nicely. lots of nice machined bits and custom fab'd stuff!

If you were real keen you could machine up a custom oil filter cover and put a external oil line on it directly to the cam journals, like the one from cappellini, but keep the stock oil transfer piece etc

similar to this but without the paper filter conversion https://www.ebay.com/itm/1965-74-Honda-CB-450-500T-Cappellini-04-oil-filter-for-original-pump-O-H-line-/160782225633



Title: Re: CB450 Tracker
Post by: Pete12 on Jun 18, 2018, 08:36:16
That's a good idea Liam, I'll look at that when I pull the motor down.
Title: Re: CB450 Tracker
Post by: Pete12 on Jun 21, 2018, 04:22:15
I pulled the bike apart today, ready to finish all the welding. While I was at it I sprayed the front disc adaptor flat black and then bolted it all together with the new disc. I also drilled and tapped a hole for the magnetic sensor for the speedo drive and fitted that up (you can see it in the photo at about the quarter to nine position, just below the disc mounting bolt)
https://i.imgur.com/JaccCIn.jpg[/img]](https://i.imgur.com/JaccCIn.jpg) (http://[img width=770 height=433)

I put it together to test the speedo pickup and it changes state when the magnet goes past, so all good there.
Title: Re: CB450 Tracker
Post by: dakine_surf on Jun 25, 2018, 18:09:06
Man this is seriously one of my favorite builds on here.  Everything is just awesome and inspiring
Title: Re: CB450 Tracker
Post by: Pete12 on Jun 26, 2018, 09:00:12
Thanks for the kind words, much appreciated.
Title: Re: CB450 Tracker
Post by: Pete12 on Jun 28, 2018, 02:04:08
I finally got the front mudguard mounted up. I know that trackers look better without one, but there is no chance of getting the bike registered in NSW without having one in place. I could take it off once it's registered but then the local law will have a field day, and we don't want that...

https://i.imgur.com/GTgYpJE.jpg[/img]](https://i.imgur.com/GTgYpJE.jpg) (http://[img width=770 height=433)

https://i.imgur.com/XVuNwPB.jpg[/img]](https://i.imgur.com/XVuNwPB.jpg) (http://[img width=770 height=433)

I initially made the clamps out of some plates that went around the forks but it just didn't look right, so I had a length of 1/2" S/S instrument tube and built them from that. It was quite fiddly but I machined a little jig to flatten the ends once I had bent the tube and it all turned out OK. I tig welded the tube onto some S/S pipe that I had already machined and threaded, and they all fitted up onto the existing brackets that are on the forks. I still need to cut all the unused brackets from the rhs fork leg, but I'll do that later.
Title: Re: CB450 Tracker
Post by: LiamG6 on Jun 28, 2018, 22:27:38
fender looks really nice. did you make the fender yourself? it's a good fit, very neat. I have similar front fender mounts from tube and round bar but I bolted them from the top of fender.
Title: Re: CB450 Tracker
Post by: Pete12 on Jun 29, 2018, 07:44:59
Thanks mate, yes, made it on the Chinese Wheel, haha. I was going to have the brackets on the top but I am going to make a sticker of the tyre pattern to go on the guard and want it to be clear.
Title: Re: CB450 Tracker
Post by: LiamG6 on Jun 29, 2018, 21:09:27
Haha I'll have to get one of those Chinese wheels, they still do the job! That sounds cool, should make the fender disappear even more.
Title: Re: CB450 Tracker
Post by: Pete12 on Jun 29, 2018, 22:35:32
I bought my wheel from Hafco. It's OK, but still flexes, unlike a cast iron one. Be nice to have one, if they weren't so rare and expensive.
Title: Re: CB450 Tracker
Post by: Pete12 on Jul 19, 2018, 05:03:32
I made up a new rear brake pedal today, as I wasn't that happy with the previous one. This one is a one piece design and has the pivot pin tacked into the pedal frame which is much better. Tomorrow I will make up new front guard brackets and then I will post the two different types and see what you guys think.

https://i.imgur.com/Q4xN1BU.jpg[/img]](https://i.imgur.com/Q4xN1BU.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: Pete12 on Jul 20, 2018, 05:21:07
I made up the new front guard mounts today, and I think it looks OK, but very happy to listen to anyone's thoughts on this. If I go with the new one I'll cut all the mounts off, so I need to be sure, to be sure.
This is the old mount:
https://i.imgur.com/XVuNwPB.jpg[/img]](https://i.imgur.com/XVuNwPB.jpg) (http://[img width=770 height=433)
and this is the new:
Title: Re: CB450 Tracker
Post by: XS750AU on Jul 20, 2018, 07:28:30
Love the new brake lever.
Not so sure about the front fender!
The old mount looks more elegant and lighter. But the new looks like a functional fork brace.
Prefer elegance in this case, but it would help to see the whole "Bike" to give it context.
Title: Re: CB450 Tracker
Post by: Pete12 on Jul 20, 2018, 07:54:41
Thanks Tim. The new one isn't a fork brace as it just has four little lugs welded in place to mount the guard to. Unfortunately the bike is all in pieces now, waiting for reassembly, so it's not possible to see it all together. I do agree about the lightness though...
Title: Re: CB450 Tracker
Post by: Popeye SXM on Jul 20, 2018, 09:15:51
Quote
Love the new brake lever.
Not so sure about the front fender!
The old mount looks more elegant and lighter.
+1
Great build, thanks for posting
Title: Re: CB450 Tracker
Post by: irk miller on Jul 20, 2018, 10:27:34
Have you considered a mount similar to the first, where the tubes go over the fender with tabs that mount to the existing holes in the fender?

Like this:

(http://flatracer.com/communities/5/004/006/325/795/images/4551672438.jpg)
Title: Re: CB450 Tracker
Post by: Pete12 on Jul 20, 2018, 10:32:39
+1
Great build, thanks for posting
Thanks Popeye.
Title: Re: CB450 Tracker
Post by: Pete12 on Jul 20, 2018, 10:38:44
Have you considered a mount similar to the first, where the tubes go over the fender with tabs that mount to the existing holes in the fender?

I had considered that mount Irk, but I'm trying to keep to whole guard as unobtrusive as possible, even to the point of making a sticker with the front tyre pattern on it. I would really like to run it without the guard, a la flat track, but the local law just won't allow it... boo, hiss.
Title: Re: CB450 Tracker
Post by: irk miller on Jul 20, 2018, 10:45:46
Stupid laws.  Despite the overly conservative politics in Georgia, we're lucky to have lenient (even non-existent) restrictions on autos.  So, with that explanation, I like the first mount better.
Title: Re: CB450 Tracker
Post by: dakine_surf on Jul 20, 2018, 18:05:43
If you absolutely need a front fender, then the first one looks to be the ticket.

The seconds one without the fender would look the most "Tracker" but with the fender, it looks less finished.
Title: Re: CB450 Tracker
Post by: Pete12 on Jul 20, 2018, 19:14:59
OK, four out of four liked the first front guard, so that's the way I'll go. The second mounts can go in with the pile of bits that I have made and not using  ;D
Thank you all for the feedback, much appreciated.
Title: Re: CB450 Tracker
Post by: LiamG6 on Jul 21, 2018, 04:08:32
I prefer the ones you milled :P but that's just because I like machined stuff. That brake lever is very nicely done too, that mill setup you have is very capable!

If you put up a different angle photo of the milled one that would help I think. Much sleeker side on.
Title: Re: CB450 Tracker
Post by: Pete12 on Jul 21, 2018, 05:05:07
Hmm. now a different thought. I'll put up some more photos with some different angles, but now I'm leaning towards the first one, so we'll wait and see.
The mill I have is good, but the rear brake pedal still required a lot of manual input. Also, I had to make up some soft sleeves so I could bend the offset in my press, but it all worked out OK.
My brother came over today and started sanding all the aluminium back and I started buffing it. We assembled the right hand footrest and it looks pretty good. Onward and upward from here haha...
https://i.imgur.com/CEgvDX5.jpg[/img]](https://i.imgur.com/CEgvDX5.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: NoRiders on Jul 21, 2018, 05:30:50
That looks trick  :) ....will it have a return spring?
Title: Re: CB450 Tracker
Post by: doc_rot on Jul 21, 2018, 06:03:38
since you have to have a fender why not make a real force brace and mount the fender to that?
Title: Re: CB450 Tracker
Post by: Pete12 on Jul 21, 2018, 09:51:47
That looks trick  :) ....will it have a return spring?

It's got a spring inside the master cylinder, so it doesn't seem to need one, which is good.
Title: Re: CB450 Tracker
Post by: Pete12 on Jul 21, 2018, 09:54:40
since you have to have a fender why not make a real force brace and mount the fender to that?

I will have a look at that, but the wheel sits very high in the forks and it would be quite difficult, but not out of the question.
Title: Re: CB450 Tracker
Post by: Pete12 on Jul 22, 2018, 04:26:07
Spent the day today with my brother, he sanded, I buffed. The bottom triple tree is finished, just not in the picture. All looks OK, we'll start rebuilding the motor next.
Title: Re: CB450 Tracker
Post by: WoodsCustoms on Jul 26, 2018, 21:46:52
Wow, nice work really glad I logged in to find this thread.


Sent from my iPhone using DO THE TON
Title: Re: CB450 Tracker
Post by: NoRiders on Jul 27, 2018, 14:34:27
FWIW I prefer the old guard mounts, but think the guard could be a little squared off on the leading edge a bit, not so much lozenge shaped.
Title: Re: CB450 Tracker
Post by: Pete12 on Jul 28, 2018, 18:39:52
Wow, nice work really glad I logged in to find this thread.
Thanks very much, glad you like it.
FWIW I prefer the old guard mounts, but think the guard could be a little squared off on the leading edge a bit, not so much lozenge shaped.
I'm going to assemble it with both setups, take some photos and we'll go from there. I don't think you'll notice the shape once the sticker is in place...
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 04, 2018, 02:07:56
I broke out the Chinese Wheel and made up an inner rear guard. I'll mount some tabs on the frame for it to fit up to, making sure that I have clearance for the chain. I set the frame up with the wheel right forward and the shocks in the fully compressed position so I know there'll be clearance.
https://i.imgur.com/BKaqB7i.jpg[/img]](https://i.imgur.com/BKaqB7i.jpg) (http://[img width=770 height=433)
I also made up a battery box for the Motobatt AGM battery that I am going to use. I would have liked to have used a Lithium battery but I understand that they are extremely sensitive to charging voltage levels. I am going to mount the battery box on the inner rear guard and I will make up a small box for the solenoid and fuse panel that will go up under the seat.
https://i.imgur.com/3w4OY3S.jpg[/img]](https://i.imgur.com/3w4OY3S.jpg) (http://[img width=770 height=433)
https://i.imgur.com/TlxcYgI.jpg[/img]](https://i.imgur.com/TlxcYgI.jpg) (http://[img width=770 height=433)
The frame is nearly finished, just need to add the seat mounts, inner rear guard mounts and solenoid tray mounts and it will be ready for painting.
Title: Re: CB450 Tracker
Post by: Ethan on Aug 04, 2018, 22:54:03
Dang dude, nice work!  Excellent fab skills. I wish I could pull off work like that!  Canít wait to see the finished project.

P.S. - If you need a home for the extra sprocket cover, let me know. I can give it a good home.


Sent from my iPhone
í68 Honda CL450 (https://www.caferacer.net/#/topics/39425)
Title: Re: CB450 Tracker
Post by: crazypj on Aug 05, 2018, 02:04:59
OK, four out of four liked the first front guard, so that's the way I'll go. The second mounts can go in with the pile of bits that I have made and not using  ;D
Thank you all for the feedback, much appreciated.
I prefer the first one as well, second would be fine if it was a fork brace but as mount it looks too bulky. painting it satin black will pretty much make it dissapear when riding and may actually look better than tyre print idea? Read through most of thread this morning, for sprocket, I have used old sprocket with teeth ground off, new sprocket and old output shaft,(to keep things in line) weld one to the other then machine out centre of new one, weld around inside and you have an offset sprocket. First one I did (long time ago) I used old parts as it was an experiment but since then I've done several using old inners and new outers. If shipping aint too crazy I think you could sell the points cover conversions you made (unless you want to be exclusive on that one?)
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 05, 2018, 20:07:59
Dang dude, nice work!  Excellent fab skills. I wish I could pull off work like that!  Canít wait to see the finished project.

P.S. - If you need a home for the extra sprocket cover, let me know. I can give it a good home.
Thanks very much Ethan. The sprocket cover is yours if you want to pay postage from Australia... send me a PM if you're interested.

I prefer the first one as well, second would be fine if it was a fork brace but as mount it looks too ?bulky. painting it satin black will pretty much make it dissapear when riding and may actually look better than tyre print idea? Read through most of thread this morning, for sprocket, I have used old sprocket with teeth ground off, new sprocket and old output shaft,(to keep things in line) weld one to the other then machine out centre of new one, weld around inside and you have an offset sprocket. First one I did (long time ago) I used old parts as it was an experiment but since then I've done several using old inners and new outers. If shipping aint too crazy I think you could sell the points cover conversions you made (unless you want to be exclusive on that one?)
Thanks PJ, yes I thought it was a bit bulky as well. My daughter has already started on the sticker and it looks really good, so I'll post it up and we'll have a look.
The sprocket has been sorted, I actually found one from an NSR250R that is perfect (http://www.dotheton.com/forum/index.php?topic=75785.0). Making one as you have suggested is a great idea, I'll keep that in mind for the future.
I have no exclusivity on the points covers, just didn't think anyone would want them.
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 10, 2018, 06:48:51
Made up a bracket for the front of the battery box, which will sit between the two air filters.
https://i.imgur.com/oGX3wLP.jpg[/img]](https://i.imgur.com/oGX3wLP.jpg) (http://[img width=770 height=433)
https://i.imgur.com/23QtChg.jpg[/img]](https://i.imgur.com/23QtChg.jpg) (http://[img width=770 height=433)
It's a shame that I can't hide it, but there's just not enough room. I welded on the retaining brackets for the front of the box and the regulator/rectifier, which goes underneath. I still have to find a spot for the starter solenoid, not too sure where to put that...
https://i.imgur.com/BzaFbJx.jpg[/img]](https://i.imgur.com/BzaFbJx.jpg) (http://[img width=770 height=433)
I then welded the bracket onto the frame at the front. The rear bracket will be an aluminium plate that bolts up to the inner guard, but as the head is only sitting there loosely I'll leave that until the engine is back in the frame. Next project is to paint the frame and start assembly - getting close now.
Title: Re: CB450 Tracker
Post by: LiamG6 on Aug 11, 2018, 05:30:24
Tidy work as always mate. Really got to get myself a house with a shed so I can tinker and make all the stuff I want to, I can only plan stuff these days and get a fabricator to make it or wait till I can get a shed and some tools.
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 12, 2018, 05:00:05
Thanks Liam, yes mate, you need to get a good shed with a house attached...

Today I cut off the lugs from the right hand side fork leg and cleaned it up. They both need stripping and then rubbing back and polished, but I think I'll leave that up to my brother, as he really likes doing that sort of work ???
https://i.imgur.com/wnhEkJ9.jpg[/img]](https://i.imgur.com/wnhEkJ9.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: crazypj on Aug 12, 2018, 15:15:13
Don't ever fit fork sliders in a vice like that, it's way too easy to distort them. Hold by the 'solid' axle end and clamp a block (2x4 or something) to bench to hold level. You may know what your doing but a lot of people may see this and just crank away (after all, look how many people fitted Firestones because they saw it on-line  ;) )
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 13, 2018, 05:02:57
Don't ever fit fork sliders in a vice like that, it's way too easy to distort them. Hold by the 'solid' axle end and clamp a block (2x4 or something) to bench to hold level. You may know what your doing but a lot of people may see this and just crank away (after all, look how many people fitted Firestones because they saw it on-line  ;) )
I appreciate your concern, but the sliders don't have tubes in them and they are clamped in the centre, so the only load on them is the weight of the vice handle, so no issue whatsoever. If people are silly enough to see that and then go ahead and clamp them up tight enough to distort, well more fool them. And what's wrong with Firestones anyway?  ;D ;D
Title: Re: CB450 Tracker
Post by: crazypj on Aug 13, 2018, 12:31:28
. And what's wrong with Firestones anyway?  ;D ;D

Absolutely nothing wrong with them- if your riding a 1940's motorcycle ;)
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 14, 2018, 06:24:43
Finally got the frame all finished with lugs in place for the seat, tank, inner rear guard, tail light, rear shocks, battery box and rear footrests. I think I'll get it sand blasted rather than rub it all back, but I'll decide on that tomorrow.
https://i.imgur.com/tRdZzD5.jpg[/img]](https://i.imgur.com/tRdZzD5.jpg) (http://[img width=770 height=433)
I also got out the powdercoater and did the sidestand and the top engine mounts. I also did the original toolbox, as it was in really good shape and will look good on the bike. I'm quite happy with the results.
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 18, 2018, 06:21:02
My brother came over today and started cleaning up the forks, ready for polishing. What a job, they were quite a mess under the paint, full of sanding marks and scratches. He still has a bit more to go but it's starting to look good. While he was doing that I powdercoated the alternator inner and outer covers, after doing a repair to the inner. It had a broken screw hole at the bottom which I welded up and machined first - damn Japanese aluminium, took a while to get it right...
We are doing the sidecovers in satin black, with polished external covers, and the main cases will be flat black, which we think will look good.
https://i.imgur.com/BeE6kM7.jpg[/img]](https://i.imgur.com/BeE6kM7.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: LiamG6 on Aug 18, 2018, 21:38:18
That looks sweet, I reckon you could sell a fair bit of this machined stuff if you wanted to. There is a CB450DOHC facebook group that you could join and I dare say a decent number of members would be interested. Fair few of them in OZ too, but mostly US and EU. Even if you kept your's unique and just offered some other custom bits that would be great.
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 19, 2018, 08:14:08
Thanks Liam, I'll have a look at that facebook page, although I'm a little busy at the moment, but definitely something to consider.

Well my poor brother spent most of yesterday and today sanding back the forklegs for his bike. It was a hard job, particularly around the brackets, but well worth it in the end. Tomorrow I get the frame back from the paint stripper so I'll give that a coat of paint over the next few days. Very windy here at the moment, so I'll have to wait for a good day.
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 23, 2018, 04:55:05
Finished off the fork legs with new seals, fresh oil and reassembly, one job out of the way...
https://i.imgur.com/J3g7wCg.jpg[/img]](https://i.imgur.com/J3g7wCg.jpg) (http://[img width=770 height=433)
I finished powder coating the outer engine covers. I still need to tear the inners apart and paint them, but that will be a bit later.
https://i.imgur.com/dE85HC9.jpg[/img]](https://i.imgur.com/dE85HC9.jpg) (http://[img width=770 height=433)

I also made up some new handlebar levers, as I didn't have a matched set previously. I know that they are only a few bucks to buy, but these are matching and made from T5 6061, so they will be plenty strong enough. The next project is painting the frame. I got a quick coat of primer on it when I picked it up from the stripper, but now it needs the full treatment.

Title: Re: CB450 Tracker
Post by: advCo on Aug 23, 2018, 09:20:31
Looking great Pete. Those levers are really trick.
Title: Re: CB450 Tracker
Post by: crazypj on Aug 23, 2018, 10:46:05
Really like the 6061 levers, not only stronger than stock but won't break when bike is dropped plus easy to re-straighten.If cost isn't too high I'll bet there's a market for them with vintage racers (and others?)
Title: Re: CB450 Tracker
Post by: MiniatureNinja on Aug 23, 2018, 23:08:47
yea those levers are sexy AF
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 24, 2018, 08:27:29
Thanks guys, much appreciated. Not too sure there'd be a market there considering they took me a day to make each one...
Title: Re: CB450 Tracker
Post by: crazypj on Aug 24, 2018, 13:04:07
Yeah, that definitely keeps them in the 'one off' range   ;D
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 24, 2018, 21:58:46
Very true, I think that $400 each may be a little excessive...
Title: Re: CB450 Tracker
Post by: crazypj on Aug 25, 2018, 14:45:07
LOL, know the feeling. Building a $20,000 CB360 ain't smart but is fun
Title: Re: CB450 Tracker
Post by: doc_rot on Aug 25, 2018, 21:45:23
Really like the 6061 levers, not only stronger than stock but won't break when bike is dropped plus easy to re-straighten.If cost isn't too high I'll bet there's a market for them with vintage racers (and others?)

arent many levers designed to break so that the lever is sacraficed instead of damaging the master cylinder? All Brembos i have seen have a small recess to make sure they snap there, unless they are the folding type of course
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 29, 2018, 07:32:19
Dead right doc. I usually leave my clamps just a tad loose so that the whole lot moves if it hits the ground, always works for me.

Got the first coats of primer on my frame and swing arm. I just need to rub it back completely and then put some colour on - frame black, swing arm silver.
https://i.imgur.com/kjQ9zwk.jpg[/img]](https://i.imgur.com/kjQ9zwk.jpg) (http://[img width=770 height=433)
https://i.imgur.com/Z34r9MZ.jpg[/img]](https://i.imgur.com/Z34r9MZ.jpg) (http://[img width=770 height=433)

In between coats I finished off the clutch lever assembly. I powdercoated the housing and made up an adjuster for the clutch cable. I still need to make up an adjuster for the choke cable which I'll do tomorrow.
Title: Re: CB450 Tracker
Post by: Pete12 on Aug 31, 2018, 07:51:34
Couldn't do any painting today as the weather is miserable, so I made a new arm for the choke lever and an adjuster similar to the clutch cable one. The other arm had the cable coming out at a different angle to the clutch cable and didn't look that good. Next time I'll make the clutch lever before the choke lever and get it right the first time....
Title: Re: CB450 Tracker
Post by: Sderbyshire on Aug 31, 2018, 11:59:07
Beautiful work !
Title: Re: CB450 Tracker
Post by: advCo on Aug 31, 2018, 12:13:26
That 5 point adjuster is slick.
Title: Re: CB450 Tracker
Post by: Pete12 on Sep 01, 2018, 05:24:38
Thanks guys.
I was watching the Polish round of the Speedway Grand Prix last weekend and that's the adjusters they use - good enough for them, good enough for me.
Title: Re: CB450 Tracker
Post by: Pete12 on Sep 10, 2018, 05:09:41
The weather has been miserable here lately, up until today which was quite good. Unfortunately I have to go to Vietnam tomorrow for a month, so the painting will have to wait until I come back. I did, however, get to make up a couple of new inlet manifolds. The ones that came with the kit are OK, but they are universal types and don't fit very well at all, so I milled two flanges that go on the cylinder heads.
https://i.imgur.com/HcybXZ0.jpg[/img]](https://i.imgur.com/HcybXZ0.jpg) (http://[img width=770 height=433)

I then machined up the two manifolds in my lathe and pressed them into the flanges.
https://i.imgur.com/ru8VoEG.jpg[/img]](https://i.imgur.com/ru8VoEG.jpg) (http://[img width=770 height=433)
https://i.imgur.com/kJsBbat.jpg[/img]](https://i.imgur.com/kJsBbat.jpg) (http://[img width=770 height=433)
https://i.imgur.com/tTPNIHW.jpg[/img]](https://i.imgur.com/tTPNIHW.jpg) (http://[img width=770 height=433)

I then welded them on the backside where the taper is.
https://i.imgur.com/sFQUvbJ.jpg[/img]](https://i.imgur.com/sFQUvbJ.jpg) (http://[img width=770 height=433)

and then machined them flat.
https://i.imgur.com/In5NZdd.jpg[/img]](https://i.imgur.com/In5NZdd.jpg) (http://[img width=770 height=433)

Once the engine is in the frame I can select a spot to drill and tap a hole in each one so that I can fit up two small spigots to attach the vacuum gauges for synchronising the carbs.

Title: Re: CB450 Tracker
Post by: stroker crazy on Sep 10, 2018, 06:02:40
... so I milled two flanges that go on the cylinder heads ...

Very tidy!
Title: Re: CB450 Tracker
Post by: Pete12 on Sep 12, 2018, 00:15:14
Very tidy!

Thanks very much, that's about all I have to make for it now. I will still need to make the battery box rear bracket but that has to wait for assembly time.
I bought a pair of Wiseco high comp pistons so I'll need to get the cylinder bored and then I can reassemble the motor and start putting the whole thing back together. Unfortunately this is all in limbo until I get back home  :( :(
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 26, 2018, 05:01:58
Finally back from Vietnam, so I made a seat base which I will take back there next week and get it covered. There are some really good upholsterers over there, and it will cost next to nothing, so it's worth a try. Tomorrow I will make up a little shroud to fit over the rear tank mount and then I can make up the sponge.

https://i.imgur.com/ODQYb4q.jpg[/img]](https://i.imgur.com/ODQYb4q.jpg) (http://[img width=770 height=433)
Title: Re: CB450 Tracker
Post by: NoRiders on Nov 26, 2018, 19:54:12
That seat will look smart when done.

I added a small flap to the front edge of the seat to cover the gap between it and the tank.

Just an idea...

(https://i.imgur.com/mdMbAsM.jpg)
Title: Re: CB450 Tracker
Post by: Pete12 on Nov 27, 2018, 06:24:27
Thanks, that's a good idea. I plan on running my seat up against the back of the tank, the photos just don't show it that way, so hopefully it works out OK.
By the way, that's a very nice bike you built.
Title: Re: CB450 Tracker
Post by: NoRiders on Nov 30, 2018, 18:12:08
Thanks, that's a good idea. I plan on running my seat up against the back of the tank, the photos just don't show it that way, so hopefully it works out OK.
By the way, that's a very nice bike you built.

Thank you.

I see a lot of nice bikes with a crap seat to tank gap, that was my attempt at fixing it :)
Title: Re: CB450 Tracker
Post by: Pete12 on Dec 03, 2018, 12:46:52
My brother picked up a yoga mat for me and I cut it up roughly with the scissors and glued three pieces together and, when it set, glued it onto the seat base. I then used an electric knife to cut it to shape, but that wasn't very successful, particularly trimming it to size. I tried an orbital sander with 80 free cut, which I had used on other seats before, but that didn't work either. I then tried my belt sander and it worked well, so I finished it off with that and it came up quite good.

https://i.imgur.com/sBhZ3Xe.jpg[/img]](https://i.imgur.com/sBhZ3Xe.jpg) (http://[img width=770 height=433)

The seat base has been extended slightly on the edges by my brother and I have sanded it so it matches the rear of the tank and looks like it's supposed to be there. I don't have a picture of that with me and as I am away I'll post it when I get home. He has a really nice girlfriend so I need to do a good job on it as she will be on the back most of the time.
I have the seat with me over here so I can now look around for a good motor trimmer to cover it.
Title: Re: CB450 Tracker
Post by: NoRiders on Dec 03, 2018, 16:55:53
That looks to be thick yoga mat....8mm?

I'll be doing the same :) but my girlfriend won't be throwing a leg over it...so she tells me :)
Title: Re: CB450 Tracker
Post by: Pete12 on Dec 04, 2018, 08:10:17
That looks to be thick yoga mat....8mm?

I'll be doing the same :) but my girlfriend won't be throwing a leg over it...so she tells me :)

It's around 10 or maybe 12mm mat, quite thick but the height seems OK.

Your girlfriend won't get on your bike - perhaps you need to get a new girlfriend  ;D. Only joking, I'm sure she's very nice.
Title: Re: CB450 Tracker
Post by: NoRiders on Dec 04, 2018, 18:38:12
It's around 10 or maybe 12mm mat, quite thick but the height seems OK.

Your girlfriend won't get on your bike - perhaps you need to get a new girlfriend  ;D. Only joking, I'm sure she's very nice.

I used 3mm closed cell yoga mat on my Honda seat. Just checked out 15mm mat and for £12 ($15) it seems a good deal, especially when built up like you've done to 45mm. Nice n comfy and will suit the flat tracker seat pad unit I reckon :)

She'll hop on tha back of a scooter on holiday and love it....just not into biking in the UK...she's cool :)