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.