1976 CB200T cafe build UK

Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

First thing on the list was to get the RS125 forks to fit the frame, and I stripped the tank the tank down to see if any repairs were needed, thankfully it was it great condition, only a few dents that could be easily sorted out.

Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

I also took a load of dimensions to allow me get something similar back on the tank when i come to paint it later on.





And stripped








Ive also stripped, derusted, and sealed the inside of the tank with a Por15 Tank sealing kit which worked brilliantly.

Next on the list was to strip down the frame because well.. it was just plain nasty.

Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

Watching for sure.

Something about CB200s makes me want one.

Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

So the frame was stripped and De tabbed, welded up where required and shot blasted. Everyone likes a little bit of added lightness. Then given a nice fresh powder coat finish!




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Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

Next up was an aluminium rear tray, I templates it in card first and the formed it from aluminium.





I also bought rear sets and nee rear shocks off eBay.



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Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion







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Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

The next big job was rebuilding the wheels was rebuilding the wheels which took me along time, both hubs were stripped down, soda blasted, painted and polished then rebuilt with fresh rims, spokes and then trued .













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Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion


I also painted up the headlamp and tool box.





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Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

Bike as it as stood - coming together slowly!



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Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

The most challenging part of this build so far for me has been getting the Aprilia forks and disk and caliper to work with the CB200 front Hub, they are clearly not meant for each other!

It was mainly challenging because I don't have a lathe in my personal tool collection! However living in near Shoreditch in London has its advantages. I joined Hackspace (if you live in London you seriously need check it out) and was able to use their lathe to make up the adapter plate that I needed as well as the spacers for the front axle. I don't have photos of the adapter at the moment but will take some when I next have the front wheel off.

The adaptor essentially joins the stud patterns of the CB200 hub and the Aprilia disk brake as well as spaces it out the required amount to allow the Aprilia caliper to be used without any spacers.

So with alot of measuring, and a bit of trial and error I have a working and very powerful front disk on the bike, using only CB200 and Aprilia RS125 parts. Win.

I matched this up with a standard RS125 front brake hose, but used a yzf r125 master cylinder and lever as it doesn't have a seperate fluid reservoir, and is made by brembo. It's prettier and is keeping it in the brembo family!

I need to get this bike on the road and give it a good shake down. Once I am content the brake adaptor is safe I will post the Cad files for it online.



I'm also very fortunate to have a mum who is a seamstress.. So I put her in charge of upholstering my seat for me! 3 hours later, this appears!







It is made from marine grade uv resistant vinyl and coated thread, we have also sealed the seams. It's a first go, so we'll see how it lasts, I'm likely to get it redone in leather by a pro later on, but Im really happy with it for the foreseeable future.


Current progress shot below:



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Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

Next up is was the begining of the paint work and the exhaust system, Ive been hunting for the right exhaust that would work with the rear sets for a long time. I loved the hooker style exhaust that I've seen floating around the forums, but they are as rare as unicorn poo.

I ended up importing an ok condition Cl175 exhaust to use as a basis for the system as they were never available in the UK.

I got the tank into a expoxy primer to seal the tank and got some high build onto the seat unit to start working out the imperfections.





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Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

I've been using this bike as inspiration for my paint scheme, bearing in mind I've never painted with a compressor before it should be an interesting challenge, if the finished scheme gets anywhere closely will be over the moon.



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Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

So I started by shooting a beige base coat, I used a ral colour, 1015 light ivory so that I could get items powder coated to match easily if I needed too later on.



I then bought some of this!



Believe me when I say it gets everywhere!

The next step involves masking the parts, spraying some clear Basecoat and covering it with metal flake. I tried a number of different ways, with home made flake guns, spay cans etc.. The best option I found was a salt shaker to sprinkle it over the flaked areas!





Then it was a case of burying the flake in about 8 layers of clear coat. The problem with coloured flakes is that if you sand through the clear the colour will sand off and you will have a load of silver specks everywhere, the easy way I found to fix this was to touch it up with a candy paint that matches. You genuinely cant see the touched up areas. However if I was to do it again I wouldn't do an isolated dry flake, I wet spray a silver flake all over the tank as it builds and even layer, then spray a coloured candy to add the tints in thin layers.

After its leveled out I masked again sprayed a gold detail and then again for the black out line. #

This article was the most valuable thing I read before starting!

http://snail.s4.bizhat.com/snail-ftopic157.html

This is how it came out before wet sanding.



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Re: 1979- CG/CB125 cafe build UK with cb200 twin conversion

I've also just added two megaphone silencers to the Cl175 exhaust and sourced some new OEM Honda badges. This is the bike as it currently stands.

Still a long list of things to do but it's really starting to take shape now.















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Heck yea, shes really lookin super!

The colour isnt my bag, but bloody lovely build. Proportions are just right. Class.

Thanks Erskine, it's a bit marmite, It does look great in the sunshine and has a bit of a 70s custom vibe about it, but Im not 100% sold on it either, might be too much of a mix of styles.

It was more of ive started down this path now I'm damn well going to finish it!

I'll see how it looks when the bike is completely finished.

Im also looking at extending the rear swing arm at the moment, to balance out the rs forks, but it's not so easy on a CB200.

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Strangely enough there is a CB 200 dumped in the forest near me that has an extended swinging arm, trouble is that it is down quite a steep track and would be a bitch to recover. Much of the bike has rusted through.

Erskine said:

Strangely enough there is a CB 200 dumped in the forest near me that has an extended swinging arm, trouble is that it is down quite a steep track and would be a bitch to recover. Much of the bike has rusted through.

Click to expand...

Thats too bad it has the hole in the tank...Ide give a $30 to get that for me. Hell Id give ya $75 for the engine. If it would fit in my 100 frame.

So i found some photos of the disc PCD adapter that I made up to match up the CB200 to RS125 Front Disk.