CrispyB550

I picked up a 1977 CB550k last month. It was an incomplete project bike but I fell in love with the lines and proportions as soon as I saw it. It has had an Aprilia RS 125 R front end and OZ wheel fitted, modified rear wheel and TL 1000 Brembo rear caliper. Here it is on the day I picked it up;



I swapped out the rear shocks for a slightly longer set of piggy back shocks and took off the Café racer seat hump as I have Brat plans for it



The engine is in bits...lots of bits! Multiples of all sorts of parts. Lots of engine cases, two clutches, three centre stands...all sorts.



It's all in decent condition but it freaked me out! So many bits and I have no experience of rebuilding engines. I dropped it all off at DM Engineering for a soda blast, clean and rebuild...along with a mild tickle for a little more poke.

Next was to fire up the angle grinder and get rid of the un-needed tabs to clean up the silhouette...



Recycling...



Nice and clean!



I'm loving this bike more with every little change I make



A little package arrived from the boys at Cognito Moto



Bolted on the rear set brackets and finalised the seat and loop. Bolted up a 2008 Aprilia RS 125 R front fender too.







A few more pieces of the puzzle arrived. Stating to actually look like a bike now



I mocked up a battery box today. The Cognito Moto one is great but no longer fits now I've had to take out the original seat brackets. Mine is bigger, acts as a bit of protection for the bottom of the seat and best of all doesn't mess with the lines of the bike's silhouette









I also designed as minimal a set of brackets as I could for the rear master cylinder to work with my Tarozzi rear sets. I'm pretty chuffed with this as it's as minimal as I could get it and the push on the cylinder is really nice and smooth.







...and that's as it stands. Watch this space.

Great start mate some cool changes too, will follow all the way with this project , front end looks mint look forward to your updates

Traced off the cardboard templates I made for the battery box, splash guard and a few other brackets in Illustrator and sent them off to Safire Water Jet. They're going to be cut in 2mm mild steel. Hopefully should be getting them back in 7-10 days. Can't wait to get them tacked up ready for a mate of mine to TIG weld them properly.

Just waiting for the postman to bring my headlight, brackets and some more parts of the puzzle.

Love the wheels. Couple of thoughts on fab and strength v lightness.

2mm is a bit thick for a simple electrics tray, IMHO. And the rear M/C brackets could have been thinner and shorter too. Grab one of the brackets you cut off and see if one can be re-purposed or grab something thin and light from a race car supply store.

You might be surprised how little metal is needed to provide sufficient strength - especially if it's folded to have flanges/sides.

In for the 550 build.

Im in for the build but it needs to be said, you have an underseat electronics tray acting as a bump stop for the rear tire in the "event" that it bottoms out.....not a good idea. You have all that space under the front of the seat OR place an actual steel bump stop under the tray, just in case so you don't jam the electrics together or smash the battery for whatever reason.
Cheers

Keep up the good work though

teazer said:

Love the wheels. Couple of thoughts on fab and strength v lightness.

2mm is a bit thick for a simple electrics tray, IMHO. And the rear M/C brackets could have been thinner and shorter too. Grab one of the brackets you cut off and see if one can be re-purposed or grab something thin and light from a race car supply store.

You might be surprised how little metal is needed to provide sufficient strength - especially if it's folded to have flanges/sides.

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The wheels are going to be even nicer when they're treated to a fresh set powdercoat. Satin or gloss black?

I agree it's a little over kill but you live and you learn. I went for 2mm as the Cognito Moto battery box I have is of the same thickness. It's also going to be used to mount the rear fender off so I figured a beefier gauge would give a sturdier surface to bolt through. C

Kamn said:

Im in for the build but it needs to be said, you have an underseat electronics tray acting as a bump stop for the rear tire in the "event" that it bottoms out.....not a good idea. You have all that space under the front of the seat OR place an actual steel bump stop under the tray, just in case so you don't jam the electrics together or smash the battery for whatever reason.
Cheers

Keep up the good work though

Click to expand...

That was a concern of mine too and through more luck than judgement it's ok. It would have bottomed out with the original rear shocks but the replacements are an inch longer and fully compressed have loads of clearance. I really wanted to keep the air box triangle completely free of anything at all.

Started working in the CB550's tank. Safe to say it's not always been silver!

Remarkably straight for a 38 years old. Just one dent that needs filling and the seams need a little TLC to get them all tasty looking. Thinking about a way to open the fuel cap door that won't need a lock and key? Magnetic closure might work.
Next big decision is colour and design!

The CB has a face!

Bit more progress on the tank in the last few days. Lots of sanding, filling, sanding, filling, priming, sanding....and repeat. But, I'm pretty happy with the result. Couple of spots I don't want to work anymore as it's ripples and creases in the steel form when it was originally made in '77. Need to decide whether to colour match the front fender now? I'm 90% sure I will as all black wheels, black tyres and black fender could look a little flat.

Still not sure how to get round not having a key and lock on the tank door? Any ideas?

Looking great so far! What is the front fender from?

djmaynard said:

Looking great so far! What is the front fender from?

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It's the matching front fender for the forks and wheels, 2008 Aprilia RS 125 R.

I'm having the same dilemma with my tank. I can't find a lock set for the fuel door so I'm liking the magnetic door idea!

And where did you find that awesome headlight and mount setup!?

Cody.linhart said:

I'm having the same dilemma with my tank. I can't find a lock set for the fuel door so I'm liking the magnetic door idea!

And where did you find that awesome headlight and mount setup!?

Click to expand...

Ive been playing with a few options this evening and came up with this. It closes and stays shut with 4 small but strong magnets and a spare Triumph Street Triple bar end cap acts as a trick little opener. Works a treat.

CrispyDesigns said:

Ive been playing with a few options this evening and came up with this. It closes and stays shut with 4 small but strong magnets and a spare Triumph Street Triple bar end cap acts as a trick little opener. Works a treat.

Click to expand...

Love that idea! Same here, I found a gem and really didn't want the lock set up. Looks so similar to stock. You can't tell until you tell someone or you get in close!

Weather was too nice today to be getting all hot and sweaty welding so I sat in the sun whilst filling, sanding and priming the Aprilia front fender. I flatted off all the flat faces of it properly to accentuate the straight lines against the curves.

Decided the front fender is going to be the same colour as the tank. Now I just need to decide the colour!

Happy dayS! Just had confirmation from the water jet cutting people that my parts will be with me on Wednesday. I'll be able to muck up the electrics box and splash guard.

Few bits done on the CB today. Splash guard (I've got two versions but still undecided which to use. This one or the longer of the two), battery and electrics box parts and I made some small indicator brackets. Slowly but surely.

Next I'll be tacking up the guard and battery box into place, order Motogadget bits and bobs and get stuck into organising the wiring and position of components.

I've also had a couple of requests for detail pictures of the magnetic closure for the fuel tank door. I'll get it finalised and post piccies up as soon as I can.

Got my parts back from the water jet people yesterday. Great quality cuts mean the parts fit as easily as my cardboard mockup did. Just tacked into place for now until my mate can lay down some coins with the TIG torch. Well chuffed with them. Little indicator brackets have worked out just as I wanted them to as well. Happy Days!