Sonny's 1966 CT90

Sonreir

Oregon
DTT SUPPORTER
So... last night I happened to score a 1966 Honda CT90 (first year for the US) for $250. This one is going to be a resto.

Here's how she sat when I got her home.
 

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And after three hours of disassembly I'm ready to start cleaning things up.
 

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Got the frame, fenders, and tank cleaned up. Deciding whether or not to keep the original paint. Definitely leaning toward doing so.
 

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OG paint for sure. It's not a show piece. Lay a nice coat of semi gloss clear over it and put it together.
 
Carb cleaned up in the new ultrasonic cleaner.

Also got the hardware tumbled and cleaned up overnight.

I've also started a box of things I'm taking to a friend's place for media blasting.
 

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I've started a "done" box, too. Everything here is ready for assembly.
 

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At first I was debating whether or not I should tear into the engine. Then I figured there's no point in doing a restoration and not restoring the most important part. Got most of the lump torn down and it's a good thing I did. Intake valve is leaking like a sieve and the piston and cylinder walls are well scored. Oil was an unhealthy looking gray color.

New +1mm pistons and rings on the way and the head will be taking a trip to the machinist.
 

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Engine fully dissected and nearly everything is in spec!

I dropped off all of the necessary parts with the machinist and the work will (hopefully) be done before the end of the week.

While I was waiting I cleaned up the wheels and washed off all of the hardware. Debating trying my own zinc plating setup to re-plate a lot of the larger pieces of hardware.

Also, unfortunately, getting a hold of new OEM gray cables is darn near impossible, so I've ordered some gray heat shrink to go over the top of the black ones I bought.
 
Started the long process of cleaning up the hardware and starting the zinc plating... Footpegs up first.
 

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This is a really cool project! I'm currently undertaking a ground up restore on a CA100 (50cc) and would love to try zinc plating some of the original hardware. Care to give a brief description of your setup?
 
Vinegar, salt, and corn syrup in with three gallons of water. I used a marine zinc anode and then hooked everything up to an old motorcycle battery (along with the trickle charger). Nothing fancy, but it's doing the trick so far.
 
Started painting and getting some of the parts ready to go back together.

Also, got a call from the machinist. The head needs new seats and he can't cut what's there. Ordered a new head from eBay.
 

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There's just something about bringing old parts back to life...

Alternator cover painted and polished.
 

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Engine back from the machinist. Time to put it all back together.

Kinda stumped on how these gears all fit in, though. I guess I should have taken some pics during the disassembly...
 

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