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Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: Marcushyden on Jan 14, 2018, 14:36:06

Title: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:36:06
Hi everyone! Greeting from Finland!

First, I'm sorry for my "not-so-perfect" english. Hope you guys can manage with it.

I've been working on my project from august 2015, and I thought that maybe I should share it with you.
Hopefully I get some comments and help if I need it.

My building history begins at young age with mopeds, motocross-bikes and 125cc roadbikes.
Years later I got my driving license (18y old) and got involved with my own car projects.

Latest project I had, was Japan imported Nissan Silvia S15, which was one of the first streetlegal Silvias in Finland. I also got my Silvia featured in finnish magazines and few internetsites in states.
Here is link to one of them, if you are intressed: http://www.stancenation.com/2011/08/30/the-japanese-masterpiece/ (http://www.stancenation.com/2011/08/30/the-japanese-masterpiece/)

...but lets get back to present project.

I've been dreaming of motorcycle that should be for pleasure, not so much driving fast. Cafe Racer -style motorcycle would be perfect for this kind of use.
So in 2015 I got to the business... After looking for a bike, I thought that I should build it myself! That way I will get the bike I want.

This first project message is like introduction to my world and to my project.
I will update this thread, so everyone knows from where did I begin and what is the situation today. Also my goals and inspirations will be revealed.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:37:50
Project started in august 2015

I was looking for Honda CB750, because there is lots of information and build-threads of this bike. Also parts are easy to find.
Unfortunately I did'n find any good CB's on sale in few weeks.

In August I found one on sale and the owner had put it online just 30 minutes ago. Quick call and I was heading to pick it up.

It was -79 CB750KZ imported from Germany. Bike was in good shape, although it has been standing in the barn from the year 2000.

Bike loaded and heading back to garage.
This is how it looked like when we unload it.

(http://imagizer.imageshack.us/v2/640x480q90/908/CWHcUe.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/905/3jQ7UP.jpg)

Few mods and repairs to get it registeration inspection. Everything in inspection was done in 15 minutes and now I had fully registered CB750!  8)

At the same night bike was already teared up.

(http://imagizer.imageshack.us/v2/640x480q90/907/mYavyj.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/633/ZqVaIJ.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/903/0XzXiZ.jpg)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:39:15
My visio is to build a bike, that is old but with a modern twist.
Inspirationbikes are these.

(http://imagizer.imageshack.us/v2/640x480q90/633/musdt9.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/908/2GYsuK.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/903/q63kJn.jpg)

Plans for this build are:
- Everything as clean as possible
- USD-front end from a modern sport bike
- Monoshock rear end from a modern sport bike
- Full engine restoration
- "Race"-style short exhaust
- New tank and new rear/side fairings
- All new wirings and electricity
- Electricity and battery under the seat and rear fairing
- Carb restoration
- New speedometer, light etc.

I have few ideas of the color scheme, but I haven't decided yet. Everything comes clear to my mind, after bike is build.
Something neutral, big NO for flakes and patterns.
Engine and frame will be semi-gloss black.

Project continued with tearing everything apart.
Next thing I did, was sandplasted the frame.

(http://imagizer.imageshack.us/v2/640x480q90/633/oFsa0q.jpg)
Frame came out really good!

(http://imagizer.imageshack.us/v2/640x480q90/911/76ItQH.jpg)
Also got myself a motorcycletable for better working enviroment.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:40:14
Removed everything from the frame,
- Steeringlock
- Suspension holders and middle-stand holders from the rear
- Hose and wire holders
- Saddlelock
- etc.

(http://imagizer.imageshack.us/v2/640x480q90/908/DCf861.jpg)

I will also open up the engine and replace crucial parts.
I want to build daily driver and it will need durable engine.

(http://imagizer.imageshack.us/v2/640x480q90/907/HsOT6J.jpg)
Engine almost in one piece

(http://imagizer.imageshack.us/v2/640x480q90/908/PqQyAg.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/910/cWbyhg.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/903/pnXBxS.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/911/ngHfqH.jpg)


One pic from my garage, which is just few steps from my homedoor.
You can also see my fathers Harley Davidson project :)

(http://imagizer.imageshack.us/v2/640x480q90/903/gi05ae.jpg)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:41:27
Engine looks good. Only minor machining need to be done.

- Cylinders will be honed (I don't know if that is the correct word?)
- New piston rings and piston cleaning.
- Cylinder head grinding, valves and channels cleaning
- All gaskets and bearings will be bought new

I don't look for more power, but engine should be working perfectly.

Parts are arriving every day, so I will post pictures of those later...

Please feel free to comment my project and ideas! 
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:42:58
New parts are arriving everyday, so here is a little summary of the arrived parts..

(http://imagizer.imageshack.us/v2/640x480q90/905/a55C3i.jpg)
From Finland I found 2005 GSX-R 1000 complete rear end with swingarm, rim, tire, brakes, shock and links, and foot rests.

(http://imagizer.imageshack.us/v2/640x480q90/910/7Kdgha.jpg)
From eBay came Kawasaki Zephyr 1100 tank.

(http://imagizer.imageshack.us/v2/640x480q90/907/rIugr0.jpg)
Also from UK eBay I bought 2007 GSX-R 1000 full front end with telescopes, triple trees, switches, bars, brakes, rim and tire.
I got what I was looking... ...in gold color  8)

(http://imagizer.imageshack.us/v2/640x480q90/908/rij1Zk.jpg)
Led-stringlight to the back

(http://imagizer.imageshack.us/v2/640x480q90/910/fHQEEp.jpg)
Frontlight with signals. I like to build this bike clean as I can.

(http://imagizer.imageshack.us/v2/640x480q90/633/g8B8n9.jpg)
From states I bought conversion stem for the front end. Cognitomoto rules!

(http://imagizer.imageshack.us/v2/640x480q90/908/pzlHCk.jpg)
Rear loop

(http://imagizer.imageshack.us/v2/640x480q90/907/inYcCX.jpg)
Gauge/dashboard that will be fitted to the bike
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:43:29
Engine, swingarm, wheels and tank... I go them sodaplasted and the result looks nice

(http://imagizer.imageshack.us/v2/640x480q90/633/mQJlqq.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/905/Yia3d4.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/633/heBjvO.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/910/N5L1Gn.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/907/ywJYXZ.jpg)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:44:51
Parts for the biggest changes are now in my garage, so I couldn't resist to fit them and see how everything will looks...

(http://imagizer.imageshack.us/v2/640x480q90/905/K61IQF.jpg)
Tank is more massive and roundish. I like it a lot!

(http://imagizer.imageshack.us/v2/640x480q90/910/GA4qmH.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/633/vZ2iKT.jpg)
Testing the rear end

(http://imagizer.imageshack.us/v2/640x480q90/910/yJxgCU.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/903/NkQeV6.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/910/pjPBs9.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/907/byKpF7.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/905/FgCTBc.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/905/P46MZa.jpg)
Headlight will find its right place after everything is done...

Bike has been asked to be show'n at national motorcycle exhibition on first weekend of february. Also bike should be in American Car & Bike Show in March, and at Hot Rod & rock Show in April...

My goal is to finish and reveal bike in national motorcycle exhibition in february. I have to boost thing up, so I will manage that  ::)


Next on my to-do-list is get the engine done and fit swingarm correctly.

To get swingarm properly to the bike, I need to drill axlehole bigger and get it "piped" for durability.
Here is image that will clarify my thoughts:

(http://imagizer.imageshack.us/v2/640x480q90/910/TCu8qy.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/911/G2NfKT.jpg)
Hole has to be drilled aprox. 5-8mm wider, so I can fit pipe and axle will fit correctly
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:45:51
Project is going forward...

For fitting the swingarm, I got advice from another builder.
I'm not going to drill holes in the frame bigger. Local shop is going to make new collets/barrels for the swingarm, that I can fit orginal CB axle. Also it will center the swingarm to the frame.

Engine is in the local machineryshop, so I will get it later next week.
Everything for engine rebuild has been bought, so all I have to do next is assemble it.

Next week my friend who knows how to weld properly will come and we start weldings.
Cutting the rear frame and weld new hoop in place. Fitting the tank and weld all unnecessary holes. Slightly modifications to the frame and box for wires and battery.

I had to took some photos just to see how the bike will look when its ready. I really like the lenght, wideness and hight of the bike.

(http://imagizer.imageshack.us/v2/640x480q90/633/LJTSfA.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/908/tT1RyT.jpg)

(http://imagizer.imageshack.us/v2/640x480q90/911/8Rue31.jpg)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:56:18
First things first... My timeschedule was pretty hard and as you can see, we can now forget it. Project deadline WAS yesterday.

But lets not think about that...

I took the engineparts to the local machineryshop and everything was done in a week.

I don't know right words for the work they did, but all cylinders are hooned (?), surfaces are straigtened (?), pistons cleaned, all valves done and every enginepart is machinewashed to remove remaining soda dust.

(http://s30.postimg.cc/80sphtqi9/kansi.jpg)

(http://s30.postimg.cc/ixu16ld9t/kansi_1.jpg)

(http://s30.postimg.cc/4jqneurg1/kansi_2.jpg)

(http://s30.postimg.cc/x83li2tm9/sylinterit.jpg)

(http://s30.postimg.cc/9ekcd4prl/m_nt.jpg)

Engine is under rebuild and should be in great condition after this  8)


Kawasaki Zephyr tankcap was not my cup of tea, so I bought Honda CBR 1000RR tank.

To replace original cap was so difficult that I let the professional machinery do to work.
It came perfect!

(http://s9.postimg.cc/xm5cjljsv/tankinkorkki_1.jpg)
Kawasaki's and Honda's tanks side by side

(http://s9.postimg.cc/5bybtpr3z/tankki.jpg)

(http://s9.postimg.cc/iu586039b/tankinkorkki.jpg)

Another job was also done by professional.
Removing ignitionswitch holder from a triple tree.

(http://s10.postimg.cc/aqcl1abop/tpala_2.jpg)
Original

(http://s10.postimg.cc/legc04lnt/tpala.jpg)
Shaved

(http://s10.postimg.cc/vlyvcj7vt/tpala_1.jpg)


Rear swingarm installation plans by drilling bigger hole to frame was abandoned. Turnery made custom made "blocks"/"barrels" to fit swingarm.
It does to job perfectly and I can use original axle.

(http://s14.postimg.cc/wk13d0xrl/holkit.jpg)

(http://s14.postimg.cc/5kx8hvbap/holkit_1.jpg)


Finally we got to do weldings...

(http://s21.postimg.cc/71qm5x7ef/per_n_katkaisu.jpg)
Rear end of the frame was cut out...

(http://s21.postimg.cc/u4h5538vr/per_n_katkaisu_1.jpg)
Once I thought that I should change my plans and build brat-style bike...

(http://s21.postimg.cc/76yytc43b/hitsaus_1.jpg)
(http://s21.postimg.cc/e8wwfj7p3/hitsaus_2.jpg)

(http://s21.postimg.cc/dn7xjfcmv/per_nsivut.jpg)
...but when the rear loop was welded, I think it is really nice! We also fabricated sides from sheet metal to finish the look.

(http://s21.postimg.cc/qsnfpj6if/runkoputki_1.jpg)
"Triangle" on sides are way too big for my taste...

(http://s21.postimg.cc/wjdm39eif/runkoputki_2.jpg)
...so we cut one tube of the frame and made the "triangle" smaller. I have seen lots of these kind of modifications in States.


(http://s21.postimg.cc/y144bxpkn/stoppari.jpg)
Frontstopper, so bar end will not hit the tank

(http://s21.postimg.cc/4n8dwcmuv/stoppari_1.jpg)


For the tank we use original places, so i can fit ignition coils to their original place.

(http://s21.postimg.cc/ntlkzj3cn/tankinetup.jpg)
Tanks front end brackets. Rubber padding will be fitted to end, so it will suppress vibration.

(http://s21.postimg.cc/fww1u6lkn/tankintakap.jpg)
Rear end was done like this. Tanks original brackets will fit to these straight. Rubber padding will be fitted to these also.


I bought very cheap ultrasonic cleanermachine. Suprise, it worked pretty well...

(http://s17.postimg.cc/amnvhosmn/kaasari_likanen.jpg)
Dirty carb...

(http://s17.postimg.cc/xpizuljhr/putsattu_kaasari.jpg)
...after ultrasonic cleaning. Rebuilded with new parts.  :D


Overall look at this point is almost same as earlier, but lots of things have been done.
(http://s17.postimg.cc/tufls10bz/yleis.jpg)

Next thing to do is to fit rear suspension and it will be tricky...

All the parts are almost here. Few electronic components and small parts are still coming.
(http://s17.postimg.cc/lrhfgpfqn/Uusia_osia.jpg)

Please feel free to comment, give me some advice or just say hello, like Adele  ;D
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:56:56
Few parts arrived. Bolts for petroltank cap and new levers...
(http://s12.postimg.cc/6gskf7fi5/IMG_9619.jpg)

Finally I figured out how I will install the rear shock. Have to weld new brackets to the swingarm and so on...
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 14:58:36
Slowly but surely... I've been so busy at work and this project is not going well. I have to sort timeproblem somehow...  :-\

Parts keep coming, although I thought everything has already been delivered to me. I always find something new to buy :D

(http://s32.postimg.cc/myjcgu3ut/osia.jpg)
Handlebar grips, volt-meter, powerswitch, petroltankcapbolts, horn, fuelhose and LED-headlightbulb.
I bought LED-bulb just for try and have to say, light is incrediable! Bulb is not road-legal but who will find that out?!

(http://s32.postimg.cc/slfpeb6dh/moottori_osia.jpg)
Mainbearings and rodbearings. Also new pistonrings.


Rear shock has now been almost installed completely. Angle is mild, but should work because shock is very stiff. Its almost like solid rear.
Lower mount was made from aluminium that welds straight to the swing. Upper mount will be welded to the frame and will have support metal on the sides.

(http://s32.postimg.cc/usojfz11h/iskari.jpg)

(http://s32.postimg.cc/r3u92r1mt/iskari_alap.jpg)

(http://s32.postimg.cc/u84wzjif9/iskari_yl_p_1.jpg)



Engine is now rebuilding and will be done in few days. Hopefully it will run as it should  :o

(http://s32.postimg.cc/ws9ql4kqt/yleiskuva.jpg)

(http://s32.postimg.cc/4cud7tvd1/moottori.jpg)


Seat is designed and will be ready soon. Sheets are unfinished.

(http://s32.postimg.cc/yisrmm29x/penkki_pohja.jpg)

(http://s32.postimg.cc/98xzzivid/penkki_3.jpg)


Seat will be covered in leather and will be same color as handlebar grips. Here's few examples for the design.

(http://s32.postimg.cc/86j838nb9/penkki_idea_1.jpg)

(http://s32.postimg.cc/5g9w61qmd/penkki_idea.jpg)


Overall I feel okay. Timeproblem is bothering me, but I think I can made this ready during this summer.
There has not been any major ups and downs.

Next we are compliting engine rebuild and start to work with rear fairing and elec.box under the seat.

Here is overall photo from the garage:

(http://s32.postimg.cc/68h5izk79/yleist_1.jpg)


I will keep updates coming!
Please feel free to say anything... Goods and bad thoughts :)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:00:55
Actually progress of this project has been very little past six months.
I have been around the world and lots of other things to do  >:(

In this post we are living somewhere in autumn 2016.

Latest work what I have done is that we have finish rebuilding the engine. Test run is not yet made because there is few issues with carburators, but after december we are putting all focus to this project.

(https://s29.postimg.cc/o5mzfhcaf/IMG_2168.jpg) (https://postimg.cc/image/rp8x5af03/)
Here you can see engine without camshafts and valvecover.

We also made first step to fabricating rear fairing.

(https://s29.postimg.cc/cckkxiqgn/IMG_0964.jpg) (https://postimg.cc/image/mzee2xylv/)

(https://s29.postimg.cc/o2yiewj93/IMG_0965.jpg) (https://postimg.cc/image/xaqqvlqb7/)

(https://s29.postimg.cc/5c16ihe2f/IMG_0971.jpg) (https://postimg.cc/image/ui24pbfcj/)

In January we will be focusing to get engine running.
Also lots of welding, fabricating fairings and electricalbox under the seat.


Front fender was cutted from 2007 GSX-R original front fender
(https://s1.postimg.cc/kz8utibhr/orkkislokari.jpg) (https://postimg.cc/image/51053dh9n/)

Goal was to made race-look-a-like front fender as tiny as possible. From my taste, the results is really good.
(https://s1.postimg.cc/uorncbir3/etulokasuoja4.jpg) (https://postimg.cc/image/n8sdqiv1n/)

(https://s1.postimg.cc/slh84niy7/etulokasuoja5.jpg) (https://postimg.cc/image/dcraqvp9n/)

Some finishing touches still to be done and some grinding


Next thing to do was under tray.

My idea was to place battery and some electrics under the seat. Box has to be small as possible, so the rear spring is still visible.
Side covers will be tiny as well.

First thing was cutting cardboard samples. I as remember, third or fourth time we get it right :D
(https://s1.postimg.cc/uek4sz44v/IMG_3346.jpg) (https://postimg.cc/image/byznvkq0b/)

Next taping samples to the bike.
(https://s1.postimg.cc/jt09gyxtb/IMG_3347.jpg) (https://postimg.cc/image/tqbaa15ez/)

It fitted well and we also made whole undersheet.
(https://s1.postimg.cc/jhit47hdb/IMG_3353.jpg) (https://postimg.cc/image/p5p3v3lpn/)

(https://s1.postimg.cc/6rj64uysv/IMG_3356.jpg) (https://postimg.cc/image/4zq79yffv/)

Next week we will cut samples from sheetmetal and weld it.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:02:28
Finally got undertray/box ready.

(https://s28.postimg.cc/tiy5xlpel/yleist_koko.jpg) (https://postimg.cc/image/5f7e9b6xl/)
Rear spring is still visible, but every electricthings can be fitted to the box.

(https://s28.postimg.cc/hbufg1jh9/boksi.jpg) (https://postimg.cc/image/8426zccex/)
I will fabricate fairings to cover part of "side triangles" so you can't even notice the box from outside.

(https://s28.postimg.cc/c6xtc5vx9/yleist_taka.jpg) (https://postimg.cc/image/pb3dounyx/)
Few holes will be drilled to the box for removing possible water. Rubbersheet will be layed bottom of the box to remove any vibrations.

I already bought sidemounted licenseplate-holder but i will forget it. I will mount the plate front of the rear wheel under the box.
I know the police will not like my oppinion, but I can manage that :)


(https://s28.postimg.cc/wbrdhmpr1/takakate3.jpg) (https://postimg.cc/image/n3z50xiop/)
Rear cowl designing started with polyurethanfoam.

(https://s28.postimg.cc/3kujrkjx9/takakate2.jpg) (https://postimg.cc/image/vkynbundl/)
This is possible the version 4 of the cowl, and I don't like it. Has to be more lower and roundish.

(https://s28.postimg.cc/ej17w0j4t/takakate1.jpg) (https://postimg.cc/image/ceguuxhi1/)
I can't recommend polyurethanfoam to this. I've been looking for polyurethanblocks, but can't figure out what is it in finnish...

...until I found it! Floralfoam! Or in finnish "kukkavaahto"  ;D

Floralfoam is much better and easier to work with.

Unfotunately I have no pics of todays work, but I will post those later.

I have already testfitted every electricparts to the box. Also found good size battery.
Seat is coming along and figured out fastening to it. Looks really nice and is very practical.

I didn't like headlight I bought so I hunted down Vrod headlight. Modern-look and still roundish  :-*
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:03:01
Few pics of the new headlight

(https://s27.postimg.cc/53rq8lnf7/etuvalo1.jpg) (https://postimg.cc/image/njc7601jj/)
For my taste, this looks much better than basic round headlight and fits lines of the bike better

(https://s27.postimg.cc/w0bpgx68j/etuvalo.jpg) (https://postimg.cc/image/m30onuymn/)
Bike is looking like a real deal...


(https://s27.postimg.cc/yk7cb0tsj/kukkasieni.jpg) (https://postimg.cc/image/unu0f18sv/)
This is so called floralfoam which is much easier to work with than basec polyurethanfoam.

I suggest to use headmask with floralfoam because it shatters in tiny particles when you cut it or grind it
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:04:17
Undertray has been modified and all electricalparts are findings their locations

(http://s10.postimg.cc/dmnei3uq1/pohja1.jpg) (http://postimg.cc/)
As you can those black dots indicates places for bolt to be welded for fastening electricalparts
Also we drill holes to the front end of the box, where all wires will be going to their final destinations

(http://s10.postimg.cc/3o2fvmlah/pohjapehmuste1.jpg) (http://postimg.cc/)

(http://s10.postimg.cc/4vgdnubex/pohjapehmuste2.jpg) (http://postimg.cc/)
To bottom of the box I found thin rubbermat that can be glued so it will work for mute some resonations

Also we will weld "cage" for the battery, that it can't move

(http://s10.postimg.cc/cmx3mefk9/pohjatukipalat.jpg) (http://postimg.cc/)
These kind of bracing will be welded and seat will be fasten to these


(http://s10.postimg.cc/yktkg6ukp/penkki1.jpg) (http://postimg.cc/)
I didn't like those gaps between the tank and the seat...

(http://s10.postimg.cc/d3dpv3dxl/penkki2.jpg) (http://postimg.cc/)
...so this metalsheet will be bended and welded to hide those gaps


(http://s10.postimg.cc/a9f5ve155/sivupala1.jpg) (http://postimg.cc/)
I managed finally fabricate sidepieces to cover big triangular holes and will be mounted with bolts

(http://s10.postimg.cc/lkhtjr809/takakate1.jpg) (http://postimg.cc/)
Rear cowl is under its way and found this bended metalstrip which is perfect for my eye.
Didn't want to go basic "round rear cowl"


(http://s10.postimg.cc/mmneok1ft/etuvilkku.jpg) (http://postimg.cc/)
Because the headlight changed which had integrated blinkers and had to found new ones. These small blinkers will be mounted to front forks

I still haven't figured out the place for licenseplate...

(https://s1.postimg.cc/1d6gysbv2n/kilpi1.jpg) (https://postimages.cc/)
This way the licenseplate won't "break" any lines of the bike, but police will have something to say (atleast in Finland).
Well, i don't know...

(https://s1.postimg.cc/6l1rls5i67/kilpi2.jpg) (https://postimages.cc/)
This way it is too much on display and I don't like it...

(https://s1.postimg.cc/25jcgitbnz/kilpi3.jpg) (https://postimages.cc/)
This might be the best way, but looks too olds school to me...


Project is going strong atm, but as I promised year before last year, it should be already finished  ;D
Right now I don't make any promises, but summer 2018 looks good
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:05:48
Well, what has been done?

- Headlight brackets ordered from UK. Slightly problem with space behind Harley headlight and brackets. Bolt are touching headlight and I can't get headlight close enough to the frame. Have to work this out

- Bought new GSX-R front fender that I will fabricate to pleasure my eye more than previous one.

- The tank is at Mr. Moore Motorcycles, who going to modified bottom of the tank to be more flat, so it will move little bit lower and hide all ugly gaps

- Huge amount of brackets, bracings and other stuff cut from sheet metal. These have to welded on next week.
* sidepanel brackets
* bracings to the frame
* steering stopper have to be modified
* front blinkers brackets
* to the traybox I have to weld bolt and brackets to hold all electricparts
* brackets to hold cables and battery in good order
* new brackets to hold tank in its position after tank modifications
* bracings and brackets for the seat


One of the biggest jobs were to make decision where to put footpegs.

We made this kind of samples to see were footpegs should go and can then I could try drivingposition
(https://s8.postimg.cc/cyq4uw3f9/tapit1.jpg) (https://postimg.cc/image/onu4iuudt/)


After we made decision, we cut samples to look more like real brackets that we will weld to the frame
(https://s8.postimg.cc/415exjaz9/tapit2.jpg) (https://postimg.cc/image/j9vcbb4nl/)
 
Don't worry, pedals angle will not be that steep.

I also ordered new adjustable footpegs, so we can move it around a bit if necessary
Pretty sure I have to make new shiftrod but that is not a problem


I started to fabricate rear cowl and made bottom base for floralfoam to be glue on

That was not easy job, because in Finland, I didn't find sheet foam from anywhere...  ::)
Talked to few enthusiast and they have made base bottom from plasticsheet

Bought sheet of black plastic and starterd to mould it

(https://s8.postimg.cc/yhbbvnwid/pohja1.jpg) (https://postimg.cc/image/sgdmyl9w1/)
First, forced it to the right shape with lots of pressure and gasburner. Have to be careful, because that plastic has low melting point. You don't want to melt your sheet to the floor...


After that I cut it to wanted shape and here is result of that :D
(https://s8.postimg.cc/xdr7jpbv9/black.jpg) (https://postimg.cc/image/qnaqa9opd/)


Finally this is what it looks like
(https://s8.postimg.cc/81ck9s1g5/pohja2.jpg) (https://postimg.cc/image/579ewbz9t/)


(https://s8.postimg.cc/uaqhgbwwl/pohja3.jpg) (https://postimg.cc/image/kdfgn9pap/)
After this pic I tied it again tightly to the frame and put some pressure on it, so maybe after few days it will stay like it should


Next step is to glue floralfoam to it and shape it like I want... Then lots of fiberglass etc... Lot to do...
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:07:33
Project is going strong atm and I am determined to finish this project before the next summer (2018)

Here is a quick update what's going on right now

Last of the parts has almost arrived

(https://s1.postimg.cc/1o9clnhibj/footpegs.jpg) (https://postimages.cc/)
New adjustable footpegs

(https://s1.postimg.cc/1h64q7vklr/mittaristo.jpg) (https://postimages.cc/)
Koso speedometer

Also new turnsignals, electricparts, lots of bolts and nuts, side mirrors etc.


Headlight brackets that I bought wasn't the right ones for this project. They were too tight, so there was an ugly gap between the brackets.
Also headlight wouldn't go as close to the frame as I wanted.

I found new ones (although they were pretty expensive) that fits perfectly to this bike.
(https://s1.postimg.cc/1dmisi3kgv/kiinnikkeet2.jpg) (https://postimages.cc/)

Next step is to modify brackets and then the front end is nearly complited. Front fender cutting and speedometer brackets under construction.

Finally I got my a good welder, who welded multiple things

(https://s1.postimg.cc/9ju3j016q7/akkukehikko.jpg) (https://postimages.cc/)
Cage for the battery. There will be leatherstrap for fastening the battery. Behind the sidepieces, there is a space for wiring.

(https://s1.postimg.cc/2k5u13rm73/s_hk_boxivalmis.jpg) (https://postimages.cc/)
Bolts are welded for attach electrical parts. "Bridge" is for volt-meter, tunrsignal relay and mainpower-switch.

(https://s1.postimg.cc/8ykfwp7t0f/sivupala.jpg) (https://postimages.cc/)
Sidepanels were welded straight to the frame to prevent shaking.

(https://s1.postimg.cc/9cqvnkiw6n/takavalo1.jpg) (https://postimages.cc/)
Base for taillight

(https://s1.postimg.cc/7ohiqdubqn/tuki_ja_jalkatappirauta.jpg) (https://postimages.cc/)
Places for footpegs and supportplates for the "triangle"


(https://s1.postimg.cc/5plc01jvy7/satula.jpg) (https://postimages.cc/)
I made new base for the seat. Next thing is to bolt fasteners to base and send the seat to upholstery


I didn't like the gap between the frame and the tank.

Tank has meen modified like this:
(https://s1.postimg.cc/57vabgmd9b/tankkipohja.jpg) (https://postimages.cc/)

And now the gap is so much smaller and more like I wanted it
(https://s1.postimg.cc/4mlmp5qudr/tankinv_li.jpg) (https://postimages.cc/)


Rear cowl design is my pain right now...

Can't figure out how I would do it or actually how I will do the mold.
Frame bed is little bit too curvy so I can't lay floral foam to it like I need to...

(https://s1.postimg.cc/3xsd551dxb/floralfoam.jpg) (https://postimages.cc/)
Shit Shit Shit :D

I bought bunch of clay, that I can design easily. It came really good. (in pictures not ready yet...)

(https://s1.postimg.cc/1rsyjdadbj/mold1.jpg) (https://postimages.cc/)

(https://s1.postimg.cc/1o9clnh2vz/mold.jpg) (https://postimages.cc/)

(https://s1.postimg.cc/4q58mvkk8v/yleinen4.jpg) (https://postimages.cc/)


Two days later, clay mold has shrinked 1/3 of it's original size and it was useless  ::)
Next thing is to go back to the drawingboard and try to figure out what to do...
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:08:39
Rearsets are bolted to the frame. Looking good and riding position is pretty comfy  :)
(https://s1.postimg.cc/794t2785db/tapit1.jpg) (https://postimages.org/)

(https://s1.postimg.cc/7uegoi4j3z/tapit2.jpg) (https://postimages.cc/)


Headlight brackets (large ones/base ones) fits perfectly
(https://s1.postimg.cc/9bklq96y4f/etukiinnikkeet1.jpg) (https://postimages.cc/)

Unfortunately with these original brackets and didn't get my headlight close enough to the frame, so we will make new ones. Easy job and they are almost ready when I'm writing this.
(https://s1.postimg.cc/2izk3sg3kf/kiinnikkeet2.jpg) (https://postimages.cc/)

Here you can see raw setup of the box under the seat and rear cowl.
(https://s1.postimg.cc/4hvqu4hypr/boxi1.jpg) (https://postimages.cc/)

(https://s1.postimg.cc/81hojxme7z/boxi2.jpg) (https://postimages.cc/)


Finally I found ignition switch that I like. It's from Harley (can't remember the model) but it looks good. Function is little bit different than normally, because by turning the whole body of the switch you can get your power on or off, without the key. Key is only for locking whole body, so you can't get power.
I also have main power switch under the seat, if I leave my bike for longer period somewhere...
(https://s1.postimg.cc/5of22qaq73/virtalukko.jpg) (https://postimages.cc/)

Tomorrow back to the garage and maybe I finish taillight and headlight install, ignition switch and start fabricating speedometer bracket and front fender.
Next week I will put my engine on the bike, so I can start figuring out chainline and other little thing
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:09:14
Rearlight installation is complited. Few holes, rubbergaskets and we're done!

(https://s33.postimg.cc/4fr2rvlcv/IMG_6366.jpg) (https://postimages.cc/)

(https://s33.postimg.cc/q2638wrn3/IMG_6368.jpg) (https://postimages.cc/)

(https://s33.postimg.cc/on4ik6y9r/IMG_6369.jpg) (https://postimages.cc/)



Seat is also ready for upholstery.

(https://s33.postimg.cc/czagp2gof/IMG_6374.jpg) (https://postimages.cc/)

(https://s33.postimg.cc/pqomvkiqn/IMG_6376.jpg) (https://postimages.cc/)


Here you can see four holes that we drilled. Seatpins will go through those by pressing it slightly down. Taking it off is also simple. Under the leather will be two small pulling straps.

(https://s33.postimg.cc/k2ic4ottr/IMG_6375.jpg) (https://postimages.cc/)


Right now, we are putting engine back to the bike. After that we can start figuring out chainline, shiftlever etc

(https://s33.postimg.cc/n9cvoar4f/IMG_6372.jpg) (https://postimages.cc/)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:09:51
I ordered HEL Performance custom made steelbraided brake hoses and they look amazing  8)
I will upload some pics after we have testfitted them.

Engine is back in the frame! The job was actually pretty easy.

(https://s33.postimg.cc/ujxerbp0v/IMG_6438.jpg) (https://postimages.cc/)

(https://s33.postimg.cc/9a9sgho5r/IMG_6436.jpg) (https://postimages.cc/)

I cut original exhaust just to see how it looks. Pretty short one and the actual one is going to be custom made and little bit longer.

(https://s33.postimg.cc/4odo85acf/IMG_6437.jpg) (https://postimages.cc/)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:11:09
From here everything is done in this month! (January 2018)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:12:24
Summer 2018 coming in speed and summer is around the corner  :P

We have been fighting with the headlight for a while... Any of headlight brackets I bought, didn't fit as I wanted, so we made ones by ourselves.
Lots of twisting, banging and forcing...

Result is good for me and finally they came perfect!
(https://s33.postimg.cc/bto3yzyr3/etuvalokiinnike1.jpg) (https://postimages.cc/)

For my eye, Vrod-headlight looks spot on! I like it a lot!
(https://s33.postimg.cc/kooy9i0e7/etuvalo1.jpg) (https://postimages.cc/)

(https://s33.postimg.cc/7xas323hr/etuvalo2.jpg) (https://postimages.cc/)

(https://s33.postimg.cc/uyrd8qxzj/etuvalo3puuttuu.jpg) (https://postimages.cc/)



Speedometer bracket was made from carbonfibre sheet. In pictures there is protectionfilm on cf, so it doesn't show clean and shine cf

(https://s33.postimg.cc/8mtkfd6lb/mittaristo1.jpg) (https://postimages.cc/)

(https://s33.postimg.cc/vbirey3en/mittaristo2.jpg) (https://postimages.cc/)



When I bought GSX-R front end, start-button was broken. Hours and hours in internet and finally I ended the hunt. You can't buy just the button.
I borrowed unbroken button from my friends bike and forwarded it to 3D printing company. Next week I will see, how it ended up.

(https://s33.postimg.cc/9cccrqua7/startnappi.jpg) (https://postimages.cc/)



Part keep on coming. Latest purchase was new ignition coils, ignition wires and sparkplug cups.
These were last part of original electricsystem, so everything is now new.

I sended emails for custom made exhaust and now I'm just waiting for offers.
Also emails sended regarding upholstery for the seat.

Brakehoses has been ordered from HEL Performance and they will arrive in next week

Next one on the list is fabricating front fender. Ideas are all over my head and goal is to make it clean and tiny.

Still trying to think how will I put licenceplate. Finnish licenceplate is huge and I can't figured it out.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:15:12
End of the last year, I decided that new deadline for my bike is 31th of January 2018, so it should be in Finlands biggest motorcycleshow in early february.
As you can see, I didn't make it, BUT I got a call from event organisator. They would still be happy if my bike can make it, even it is not ready...

So 2nd - 4th of february my bike is in the show.
It is not painted nor 100% finished, but still.

It gave me lots of motivation and there is so much going on right now



Start-button
As I wrote, I got start-button from a friend.

We scan it to 3D-model and after that printed it.
It came pretty good. Few minor grinding to do, but it works!

(https://s18.postimg.cc/gwitkczux/startnappi2.jpg) (https://postimages.cc/)
Original button

(https://s18.postimg.cc/vfpylsg55/startnappi1.jpg) (https://postimages.cc/)
First version

(https://s18.postimg.cc/93s5se1ll/startnappi3.jpg) (https://postimages.cc/)
Final version

(https://s18.postimg.cc/jqlyxsmll/startnappi4.jpg) (https://postimages.cc/)
Need to polish it and its good to go


Steeringstem
Way back I ordered steering stem adapter to fit GSXR front end to CB750 frame from Cognitomoto. Like they said, it is bolt-on.

(https://s18.postimg.cc/8r0rm7r1l/Ohjausakseli1.jpg) (https://postimages.cc/)
Original GSXR stem in triple tree, next to new stem.

Just press the old one out and new one in

(https://s18.postimg.cc/qh2g78hh5/Ohjausakseli2.jpg) (https://postimages.cc/)
Here you go.



Part, parts and more parts
Almost everything has been ordered and delivered (I have said this thousand times :D)
Just arrived. New tires, blinkers, bolts and nuts...

(https://s18.postimg.cc/kg4ra6xft/uudetkumit.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/xlk9g1jix/Etuvilkut.jpg) (https://postimages.cc/)

Still to come: exhaust tips with removable silencers, front fender brackets, brakehose brackets...



Welding and grinding
Yesterday we welded few last things and just exhaust brackets and supportframe for carbs are still left.

(https://s18.postimg.cc/f4pupfdx5/koonti1.jpg) (https://postimages.cc/)
Sidepanels grinded, rings for hoses and wires, swing arm spools/sliders bracket, grinded small piece from swing arm, that hit the engine.

(https://s18.postimg.cc/57etwde15/koonti2.jpg) (https://postimages.cc/)
Moved licenceplateholder closer to the wheel, extension to the seatpan, supportpiece to rear shock, brakehose bracket and moved side stand forward, because it was too close to shiftingrod.



Seat and exhaust

I have talked to upholstery who will make my seat complete. It will be done just after the motorcycleshow in february.

Also talked to man, who will make exhaustpipes for this bike in february.
Four invidual pipes from the engine. Two of those will join together on each side under the engine. Two silencers, one in each side will come out just under rear footpegs.
Pipes will be ceramic-coated.


Assembly of the bike is starting next week and then we are going work with rear cowl.

Now it looks like this project will finally finish before this summer  8)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 14, 2018, 15:16:16
We are now swapping front end with correct parts.

As you saw in my last post, stem is already in its place.
Yesterday we push bearing housing to the frame.

(https://s18.postimg.cc/uv3618wvd/laakeripes_1.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/fz4mtnt6h/laakeripes_2.jpg) (https://postimages.cc/)



I ordered two silencers and they look like this:
(https://s18.postimg.cc/ro8mhlpa1/ulostulo.jpg) (https://postimages.cc/)

Exhaust tips will come like this, but not that far:
(https://s18.postimg.cc/uv3618p5l/ulostulot.jpg) (https://postimages.cc/)



Few questions to you readers

1) Enginepaint. What do you suggest, when bike is aircooled? What paint and how? Color should be semi-gloos black.

2) What options is for carburators if I want to get rid of original ones, as they are pain in my ass to get work right.
I would like to get list of carburators from another bikes and also aftermarket-carbs that would do the thing on my bike.

3) Front sprocket is on my searchlist. Below you can see original splined one. I would like to buy 15- or 16-spikes on 530-chain.
What bikes share the same splines? (VFR?).
(https://s18.postimg.cc/vklydl2jt/eturatas.png) (https://postimages.cc/)

4) Is the original front sprocket to chain 530 or to something else?
Has someone welded two sprockets together, to get some off-set?

5) What kind of setup on sprockets you run? I'm thinking 15/40. Is it okay to get some lower torque, but still runnable on highways without hitting revlimiter at 50mph?

6) Where can I order new VIN-plate for my bike?
Picture below.
(https://s18.postimg.cc/p6wvacd3d/vinplate_oikeanumero.jpg) (https://postimages.cc/)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Coopacoopacoopa on Jan 20, 2018, 15:02:23
That last exhaust picture you posted. AutoFabrica right? They build some great looking bikes. Love the project so far!
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: irk miller on Jan 20, 2018, 19:59:13
You're flying through this build, my man.  I love the shape of that Zephyr tank, just curious on that front angle drop.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: irk miller on Jan 20, 2018, 20:05:48
6) Where can I order new VIN-plate for my bike?
Picture below.
(https://s18.postimg.org/p6wvacd3d/vinplate_oikeanumero.jpg) (https://postimages.org/)

There are a couple outfits out of Switzerland and the Netherlands that produce and engrave VIN plates and sell them on eBay.


Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 21, 2018, 13:10:35
That last exhaust picture you posted. AutoFabrica right? They build some great looking bikes. Love the project so far!
AutoFabrica builds amazing bikes! And yes, picture is one of their builds. Thanks!  :)


You're flying through this build, my man.  I love the shape of that Zephyr tank, just curious on that front angle drop.
Thanks! Sorry for my understanding, but what do you mean about front angle drop?


There are a couple outfits out of Switzerland and the Netherlands that produce and engrave VIN plates and sell them on eBay.
I just ordered VIN plate from Khneisser. If I remember correct, they are based in Switzerland
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: irk miller on Jan 21, 2018, 13:48:57
Thanks! Sorry for my understanding, but what do you mean about front angle drop?

I just ordered VIN plate from Khneisser. If I remember correct, they are based in Switzerland

It may be just pics, but with the shorter front wheel that the GSXR front end has plus fitment, the tank drops pretty significantly at the front.  It gives it an angle that doesn't match your frame and seat.  More importantly, depending on where you petcock is located you may lose a significant volume of usable fuel space.  If you draw a level line from the petcock forward, anything below that line will never reach the carb.  Plus, many petcocks have two straws for fuel- one for normal operation and one for reserve.  It's possible you'll have to switch your petcock to reserve with 1/3 tank left.  I could be wrong, so I'm just offering food for thought.  It's a situation I myself have had to adjust for in the past.

(https://s1.postimg.org/4q58mvkk8v/yleinen4.jpg)

I wonder if Khneisser is the same company.  The eBay username is different, but their location is Osagna, Switzerland.  If you think they are the same company, please report how good the quality is.  I need to have a plate remade for one of mine. 
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 21, 2018, 13:55:30
Today we put bike "together". Only 1,5 weeks to go before Finlands biggest motorcycle exhibition.
Lots of parts are now in place but fitment is something like "almost alright", if you now what I mean.

Front end not in its place, upper tripletree and speedometer is too high. Carbs are just hanging there and there is not enough room for middle airfilters.
Exhaust is not the one, which will finally be there. Shiftingrod is attached with zipties. Etc.

So we have less than two weeks to finalize as much of the parts as we can.
Main thing is to work on rear cowl to make bike look more ready and few carbonfibre parts has to fabricate.

Still here is few pics. Feeling much more satisfied when I look my project right now. Looking good for my eye  8)

(https://s18.postimg.cc/5cxu86b7d/kuva1.jpg) (https://postimages.org/)

(https://s18.postimg.cc/jjdl3f1i1/kuva2.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/oi13hyd0p/kuva3.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/7u9lfg2tl/kuva4.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/sr5tk4vpl/kuva5.jpg) (https://postimages.cc/)


If you are in Finland between 2nd to 4th of February, visit Exhibition Center in Helsinki  ;)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 21, 2018, 14:03:51
It may be just pics, but with the shorter front wheel that the GSXR front end has plus fitment, the tank drops pretty significantly at the front.  It gives it an angle that doesn't match your frame and seat.  More importantly, depending on where you petcock is located you may lose a significant volume of usable fuel space.  If you draw a level line from the petcock forward, anything below that line will never reach the carb.  Plus, many petcocks have two straws for fuel- one for normal operation and one for reserve.  It's possible you'll have to switch your petcock to reserve with 1/3 tank left.  I could be wrong, so I'm just offering food for thought.  It's a situation I myself have had to adjust for in the past.

(https://s1.postimg.cc/4q58mvkk8v/yleinen4.jpg)

I wonder if Khneisser is the same company.  The eBay username is different, but their location is Osagna, Switzerland.  If you think they are the same company, please report how good the quality is.  I need to have a plate remade for one of mine.

Good catch/notice!
I haven't thought about that...

Petcock is located exactly middle of the tank and from your notice, this might be a problem.
I will test that in future.


What comes to VIN plate, I just look at emails and it is the same company, located in Osagna.
I will write about quality of my new VIN plate when it arrives and get back to you  :)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jan 23, 2018, 07:42:33
VIN plate just came today!
Quality of the plate is very impressive!

(https://s18.postimg.cc/duc3eumrt/IMG_6792.jpg) (https://postimages.cc/)

If you are looking for a new VIN plate, I highly recommend this company  8)

http://www.khneisser.ch (http://www.khneisser.ch)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: irk miller on Jan 23, 2018, 08:42:34
That's awesome.  Turn-around time seems quick, too.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: 1fasgsxr on Jan 23, 2018, 13:18:36
very nice looking machine !! :D
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Integra99 on Jan 23, 2018, 13:57:11

Looking good... excited to see where it goes!
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Popeye SXM on Jan 23, 2018, 17:35:32
Great bike. I like the swing arm goes well with tank and forks, the vrod light is good too. Custom work takes time huh?
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: ZenMoto on Jan 24, 2018, 05:36:59
VIN plate just came today!
Quality of the plate is very impressive!

(https://s18.postimg.org/duc3eumrt/IMG_6792.jpg) (https://postimages.org/)

If you are looking for a new VIN plate, I highly recommend this company  8)

http://www.khneisser.ch (http://www.khneisser.ch)

This is a great find. ...and a great looking build you have going; I can't wait to see the finished product!

Maybe I should have said the Finnish-ed product?  lol
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: WhyNot on Jan 24, 2018, 06:54:11
Really looks good......

Nice job...
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Feb 10, 2018, 05:30:22
That's awesome.  Turn-around time seems quick, too.
Plate came very quickly!


very nice looking machine !! :D
Thanks!  :)


Looking good... excited to see where it goes!
Thanks!  :)
I'm just starting to feel excited, because this build is now moving on in speed


Great bike. I like the swing arm goes well with tank and forks, the vrod light is good too. Custom work takes time huh?
I had lots of negative thoughts and swing arm confused my head in one point of this build. I didn't know do I like it or not  :D
After assembly of the bike to this point, it now looks really good. Lines and shapes goes well with everything else, just like you said  ;)


This is a great find. ...and a great looking build you have going; I can't wait to see the finished product!

Maybe I should have said the Finnish-ed product?  lol
;D ;D ;D  Thanks!


Really looks good......

Nice job...
Thanks!  :)


And thank you guys for leaving comments and questions!
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Feb 10, 2018, 06:03:18
Exhibition weekend was last week and it went great!
We had a blast!

Here are few pics from the event

(https://s18.postimg.cc/hzijlreop/mpmessut2.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/v3o3yf45l/mpmessut1.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/smccr729l/mpmessut3.png) (https://postimages.cc/)

(https://s18.postimg.cc/bltgii22x/mpmessut4.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/8eywyv9x5/mpmessut5.jpg) (https://postimages.cc/)
Nice to see lots of people looking and talking about my own project...


As you may have already guessed, I didn't won in any class  :D
Bike is way too unfinished, so we will have to wait until next year...

You also might note that rear cowl is looking like s**t.
I made it in one day from woodboards  :o  I thought that it will look pathetic if I don't make some kind of rear cowl.

(https://s18.postimg.cc/ktloz6tpl/per_1.jpg) (https://postimages.cc/)
Base is almost finished

(https://s18.postimg.cc/94hpbcd2h/per_2.jpg) (https://postimages.cc/)
Lots of grinding and some more grinding

(https://s18.postimg.cc/h9zr9elux/per_3.jpg) (https://postimages.cc/)
This is the final shape and after that, I used filler, then some more grinding and finally put paint on it.

This will not be even close to what I'm looking for to do.



Also had a major backfire. From this picture you can see my problem

(https://s18.postimg.cc/827isnp2h/eitilaa.jpg) (https://postimages.cc/)
I don't have enough room for two middle pods, because rear shock has its capsule/container in the way...

Well I just bought new shock(s) and thinking of doing something uncommon... Stay tuned...
(https://s18.postimg.cc/bltgijcdl/iskarit.jpg) (https://postimages.cc/)



Today my friend is welding my sidestand shorter, because bike is way more lower than original, sidestand cannot be used right now.
He will also weld offset front sprocket.

(https://s18.postimg.cc/5xn5ro2w9/rattaat1.jpg) (https://postimages.cc/)
Chain will be 530.
Old sprocket will go to turning machine (lathe) and it will remove all teeths from the sprocket. Also centerledges on both side will be shaved off.
New sprocket will have its one side centerledge to go.

(https://s18.postimg.cc/584dfamx5/rattaat2.jpg) (https://postimages.cc/)
After previous step, they will be joined together.


In two weeks I will receive my seat from upholstery. Can't wait to see it.
Next week my bike will go to mastermechanic, who will make custom exhaust for my bike. So it will stay in there about 2 weeks.


There might be a little silence in here for two weeks, but I will get back to as soon as possible  8)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Feb 10, 2018, 06:07:40
I have question and I hope you guys could help me.
This might be very stupid, because I haven't done my homework/googling enough. Didn't find answer quickly...

What kind of options there is to upgrade DOHC engines eletronic ignition?
And does these thing have already electronic ignition?
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: LightsOut on Feb 10, 2018, 08:59:22
Not sure about the K bikes, but the Fs have electronic ignition. It can definitely be upgraded if a lot of engine work has been done to make sure it runs as good as possible. Dyna is available but Ignitech is supposed to be even better. For the Fs one of the best and easiest upgrades is replace the coils with CBR F2 coils, which are just plug and play. Not sure if that applies to the Ks as well.


Sent from my iPhone using DO THE TON
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: john83 on Feb 11, 2018, 13:51:18
Good looking work so far!
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Feb 12, 2018, 00:47:41
Not sure about the K bikes, but the Fs have electronic ignition. It can definitely be upgraded if a lot of engine work has been done to make sure it runs as good as possible. Dyna is available but Ignitech is supposed to be even better. For the Fs one of the best and easiest upgrades is replace the coils with CBR F2 coils, which are just plug and play. Not sure if that applies to the Ks as well.
I have been looking for Dyna-kits, but everyone I have found is suitable only for SOHC engines.
I haven't put effort enough for the search and still like to here suggestions from you guys  ;)

Coils are already upgraded!


Good looking work so far!

Thanks!  :)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: LightsOut on Feb 13, 2018, 15:38:43
I have been looking for Dyna-kits, but everyone I have found is suitable only for SOHC engines.
I haven't put effort enough for the search and still like to here suggestions from you guys  ;)

Coils are already upgraded!


Thanks!  :)

Here's a DOHC kit on DCC (this one's with coils, didn't look if there was one without)
https://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-dyna-high-performance-ignition-kit-cb750-cb900-cb1100-618-861.html
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Feb 28, 2018, 15:40:15
Bike is currently in a workshop for a custom exhaustsystem. Work will be done in mid-March.
Workshop will also fabricate plug for stopping oil spreading all over the engine from tachometercable hole (idk what it is called  ;D)

Before we took it there, we finished shorting the sidestand.

(https://s18.postimg.cc/6c1yhf0ih/project.jpg) (https://postimages.cc/)
 
(https://s18.postimg.cc/z1oue2zdl/jalka1.jpg) (https://postimages.cc/)
Shortened sidestand. Bike is way more lower than original, so it had to be done.

(https://s18.postimg.cc/iqoqhr7g9/tappi1.jpg) (https://postimages.cc/)
Welded little pin to the frame, which will stop sidestand hitting the frame. Have to buy a little rubberpiece end of it, so it will not scratch the paint

(https://s18.postimg.cc/yc621pr49/tappi2.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/nckuq4g4p/jalka4.jpg) (https://postimages.cc/)
It came perfect


Friend of mine finished welding the offset front sprocket.

(https://s18.postimg.cc/4k8zmh6ux/eturatas.jpg) (https://postimages.cc/)
Looks amazing and works perfectly

(https://s18.postimg.cc/ormfetmcp/ketjulinja1.jpg) (https://postimages.cc/)
Have to do minor work for the chainline. It is almost straight, but not enough yet


My seat came from the upholstery.

(https://s18.postimg.cc/wkd36rxgp/satula.jpg) (https://postimages.cc/)
I'm digging it  :-*

Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: LightsOut on Mar 02, 2018, 08:41:37
Looks great! Donít think Iíve seen a custom welded front sprocket before, but thatís some really neat welding. I believe there are offset sprockets available from somewhere in Germany, not that you need it now.


Sent from my iPhone using DO THE TON
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Mar 05, 2018, 08:15:29
Looks great! Donít think Iíve seen a custom welded front sprocket before, but thatís some really neat welding. I believe there are offset sprockets available from somewhere in Germany, not that you need it now.

Sent from my iPhone using DO THE TON

If you know the company who makes these offset sprockets in Germany, please let know, because you never know when you need on of those  :)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Tim on Mar 05, 2018, 10:47:06
That's some serious welding - I didn't know you could effectively weld hardened steel like a countershaft sprocket.  Looks like two sprockets became one?  Turned down another to use the splined section?

Too bad the weld will be invisible once installed - that's some pretty welding.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Popeye SXM on Mar 05, 2018, 12:08:48
I am not sure these sprockets fit your bike, you will have to measure the shaft, but check Speed Moto out. www.speedmotoco.com/category-s/6.htm or PBI Sprockets, www.shop.pbisprockets.com/product.sc;jsessionid=9D81BFE4A4E43B6242C22057A77DD544.p3plqscsfapp004?productId=465
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: cb250nproject on Mar 06, 2018, 00:13:41
Insane build canít wait to see it finished


Sent from my iPhone using DO THE TON
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Mar 06, 2018, 08:17:27
That's some serious welding - I didn't know you could effectively weld hardened steel like a countershaft sprocket.  Looks like two sprockets became one?  Turned down another to use the splined section?

Too bad the weld will be invisible once installed - that's some pretty welding.
I didn't know either, but somehow my friend did it. He said also that this thing will last and do not break in two pieces, with power bike has atm.


I am not sure these sprockets fit your bike, you will have to measure the shaft, but check Speed Moto out. www.speedmotoco.com/category-s/6.htm or PBI Sprockets, www.shop.pbisprockets.com/product.sc;jsessionid=9D81BFE4A4E43B6242C22057A77DD544.p3plqscsfapp004?productId=465
I will check these out


Insane build canít wait to see it finished
Sent from my iPhone using DO THE TON
Thanks!  8)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: LightsOut on Mar 07, 2018, 09:35:41
If you know the company who makes these offset sprockets in Germany, please let know, because you never know when you need on of those  :)

KrŁger & Junginger - http://www.krueger-junginger.de/html/versatzritzel.html
Ritzel is apparently sprocket in german :)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Mar 19, 2018, 11:24:41
UPDATE!

As I told in my previous post, the bike was in a workshop for exhaust modification and to plug tachometer hole.

Around 1,5 weeks ago, I found used carbs from Germany. Those should be much easier to adjust/set/tune to work with pods.
I called to the seller and we talked several times. Carbs are in good condition and straight from the bike, so they haven't been laying down for long.

I paid upfront and crossed my fingers, that the package will arrive and it includes right items  ;D

Finally, I got the package and these beauties were inside:
(https://s18.postimg.cc/unqlv32xl/vm29ss.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/dagbgca89/vm29sss.jpg) (https://postimages.cc/)

From 1985 Suzuki GSX-R Mikuni VM29SS Flatslide carbs
The package included 6 sets of different size jets.

I delivered carbs to the workshop as fast as I could.

They changed the distance of the carbs to each other, so it could fit.
They also made sleeves for intake rubbers to fit them.


Yesterday I picked up my bike and I think the work they have done, is brilliant  8)

Tachometer hole was blocked by detachable piece.
(https://s18.postimg.cc/vd9e7gqmh/tulppa.jpg) (https://postimages.cc/)


Carbs
(https://s18.postimg.cc/pp33gl1pl/kaasarit1.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/6jzu6ss6h/soviteholkit.jpg) (https://postimages.cc/)
 
While they made this fitment, they checked the condition of the carbs. Everything was good. The only thing they fixed was twisted choke rod.
Still, have to clean outer shell of the carbs.

I ordered new pods, although those velocity stacks look really good  8)


What about the exhaust?
Firstly I wanted 4-2 exhaust system with two exhaust tips.
We put that idea aside because the chain was so low, that exhaust tip on that side would look terrible...

Also, we needed as much ground clearance as possible because the bike is way lower than original.
The 4-1 system would have so huge connector that I didn't want it.

The workshop suggested that we do 4-2-1 system

First pictures of connector pipes:
(https://s18.postimg.cc/pcbpaebq1/yhdysputket2.jpg) (https://postimages.cc/)

Here are the pics:

(https://s18.postimg.cc/ywvbx8bbt/alkukayrat.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/x52d2dx4p/yhdysputket.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/m5h5qrbuh/jousikiinnitys.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/a3lrwlfgp/putkikokonaan.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/5uh1uewrt/putkistokokonaan2.jpg) (https://postimages.cc/)

(https://s18.postimg.cc/lfydedgft/ulostulo.jpg) (https://postimages.cc/)

I know this thing will not be the quietest bike in a hood, but the silencer will have a tube, wrapped in silencing fabric, so will see if it makes a difference...
If not, I have to buy a real silencer

This Friday I am finally able to move in the new garage and can get to the business!
Three most crucial jobs are to get chainline corrected, make a new bracket for rear shock(s) and to fabricate rear cowl.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Apr 07, 2018, 08:22:31
Things happening in my garage and summer is coming fast!

My own deadline that I set to myself is 1st of June (yes, this year!  ;D)
If I don't face any major problems, I think I can finish this before June

I'm pretty sure I mention in my previous posts that I have to move my garage to new location.
It happened two weeks ago.

Found a new place and I'm sure that I don't run out of space  ;D

(https://s31.postimg.cc/8ia1uyp63/talli1.jpg) (https://postimages.cc/)

(https://s31.postimg.cc/pisy3muhn/talli2.jpg) (https://postimages.cc/)


Recap of whats going on

Bought new rear sprocket and chain. The chain is 530 X-ring and rear sprocket is Snell's 40 tooth.

We've been fighting with the chainline to long. Finally I can say it is straight! Problem was solved with that offset front sprocket.

(https://s31.postimg.cc/3wdxmklmj/ketju1.jpg) (https://postimages.cc/)

(https://s31.postimg.cc/3jmjgdvmz/ketju2.jpg) (https://postimages.cc/)

(https://s31.postimg.cc/9xbmjml3f/ketju5.jpg) (https://postimages.cc/)

(https://s31.postimg.cc/u4p2bysvf/ketju4.jpg) (https://postimages.cc/)
It helped a lot when I bought chainlining tool. It doesn't looks bullet straight in this pic, but should be

(https://s31.postimg.cc/gns3t334b/ketju3.jpg) (https://postimages.cc/)


We replaced rear chain tension bolt, because old ones were damaged and they had very small head
I have ordered new wheel bearings also.

(https://s31.postimg.cc/jumncqiff/uudets_t_pultit1.jpg) (https://postimages.cc/)


First time ever, I was able to fit seat to the bike with tank on.
I like it a lot and I was able to get more riding feeling when I sat on the bike.

(Please, do not note that awful rear cowl  ;))

(https://s31.postimg.cc/6dpottanv/etuviisto1.jpg) (https://postimages.cc/)

(https://s31.postimg.cc/wm0tj8khn/IMG_7221.jpg) (https://postimages.cc/)

(https://s31.postimg.cc/3jmjgeisb/sivu2.jpg) (https://postimages.cc/)
Still able to find few "cafe racer" twists or touches from this bike

(https://s31.postimg.cc/kk5fp4du3/takaa1.jpg) (https://postimages.cc/)
I like the lines in this pic

(https://s31.postimg.cc/e6gclsw2j/sivu1.jpg) (https://postimages.cc/)

(https://s31.postimg.cc/h0jhzb3ej/IMG_7208.jpg) (https://postimages.cc/)


Some of you notice earlier that I might have a problem with my fuel petcock.
That because it is located in back of the tank and tank is leaning forward a bit.

So will it work? Do I get enough fuel out of it?

We tested this out:
Capacity of the tank is 15 litres
Petcock in On-position -> 11 litres came out easily
After that, petcock in Reserve-position -> 3 litres came out

Overview:
Basically there is 1-2 litres fuel that cannot be sucked in the engine.
I think that 12-13 litres is okay. I'm used to fill up my tank when I'm running around 50% of capacity of the tank.
And we are not building touringbike  ;)

New licenceplate holder came and minor modifications have to be done.
New ignitionswitch came and I already figured out, where I want to locate it


Next week I'm planning to do smaller tasks, because I'm waiting my new rear shock to arrive.
(I'm not going to use those two cheap china shock I ordered)

I'll get back to you, when I have something more to share  8)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: J-Rod10 on Apr 07, 2018, 08:27:08
It may not have much of an effect, but it may. But, a 4-2-1, you want 1 & 4 connected, and 2 & 3.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Apr 07, 2018, 08:32:22
It may not have much of an effect, but it may. But, a 4-2-1, you want 1 & 4 connected, and 2 & 3.

I'm feeling stupid right now, but what are you saying?
I don't know which question did you answer  :-[
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: irk miller on Apr 07, 2018, 09:28:13
I'm feeling stupid right now, but what are you saying?
I don't know which question did you answer  :-[

He's referring to your exhaust.  Because of the firing order on these, best performance is achieved when exhaust port 1/4 and 2/3 are matched together.  You have 1/2 and 3/4 matched.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: J-Rod10 on Apr 07, 2018, 12:22:03
What Irk said.

This is the proper routing for a 4-2-1 header.

Something or another to do with exhaust scavenging. (https://uploads.tapatalk-cdn.com/20180407/b2e8a0737f77c75b2f43b7afc9117fe5.jpg)

Sent from my VS988 using Tapatalk

Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Apr 11, 2018, 00:25:39
Thanks guys!
I wonder how much effect this does, but we will see.

Guy who made exhaust is well known racingbike builder, so I think he knows what he do.
But we will see.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Apr 23, 2018, 07:32:27
Just fixed links to pictures.
Problem with the picturehost...

Update coming in later this week!!
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Brent on Apr 23, 2018, 08:06:00
The pipe length from port to collector should be the same on each cylinder.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Brent on Apr 23, 2018, 08:08:20
Guy who made exhaust is well known racingbike builder,

That's surprising.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Rat_ranger on Apr 23, 2018, 09:35:47
Not that surprising with how many modern sportbikes have 1-2, 3-4 merge.  Well set up I don't think it'll make a huge difference.  I know merging 1-4, 2-3 helps mid range torque, but merging 1-3, 2-4 done right just acts like a 4 into 1 which is more for top end.  And if it couldn't be made to perform I think factories would have changed it up by now.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: 1fasgsxr on Apr 23, 2018, 13:15:46
Not surprising to me.. here is a stock Gsxr 1000 header from 01-02.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: irk miller on Apr 23, 2018, 13:35:50
I'm pretty sure the firing order on a GSX1000r is 1-2-4-3 (outside in), which is  different from the CB750.
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: 1fasgsxr on Apr 23, 2018, 15:09:59
maybe I should have owned more Hondas over the years  ;D
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on May 05, 2018, 08:04:46
Solved few big problems...

Rear shock.
Original GSXR1000 rear shock had a gaschamber and it was way too close to the carb, so I couldn't fit the pods.
Finally solution was to buy a new rear shock

YSS MZ456-305TR-28X. Model is made to fit in Honda CB600 and length of it is 305mm.
(https://s31.postimg.cc/sf0jf1waz/uusi_jousi.jpg) (https://postimages.org/)

Only problem was that this shock had loop-style lower end and I needed fork-style lower end. Also this shock doesn't have interchangeable lower end.

(https://s31.postimg.cc/61ssst8e3/alkuper_inen_haarukkakiinnike.jpg) (https://postimages.org/)
Original fork-style lower end

(https://s31.postimg.cc/h1e04fe8r/uuden_jousen_silmukkakiinnike.jpg) (https://postimages.org/)
New shock with loop-style lower end

After some googleing I contacted YSS seller in Finland and they said straight away: "Sure we can change it"  8)

Sended shock to them and after couple days they had switch the whole lower body and center arm. Lenght extended from 305mm to 320mm, which was better than great to me!

(https://s31.postimg.cc/3yidkknuj/uusi_jousi_uusi_kiinnike.jpg) (https://postimages.org/)
Ready to rock!

Now rear shock is attachted. Shock is just right length and has great stiffness, so when you sit down, the rear end doesn't get much lower than in the pics.

(https://s31.postimg.cc/uv2ctfwjf/jousi_kiinnitettyn.jpg) (https://postimages.org/)

(https://s31.postimg.cc/nf337mdyz/jousi_kiinnitettyn_2.jpg) (https://postimages.org/)
Stance is great! I like size of the gap between rear wheel and rear end of the bike


Shipment from the states
4into1 send me a package. It contains new pods, sidestand spring and exhaust gaskets.
Pods look and feels good and finally they have enough room to fit in.  8)

(https://s31.postimg.cc/4zimaacq3/suodattimet.jpg) (https://postimages.org/)

(https://s31.postimg.cc/dujgksm2z/suodattimet_1.jpg) (https://postimages.org/)


Parts keep coming, but I think I can finally see end of this buying period  :D
Last purchases
- Kawasaki Z750 -06 clutchlever setup
- Shorty-style clutch- and brakelevers
- New front and rear brake fluid reservoirs
- Rubber bits for fastening the tank etc.
- New throttlegrip
- Fuel hoses and filter
- Brake fluid hoses

(https://s31.postimg.cc/fz3tlv8a3/osia.jpg) (https://postimages.org/)

(https://s31.postimg.cc/gomly768r/kytkinkahva_shortylla.jpg) (https://postimages.org/)
Z750 clutch setup and new lever

(https://s31.postimg.cc/tss6aw60b/jarrukahva_shortylla.jpg) (https://postimages.org/)
GSXR1000 brake setup and new lever

Still to come:
- New battery
- Wires and electricparts
- Leather wax for the seat
- New mirrors


I also bought Por15-set to coat/seal tank from from the inside.
More of this later.


Next huge thing is to settle wires and start this beauty for the first time in 18 years. Fingers crossed!!
First step for the wiring is done, but lets get back to that later

(https://s31.postimg.cc/xp5i6uoez/alk_per_johtosarja.jpg) (https://postimages.org/)
Original wirings


Months ago I bought bar end mirrors and turn signals.
Just like I thought, I can't install them at the same time because they both use same kind of fastening.

I really want mirrors and turn signals to my bike, although legally you could leave turn signals and one of the mirrors to the garage.

So we came up with this plan:

(https://s31.postimg.cc/hqwsgqhcb/peili_vilkku_alku.jpg) (https://postimages.org/)
From the factory this is the set-up. Lens -> threaded rod -> rubber -> washer -> nut.
By tightenin the nut rubber will expand and when you push whole thing inside of your bar, it should stay there.
(same set-up with the mirrors)

This is what we did.
I bought same size threaded rod but longer piece. Drill it through, so it became threaded tube and pull the wires through.
Rod to the lens -> fabricated metal sleeves(?) for the mirror -> mirror in -> nut to tighten mirror to the lens -> Rubber piece (will buy longer one) -> washer -> nut.

Pics:
(https://s31.postimg.cc/cs9a288ej/peili_vilkku_asetelma.jpg) (https://postimages.org/)
Exploided set-up

(https://s31.postimg.cc/aaxiuyw7v/peili_vilkku_valmis.jpg) (https://postimages.org/)
Finished set-up

This way I got what I wanted.

Clip-ons has to be modified. Have to drill a hole to get wires out.
Wires will come out to the original "box" where all main switches are. Then from there in same route that all the other switches wires goes.


Thinking the future... Wiring, start-up, rear cowl and paint.
Have a good weekend!  ;)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: cb250nproject on May 14, 2018, 08:01:36
Iím loving this build thread, inspirational


Sent from my iPhone using DO THE TON
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on May 19, 2018, 07:21:01
All the parts for the first startup is now ordered and should arrive in next week.

I ordered a new neutral switch, an oil pressure switch and a small diode for the main wiring.
All the hoses, filters and wires has already arrived.

New coils, sparkplug wires and -caps
(https://s7.postimg.cc/lr0m6hk7f/coils.jpg) (https://postimages.org/)

All main wires are connected. (battery->ground / battery->starter relay / starter relay->startermotor)


I have red from multiple forums about regulator location.
I'm going to move the regulator from the tray to outside to get some air.
Have to figure out where to put it...


Location of the licenceplate... Well had to make decicion and the plate found place side of the bike.
(https://s7.postimg.cc/40yxlf41n/licence1blurred.jpg) (https://postimages.org/)

Workshop machined 1/3 off from the bracket so it have a step in the bracket and can be locked to end of the rear swing.
(https://s7.postimg.cc/hunaai6xn/licence2.jpg) (https://postimages.org/)

Licenceplate lights
(https://s7.postimg.cc/x3d7o8y17/licence3.jpg) (https://postimages.org/)
(https://s7.postimg.cc/su8hm3hx7/plate.jpg) (https://postimages.org/)


I was bored so I made these carbonfibre plates to cover front fender fastening points.
(https://s7.postimg.cc/9p58cal8r/cfparts.jpg) (https://postimages.org/)



I picked up my clip ons from the workshop.
They drilled inner hole longer and made hole to the side so I can get front turn signal wires out.
(https://s7.postimg.cc/9p58cbntn/drilled.jpg) (https://postimages.org/)
(https://s7.postimg.cc/shh3fxmsr/drilledclipons.jpg) (https://postimages.org/)


This is the final setup
(https://s7.postimg.cc/vbk8tcu3v/finalsetup.jpg) (https://postimages.org/)

For the final setup we changed few things:
I made new metal sleeve that goes straight through to mirror. To this sleeve we made threads so it can not rotate.
Also we drilled the locking pin through mirror and that sleeve, so the mirror can not rotate on the sleeve.

At this point it might work  8)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Jun 02, 2018, 06:19:36
Fuel lines done

Fuel line from the tank -> fuel filter -> carbs.
It was little tricky to figure out where and how to put fuel filter without too much "uphills" and turns to the hose.

(https://s15.postimg.cc/jjypoqx6j/IMG_7643.jpg) (https://postimages.org/)
I used pipeclamp with rubber insulation to hold fuel filter in its place

(https://s15.postimg.cc/5diytjh6j/IMG_7644.jpg) (https://postimages.org/)




Coating the tank

(https://s15.postimg.cc/km8w7anpn/IMG_7664.jpg) (https://postimages.org/)
The fuel tank is old and has little rust inside. When I filled it with water, it was all over rust-colored when I poured it out.
Also you could hear little crumbles rolling around at bottom of the tank.

I bought Por15-kit.

First I have to say you all who are planning to do this: the process is from hell and takes huge amount of your time  ;D

(https://s15.postimg.cc/qzxzalam3/IMG_7663.jpg) (https://postimages.org/)
First instructions advice you to flush the tank with fresh water to get bigger particles out straight away.
Remove every removable part (petcock, fuelcap etc.)

(https://s15.postimg.cc/j77bilhhn/IMG_7665.jpg) (https://postimages.org/)
After that you have to clog all holes excluding filling hole.
First issue comes at this point. As you may know or guessed, these duct tapes doens't hold when you are going to use hot water...

My advice to you is to fabricate pieces from a sheet metal or something that you could bolt tightly to cover holes.

(https://s15.postimg.cc/tu14o1ki3/IMG_7667.jpg) (https://postimages.org/)
1. step in the real process is to put Marine Clean in. Add same amount hot water.
This will remove grease and other not-wanted-stuff.

(https://s15.postimg.cc/pkwelvwob/IMG_7668.jpg) (https://postimages.org/)
After that seal filling hole and pray it will hold  ;D

I shaked the tank about 15 to 20 minutes and after that I let it stand 10 minutes on its each side.
Finally flush it with fresh water to get all cleaner out

2. step is to put Metal Prep in. It will prepare metal to receive coatingliquid.
Same process again. Clog holes, metal prep in, seal the filling hole.

I shaked the tank approx. 20 minutes and after that let it stand 20 minutes on each side of it.

Finally flush it good with fresh water. Even the last drop of metal prep has to get out.
After this you should get the tank 100% dry and fast as possible.

I took the tank outside to the sunlight... (its been crazy May in Finland. Temperature between 24 to 28 celsius. Normally we would talk about 15 celcius)
I shaked most of the water out and finally put hot air blower to heat up. (you are not allowed to use compressed air)

Last phase its coating

Before you clog holes one last time, you should put bolts in, because coatingliquid will coat up threads also.

You should not shake the canister, because it would produce some air bubbles and you don't want them. Although you have to stir it well before using.
(https://s15.postimg.cc/z5g18rtq3/IMG_7669.jpg) (https://postimages.org/)

(https://s15.postimg.cc/6skjibfpn/IMG_7670.jpg) (https://postimages.org/)
Liquid in, seal holes and gently rotate tank all around.

Many times I thought will this work and will it cover all edges and sides of the tank.
Apparently liquid is pretty "smart" and will expand all over the tank.

After rotating 15 minutes I poured excess liquid out and cleaned outside spills asap.
You should use gloves because this stuff will be in our hands atleast two weeks  ::)

It will dry 96 hours and after 7 days you can put gasoline in.

These pics are after two days of drying and as you can see, some air bubbles formed during the last phase.
Surface looks good
(https://s15.postimg.cc/cti8fea1n/IMG_7676.jpg) (https://postimages.org/)

(https://s15.postimg.cc/g0crz1x2j/IMG_7677.jpg) (https://postimages.org/)


I'm not sure did I post picture of this already, but my friend from the states dropped me cognitomotos gearlever adapter.
(https://s15.postimg.cc/pxnss1cd7/IMG_7645.jpg) (https://postimages.org/)

(https://s15.postimg.cc/7i3bumb3f/IMG_7646.jpg) (https://postimages.org/)
In these pics adapter is in wrong way because gear selection order is upsidedown.



What comes to wiring this beauty, new diode arrived...


(https://s15.postimg.cc/tu14o2usr/IMG_7695.jpg) (https://postimages.org/)
...new neutral switch...


(https://s15.postimg.cc/y35uq9dhn/IMG_7697.jpg) (https://postimages.org/)
...and new oil pressure switch.


We are now going through wiring and this picture shows my mood atm
(https://s15.postimg.cc/75bxoj0kb/IMG_7710.png) (https://postimages.org/)

This wiring sh*t is not my cup of tea.

But will see...
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Marcushyden on Aug 21, 2018, 03:54:35
Two and half months since last post...
Positive progress has happened but lately some negative things also

Wiring this bike was pretty difficult for me and finally I made a decision to buy a m-unit with goodies

(https://s33.postimg.cc/ytmrvcwcv/s_hk_t.jpg) (https://postimages.org/)
Set included m-unit V.2, m-switches and m-button

With these great items I figured out wiring and also made it very easy.
Finally bike was ready for her first start up

I might have told you but this bike hasn't been running since year 2000.
Its 18 freakin' years!

Well that day came and after long time period of trying, it finally came alive.
I was so nervous but happy after everything.

Here is a short video of its very very first start up.

https://youtu.be/mvBoKwl0aLY (https://youtu.be/mvBoKwl0aLY)


What about those negative things...

Time. As you all know, time is one of the hardest thing to control.
This project should be on the road if you ask me, but our time is limited and first thing where you see it is here in this project. Unfortunately.
It was greatest summer in Finland that I have ever lived, so I was more in to other things than this project.

Next big thing is location. Bike is currently in my parents house 18km away from my home or from my work.
You don't just go and do few things for a hour.

By now it looks like this bike is not going to be driven this summer/autumn, so I think I will have my own garage opened again in autumn.
After that it is easy to take few stairs and go to do something.

New problem came when we noticed that lower cylinder gasget is leaking a lot.
(https://s33.postimg.cc/kafmtyaxr/tiiviste.jpg) (https://postimages.org/)

This mean I have to open the engine again and change that gasket.
Motivation level just dropped to zero  ;D

Someone could say "this is motorsport" and I think that someone would be right.

Also two carbs was overleaking and we found out that needlevalves were faulty. Ordered new ones and changed them. Doesn't leak anymore.
(https://s33.postimg.cc/wcb0o34qn/neulaventtiilit.jpg) (https://postimages.org/)

My to do -list is simply and ready so I know exactly what to do and everything is already planned.


p.s.
Do you know any companys around Europe that could make customlength cables for throttle and clutch?
Not feeling right with original long ones.
(https://s33.postimg.cc/e9hxwvw1b/vaijerit.jpg) (https://postimages.org/)
Title: Re: New Age Cafe Racer - Honda CB750 -79 from Finland
Post by: Bevelheadmhr on Aug 21, 2018, 08:00:04
I always use Venhill for cables, they make kits and also bespoke cables.. 

https://www.venhill.co.uk/cables-amp-components/workshop-kits.html