DO THE TON

Blood Sweat Tears and Grease => Projects => Bob and Chop => Topic started by: clem on Oct 20, 2011, 22:42:50

Title: Nighthawk Bobber - CB550sc
Post by: clem on Oct 20, 2011, 22:42:50
Well, I hope that I don't get the axe for having a DOHC honda but here we go. I bought the bike back in the early 90's for $500 and it was in good condition. I rode it for about 2 years then it started having charging issues and I parked it. I figured that I would tear the bike completely down, clean it, then troubleshoot the electrical when it was going back together....It never got put back together! About 5 years after that I tried an ill faded attempt at a mild "Kong" job only to go unfinished due to no welder. That brings us to the early part of this year when I got the idea to do a full hardtail bobber even though it is a shaft drive.
Here is how it once looked:
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/Honda20CB550SC2082.jpg)
After the Konging!Lol
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/IMG_0536.jpg)
The bobbing process:
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/IMG_0540.jpg)
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/IMG_1237.jpg)
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/IMG_1242.jpg)
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/IMG_0628.jpg)
I've got the engine torn down right because I found water in the oil. I realized that I left the engine on the floor of my dad's shop back in 98 for a hurricane and it got about 6" of water in the shop!
Hopefully I'll get it back together soon.Looking to get the bike on the road by April.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Oct 23, 2011, 22:29:43
I spent most of the afternoon soda blasting the engine cases today. After being covered from head to toe in baking soda I actually feel refreshed.
I was looking at the cyclinders today and I'm hoping a good honing will fix them up then I'll have to hunt down a new set of rings. Going through this thing is showing me how bad it actually is to let an engine sit for 10+ years.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Oct 23, 2011, 22:39:48
Does anybody have a good recomendation for removing the old gaskets? Tried the NAPA gasket remover but that's a mess in a can.
Title: Re: Nighthawk Bobber - CB550sc
Post by: sasquach on Oct 24, 2011, 01:27:20
Looks good .
Title: Re: Nighthawk Bobber - CB550sc
Post by: Maritime on Oct 24, 2011, 10:31:25
I used a scotch bright pad to get rid of old gasket.  A razor blade can work but you have to he very careful not to cut the aluminum and ruin your mating surfaces.  Cool build BTW.

Nice to see a good frame built with a Jig Etc.  Are you going to run the shaft exposed?  It would be neat to coat it in a nice powder colour that contrasts with whatever you do for a frame colour.
Title: Re: Nighthawk Bobber - CB550sc
Post by: MotorbikeBruno on Oct 24, 2011, 11:16:09
Looking forward to this build!  I agree with Maritime too...a nice contrasting color would be slick.


Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Oct 24, 2011, 17:20:13
Thanks for the tip on the gasket removal. I really thought that the soda would take it off but it didn't. The shaft will be exposed like an old BMW. As far as paint, I was shooting to do the tank and rear fender like the old elsinore honda's from when I was a kid. I think they were silver with the black strip down the middle, the frame will be black and I'm going to blast the rims and clear over the aluminum. I thought about putting some powder coat on the shaft but other than black, I'm clueless as to what may look good on the shaft.
Title: Re: Nighthawk Bobber - CB550sc
Post by: Erskine on Oct 24, 2011, 19:12:13
Very nice bit of engineering there mate :)
Title: Re: Nighthawk Bobber - CB550sc
Post by: Maritime on Oct 24, 2011, 19:36:11
Match the tank, that would be cool.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Oct 24, 2011, 20:14:57
Very nice bit of engineering there mate :)
You talking about the unistrut frame jig? Haha

Maritime that would be cool to have some pinstripes on the shaft! There is a housing at the end for the worm gear that's thicker, would be cool to paint a little number plate on there. I think they were green back then, I'll have to find some of my dads old pictures of his cr250.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Oct 26, 2011, 09:47:44
Thought that I would post a pic of the custom triple clamp that Dave Munz over at Munz Engineering made for me
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/ae254d14.jpg)
Title: Re: Nighthawk Bobber - CB550sc
Post by: dean owens on Oct 26, 2011, 12:40:44
love the jig.  i'd love to one day have those skills.
Title: Re: Nighthawk Bobber - CB550sc
Post by: MotorbikeBruno on Oct 27, 2011, 11:44:50
Looking real slick. Love the "old" honda dash (that is in incredible condition!)  And that triple clamp looks awesome!
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Oct 27, 2011, 17:26:17
Looking real slick. Love the "old" honda dash (that is in incredible condition!)  And that triple clamp looks awesome!
Thanks Dude, Dave Munz was easy to work with for the triple clamp. He'll do one off customs at reasonable prices. The thing that tripped me out about the old Honda instrument light cluster is that the lower portion is from a 2008 CRF450R motocrosser and the shape and bolt hole pattern are exactly the same. I was thinknig that since there is close to a 30 year difference between the two parts that they might not line up but they fit perfectly. Since the bike had no cool factor when I bought it I figured that I would take stuff from different era hondas and mix them up on this build. Hey I may soda blast that indicator light cluster and polish the raw aluminum.
Title: Re: Nighthawk Bobber - CB550sc
Post by: CrescentSon on Oct 30, 2011, 06:23:25
I so want you to pull this off. A nice Nighthawk bobber would fit in well around here.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Oct 30, 2011, 23:02:50
I so want you to pull this off. A nice Nighthawk bobber would fit in well around here.

Yea, I want to do it right. I've seen alot of bikes that just look like they were hacked up and I don't want to do that! This site has some of the best garage/home builds that I've seen and that's a big reason why I'm here.
Does your name refer to the Cresent City?
Title: Re: Nighthawk Bobber - CB550sc
Post by: CrescentSon on Oct 31, 2011, 03:35:35
Nope, it is an over thought play off the heraldic marks of cadency.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Nov 01, 2011, 14:03:58
Started painting the engine after soda blasting it:
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/a99b017d.jpg)
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/aa85d2fe.jpg)
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/db6e28c6.jpg)
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Nov 11, 2011, 21:41:10
Well, I set the case with final drive to make sure I had the right angle on the shaft. I figured that I would angle it to where it is when I was riding the stock frame. It lines up perfect.
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/b36748ae.jpg)
Blasted the front rim at work today
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/a1db82ef.jpg)
Then I recieved my tires
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/ebfc9d20.jpg)
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Dec 06, 2011, 08:43:57
I got the rims back from the powder coat guy, he charged me $50 a rim.
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/69c2e280.jpg)
Then proceeded to chip them....sucks cause the guy wants $225 to redo them.
Then I started putting the engine together
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/f69cf60e.jpg)
That part is going pretty good so far but then I disassembled the starter to repaint it and when it was done I dropped it on the cement floor, not good. I hope that this is the last of the bad luck for this build and that I can get this thing rolling soon. Peace.
Title: Re: Nighthawk Bobber - CB550sc
Post by: sxecafe on Dec 08, 2011, 12:56:11
This is looking really good so far. Love the shock for the seat.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Jan 02, 2012, 22:06:26
Well, I finally got the PC on the rims straight and got the tires mounted. I went throught the frame again today to double/triple check that everything is inline. The front and rear tires are level and square with each other and the engine mounts are perpendicular to the wheels so I'm cool now. I'm going to remove the wheels and forks from it and have it welded then put the engine in it to start doing a mockup. I still need to insatll the rear fender and then place the footpegs and controls once the engine is back in. I'm kinda pumped cause I feel like I may be getting near the peak of this build. Sill have a few more things to buy like clutch and front brake controls, headlight and mounts, rear fender and a taillight. I think that I may be able to meet my April deadline if money allows!
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/IMG_1635.jpg)
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/IMG_1633.jpg)
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/IMG_1636.jpg)
Title: Re: Nighthawk Bobber - CB550sc
Post by: MickyC on Jan 02, 2012, 22:13:23
looks sweet so far. tank and seat look great
Title: Re: Nighthawk Bobber - CB550sc
Post by: sxecafe on Jan 03, 2012, 15:16:34
Nice progress, man. Feeling the white grips too.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Jan 04, 2012, 22:28:21
Nice progress, man. Feeling the white grips too.
The package that the grips came in said they were "titty"grips but they feel a little too hard to be using the word titty around them.
I did get a stainless bolt kit for the engine covers this week,it's coming along well.  The saints have a playoff game this weekend so I'll have to wait until the following weekend to bring the cylinders to my cousins shop for a hone job. After that I should be able to get the top end of the engine completed.
Title: Re: Nighthawk Bobber - CB550sc
Post by: jelloelstone on Jan 05, 2012, 01:51:31
Im likin it! never seen a shafty bobber, its interesting! keep it up man.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Apr 27, 2012, 14:58:52
Well, I figured I'd update this thread since it's been in limbo for a few months. I finally got my cylinders back from my cousin and three of the four cylinders honed out good. The number four has to be punched out and re-sleeved. I can't find any oversized rings for this bike. It sucks. I did find some larger pistons on ebay but no rings are available so it doesn't do any good to have those in hand. I'm going to drop the jug off today at the block shop. I'm starting to realize that a bike that has ben sitting around for awhile can be trouble. I had this engine sitting up for awhile and although it ran perfectly when I abandoned it, it's still a mess. Some valves on the exhust side must have been opened enough to let condensate get in and pit the sleeves right above the pistons. Anyway, I got the valves out and am in the process of cleaning the head and soda blasting it while my cylinder is being re-worked.  I'll post pics of the engine when it's back together, it really looks slick with the silver case/ black jugs and polished aluminum covers.
Title: Re: Nighthawk Bobber - CB550sc
Post by: Erskine on Apr 29, 2012, 18:37:15
Yip yip. :)
Title: Re: Nighthawk Bobber - CB550sc
Post by: ProSimex on Apr 29, 2012, 20:38:56
whoa that frame is really nice.   Its rare to see a shaft drive hardtail that looks like its been done properly.  Exposed shaft is cool but are there going to be any issues with grit and crap getting into the seals and bearings?  not poo pooing the idea, just curious.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Apr 29, 2012, 23:00:54
I haven't considered the grim factor yet.The front part of the shaft is sealed so the only part that might reak havoc is where it fits into the shaft hub. It may require more periodic maintenance. I may be able to come up with some type of seal for that part, I'll have to look into it. Thanks. I left work Friday to drop off the block and the dude wasn't there! I ain't having any luck with this.
Title: Re: Nighthawk Bobber - CB550sc
Post by: Maritime on Apr 30, 2012, 08:53:42
You may be able to adapt a CV joint boot from a small car like a civic or something.  LOoks great so far.

Cheers

Maritime
Title: Re: Nighthawk Bobber - CB550sc
Post by: ProSimex on Apr 30, 2012, 10:18:26
I think that could be figured out.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on May 03, 2012, 14:11:53
This is how the shaft fits into the hub. The frame plate that it mounts to covers some of it but a little of the hub gear is still exposed. Maybe some type of boot will work to keep debris out.
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/20120502_185817.jpg)

This is where the engine is now. I am going to try and drop off my cylinder to the block shop again today. The guy says the job should take longer than a week but less than a month. Funny stuff right?
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/20120502_190024.jpg)
(http://i1190.photobucket.com/albums/z450/5150clem/Bike%20Build/20120502_190038.jpg)

I bought a CB160 speedo and headlight bucket so I am going through it to clean it up and hopefully get a new faceplate decal for it. This bike will be the culmination of various years of Honda parts that I dig, it's unfortunate the only thing that I liked about the bike before was the engine minus the shaft drive.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on May 05, 2012, 13:53:05
Well, I dropped the pistons and cylinders off and the outcome looks expensive. If I need to punch out all of the sleeves, it'd be about $800. There aren't any drop in replacement sleeves available so the will have to be made. Option two is to get custom pistons made and overbore all 4 cylinders to fit newer rings so that they are readily available. The bore is 60mm right now so it may go up to 61mm to fit 750 rings. It should have enough meat to go that far with it.
Title: Re: Nighthawk Bobber - CB550sc
Post by: ProSimex on May 06, 2012, 11:34:47
have you tried sourcing new jugs?
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on May 06, 2012, 21:07:03
have you tried sourcing new jugs?
I did find some on ebay but it would be taking a chance that i would find something better than I have. And to think that I only had 14,000 miles on this bike. Being that they only made this bike for one year in the us, I doubt there would be a NOS cylinder out there. I do kind of like the idea of a bigger bore, it's 572cc right now. The thing to do would have been to swap the cylinder for the 650. It has he same bore with a longer stroke but by the time I thought about it,I had already put the cases back together and didn't feel like splitting them to change the rods and chain.
Title: Re: Nighthawk Bobber - CB550sc
Post by: 7aliveatlast7 on Dec 13, 2014, 23:31:16
how did you chip your rim?  just curious cuz i recently powdercoated my rims and will be putting tires on at some point soon.
Title: Re: Nighthawk Bobber - CB550sc
Post by: clem on Dec 24, 2014, 16:20:45
how did you chip your rim?  just curious cuz i recently powdercoated my rims and will be putting tires on at some point soon.
It chipped while putting the tire on. It was a poor powder coat job. I had them redone by another and had no problems.
Title: Re: Nighthawk Bobber - CB550sc
Post by: Hurco550 on Oct 25, 2016, 15:00:07
did you ever finish this thing?