82' CB650 Project Bike Update: Brake overhaul, cylinder prep, hone, paint...

[adrianm1972]

Made a lot of progress this weekend.

I ordered a ton of parts from Service Honda (gaskets, orings, brake rebuild kits....) mainly for engine assembly so I cleaned up, flexhoned and painted my cylinders.




My front brakes were not working so i took them apart.  The caliper piston was rusted and pitted taking out the seal.  What fluid was left was orange from rust.  I cleaned everything and while waiting for the rebuild parts to show up I cut off the mirror mounts from the master cylinder, clutch lever and reshaped them to appear they were made that way.  I decided to use VHT gold (looks bronze)) engine paint as my accent color on the bike.  I painted the caliper, master cylinder and clutch perch this color going for the Brembo look.  The levers were worn looking so i gave them a light sanding, etch prime and painted them with Duplicolor semi-gloss black engine enamel.  Everything got bakes to give it best chance of resisting the brake fluid (no i didn't paint any areas that contained the fluid).

I am getting a new fluid reservoir.  The old one is just on for pics. 

I think it all came out great.  The bike is going to have a bright red tank and tail, The frame will be a metallic charcoal and there will be very little chrome.  I think the gold/bronze will look good.









[

[adrianm1972]

Wash your barrels out like three times with very hot water and detergent using a kitchen dish brush.Rinse with hot water.It gets the grit out,solvents don't.Then a thin spray of CRC or WD40,NO oil.....

Thanks for tips. I had read the same cleaning procedure on the SOHC4 forum. I did a quick cleaning after honing with soap and water but I will go nuts on it to make sure it is crystal clean before assembly.

I am traveling next week and have a lot of parts on the way so next updates will be a week from today.

[adrianm1972]

I appreciate a positive response with that cleaning method.....I DO know my shit.....Cool.....

This thread should get realer like,in the next few weeks:

http://www.dotheton.com/forum/index.php?topic=37578.0

No doubt. I have seen you on a lot of threads and I know you know your shit.  I am not a knucklehead and I listen to those that have more experience.

My goal is to build the best bike I can.  I want a well finished end result. Everything has to fit right, have nice flowing line and look like its either production or custom. No cobby shortcuts.

[adrianm1972]

Well...After all that work on the brakes it turns out the PO had swapped on a 5/8" Master Cylinder on to my single disc CB650.  Thats a no go so after spending $100 rebuilding and hours sanding cleaning and shaping they (MC and Clutch Lever) are on ebay now.  Getting a more appropriate 12mm MC and a matching clutch lever.

I just got my Chinese/Ebay Clip ons from MotoGP888.  $68 and they are great.  Nice CNC work on the blocks and stout alloy handle bar tubes.  I also decided to cut up my frame and go to straight seat rails.  I have some fab work to do next weekend!

[adrianm1972]

Its been quiet here as i have been traveling for work a lot.  I got some fun stuff in the mail and got to work modding my frame today.

CNC Clipons from ebay.  They were $79.99 shipped and they look great.  I like that I can go to longer or shorter bars by spinning a few screws.  They are light and very well made.








Here are the shorty lever master cylinder/clutch lever kit you guys have seen on ebay.  I got them shipped for $115.  Quality and finish look great.






I never liked the kinked seat rails on the 81 and 82 CB650 frames so I had a Ton'er make a long tail loop and went to town with an angle grinder.  I used curved tubing from the old kinked seat rail to make new mitered  frame adapters to fit the new rail.  There are 7/8" schedule 40 steel tubing inserts that will be plug welded then the butt joints will be welded. I am confident this will be stronger than stock.  The overhead shot looks crooked but I measured everything six ways to sunday and its all dead balls straight.  Btw, all the tubing was hand mitered with a cut off wheel and a 36 grit flapper sanding wheel....yes it took forever.  I messed up on the front right frame adapter but i think it will be ok.I plan on mig welding the crap out of all the plugs and joints...1 or two passes...then sanding them flush.  My goal it to not see that there were any mods after painting.