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Author Topic: Another Honda CB400F cafe racer  (Read 63863 times)

Offline andycafe

  • Posts: 1173
  • Northern Suburbs, Melbourne Victoria, Australia
Re: Another Honda CB400F cafe racer
« Reply #20 on: Aug 20, 2012, 07:22:46 »
Awesome work, wanna rebuild my set of carbs too?lol.....
definitely staying tuned for your seat.... :D

Offline joeficsit

  • Posts: 38
Re: Another Honda CB400F cafe racer
« Reply #21 on: Aug 21, 2012, 15:12:50 »
I have got to get off my butt and start to work on my projects. Looks great sir. Can't wait to see the finished product.

Offline swan

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  • Kickstart, shift on right, drum brakes and spokes
    • 1962 BSA Gold Star barn find restoration
Re: Another Honda CB400F cafe racer
« Reply #22 on: Aug 22, 2012, 10:48:27 »
Awesome work, wanna rebuild my set of carbs too?lol.....
definitely staying tuned for your seat.... :D
I will if you buy the beer....

Alright, seat update: I brushed three layers of black gel coat into the waxed and PVA release film coated mold-


After it dried, I added a layer of fiberglass and epoxy resin. I use West Systems 105 epoxy and 205 hardener because I am experienced with it.


And then a layer of some thick woven carbon fiber-


After it dried I popped he seat out of the mold and trimmed the flanges. Looks good with a few minor defects that I will touch up. It is very lightweight and strong.


I plan to do the touch ups, the final cutting and sanding of the edges tonight along with adding rubber spacers and a hinge and then on to foam and sewing a vinyl cover. Also my new K&N filters arrived so they will go on too. Stay tuned....

1966 Triton cafe, 1962 BSA Gold Star DBD34, and 1966 T120 Triumph Bonneville.
BSA Gold Star barn find restoration
1975 CB400F Cafe Racer build
1966 Triumph Bonnevile restoration

Offline swan

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  • Kickstart, shift on right, drum brakes and spokes
    • 1962 BSA Gold Star barn find restoration
Re: Another Honda CB400F cafe racer
« Reply #23 on: Aug 26, 2012, 12:29:15 »
Another update, she LIVES!!! Fired her up, timed the ignition and she is running well. Sounds great with the Dunstall muffler. Carb #2 is a bit intermittent and I have determined it is not the coil or the plug so I need to examine and clean carb #2 again and plan to do so tonight.

Cables:

I shortened the throttle and brake cables to fit the clubman bars. I use a ferrule or wire stop as the new end. After carefully measuring the existing exposed part of the cable, I measure and cut the sheathing to the length I want. I cut the cable and sheathing with a cutting wheel on a Dremel, clean with carb cleaner, slide ferrule to postion, tighten the screw, flux, solder and then cut and sand it to shape. This method works great.



Voila!

Tank:

I had done much of the prep work on the tank prior to storing it. There were a few small dings which I filled with body filler, sanded and primered. I did some tiny spot filing, seal and sanding guide coats, sanded again and then a final coat of grey primer.



I found Plastic-Cote Honda Milano Red is very, very close to the original OEM CB400F Honda red.


Original OEM Honda red.

I sprayed several light, even coats of the Milano Red followed by three medium coats of catalyzed auto clear coat. I will let this sit and off-gas for a couple of days, wet sand, add the decal and spray more coats of clear. Then more fine sanding and buffing with several grades of compounds and glazes until done.


I will clean the inside of tank one more time before adding fuel. If you are going to do it, do it right- new OEM petcock and fuel cap for the freshly painted tank.


Still need to paint the side covers, and headlight bucket, finish mounting and upholstering the seat, paint the undersides of the fenders and few other minor things and soon she will be ready to take out and shake down. Stay tuned...
1966 Triton cafe, 1962 BSA Gold Star DBD34, and 1966 T120 Triumph Bonneville.
BSA Gold Star barn find restoration
1975 CB400F Cafe Racer build
1966 Triumph Bonnevile restoration

Offline juan@crqcycles

  • Posts: 234
  • Not a lot of cafe's down here in Mexico...
    • CRQ Cycles
Re: Another Honda CB400F cafe racer
« Reply #24 on: Sep 10, 2012, 23:05:30 »

Offline swan

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    • 1962 BSA Gold Star barn find restoration
Re: Another Honda CB400F cafe racer
« Reply #25 on: Sep 12, 2012, 10:50:05 »
Show us more pics please!
Here ya' go... Quick update:

Tank and side covers are clear coated with graphics. They will be sanded, polished and waxed, but look good already.


The seat was a challenge to line up correct with the stock locking mechanism. I made hinges and cut and pop riveted strips of aluminum as 'teeth" to hold the vinyl seat cover in place once it is stretch over the sides of the seat. Tonight I should be able to sew a seat cover and mount the seat. Stay tuned.

1966 Triton cafe, 1962 BSA Gold Star DBD34, and 1966 T120 Triumph Bonneville.
BSA Gold Star barn find restoration
1975 CB400F Cafe Racer build
1966 Triumph Bonnevile restoration

Offline john83

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Re: Another Honda CB400F cafe racer
« Reply #26 on: Sep 12, 2012, 18:40:02 »
That paint really came out looking great!

Offline juan@crqcycles

  • Posts: 234
  • Not a lot of cafe's down here in Mexico...
    • CRQ Cycles
Re: Another Honda CB400F cafe racer
« Reply #27 on: Oct 07, 2012, 00:46:01 »
Hey! What happened with this bike? DOne already?

Offline Kwality

  • Posts: 54
Re: Another Honda CB400F cafe racer
« Reply #28 on: Oct 07, 2012, 10:51:02 »
+1  any updates Swan?

Offline swan

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  • Kickstart, shift on right, drum brakes and spokes
    • 1962 BSA Gold Star barn find restoration
Re: Another Honda CB400F cafe racer
« Reply #29 on: Oct 07, 2012, 14:50:25 »
Sorry all, I have been busy with work and other projects. I did however finish polishing the tank last night. Looks good, and plan to install the cap, fuel line and petcock tonight.

I use a heavy duty DeWalt variable speed buffer, several different 3M brand cutting, polishing and final glaze compounds on small wool and foam pads to polish clear coat.


I have been struggling with getting power to the headlight and taillight. I t is not a grounding issue and after many frustrating hours with a multi-meter now believe I may have the wrong left hand control switch. Gonna work on it some more tonight. Once that is sorted It is time time to install the front fender and start riding and shaking her down.
1966 Triton cafe, 1962 BSA Gold Star DBD34, and 1966 T120 Triumph Bonneville.
BSA Gold Star barn find restoration
1975 CB400F Cafe Racer build
1966 Triumph Bonnevile restoration