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Author Topic: Honda RS1000 - CB400F Mini Replica  (Read 1542 times)

Offline Rick4004

  • Posts: 54
Re: Honda RS1000 - CB400F Mini Replica
« Reply #20 on: Mar 07, 2019, 19:57:26 »
I formed the front seat section flanges by starting them on the bead roller using a "tipping wheel". This gets the flanges to about 70 degrees, and it's easy to get them to 90 by just backing the flange with a 2x4 and forming with a soft hammer.
To form the 3" radius flange i used a combination of hand forming over a piece of tube, and using the English Wheel.

Offline Rick4004

  • Posts: 54
Re: Honda RS1000 - CB400F Mini Replica
« Reply #21 on: Mar 07, 2019, 20:01:19 »
My tooling arrived, so I switched back to the chassis. I added the first set of tubes to brace the shock mount area. I might do additional bracing, but I'll wait until I decide where the battery is going to mount.

Offline Rick4004

  • Posts: 54
Re: Honda RS1000 - CB400F Mini Replica
« Reply #22 on: Mar 07, 2019, 20:10:06 »
I threw the frame up on the frame jig to get the rear wheel aligned. I checked the rear wheel position and compared it to my CAD models and they are within 1mm, so that's good.

The sprockets are about .25" out of line. I can get an offset front sprocket, or machine .25" off the sprocket carrier. I think I'll wait until the tires show up to decide. Offset front sprockets are $80 USD, and I can machine the carrier for nothing, so as long as I have clearance from the chain to tire, I'll likely lean towards machining the carrier.

Offline Rick4004

  • Posts: 54
Re: Honda RS1000 - CB400F Mini Replica
« Reply #23 on: Mar 09, 2019, 17:43:15 »
I marked out the shock mount locations, clamped them in place, checked alignment with a thru rod, and tacked the mounts in place. I have a gusset made for the right hand mount, but I'll wait until I get the rear wheel positioned and spacers made before I commit to fully welding the shock mounts. I made the mounts a bit wider than the shock mount to allow for some adjustment. When the time comes I'll machine some spacers to take up the gaps.

Offline Rick4004

  • Posts: 54
Re: Honda RS1000 - CB400F Mini Replica
« Reply #24 on: Mar 11, 2019, 18:38:25 »
Mail today! (actually DHL). I did some research for these Arashi disks, and people seemed to be happy. The price was right compared to new, and at least you aren't getting worn out or bent used samples on Ebay.

I laid out the stock GS disk and a CBR954RR disk in CAD and the CBR disk was going to make the caliper mounting easier to the CBR600F4 forks that I'm using. I need an adaptor to go from the 5 hole GS disk to the 6 hole CBR disk. I 3D printed an adaptor that seems to work well. Once I have everything nailed down I'll machine this out of aluminum.

Offline Rick4004

  • Posts: 54
Re: Honda RS1000 - CB400F Mini Replica
« Reply #25 on: Mar 13, 2019, 19:20:39 »
I 3d printed a prototype caliper bracket to mate the CBR954RR caliper and disk to the GS500 wheel and CBR600F4 forks.
I really hesitated before buying a 3d printer, but after getting it I haven't regretted it for a second. Something like this bracket used to mean a couple of hours programming, and 4 hours of standing in front of the milling machine, and $20 of aluminum.
Now, it's 20 minutes of CAD modeling, and 4 hours of doing something else while the part prints using $1 worth of print material.

Offline Rick4004

  • Posts: 54
Re: Honda RS1000 - CB400F Mini Replica
« Reply #26 on: Mar 13, 2019, 19:27:06 »
Taking .25" off the cush drive was easier said than done. The back of the carrier has 5 drive spokes, so it wouldn't fit in a 3 jaw chuck, or a 4 jaw chuck.
I ended up holding the front of the carrier in a 3 jaw, and machining "backwards". I used a long drawbar thru the spindle to secure the carrier against the cutting force.

Offline Rick4004

  • Posts: 54
Re: Honda RS1000 - CB400F Mini Replica
« Reply #27 on: Mar 19, 2019, 14:25:48 »
Right side rearset and brake finished. The rearset is a prototype that I did a few years ago and never put into production, the pegs/levers are Tec-Bike that I had bought just to check out the quality, (not bad, but not to Tarozzi standards) and the master cylinder is a Yamaha/Brembo from a 1999 R1 that was lying around in the parts bin.

Say what you will about Amazon, but I ordered the remote reservoir on Thursday and it was delivered on Sunday. USA guys are used to quick/cheap shipping, but us in the Great White North are not. Before Amazon, everything took 2-4 weeks to arrive.

Offline Maritime

  • DTT SUPPORTER
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  • Posts: 9616
Re: Honda RS1000 - CB400F Mini Replica
« Reply #28 on: Mar 19, 2019, 14:44:42 »
Yep, especially to the maritimes or Winterpeg LOL. Toronto or Vancouver you had next day or 2 day. We've never had that.  Looking great!
The GL Rebirth: http://www.dotheton.com/forum/index.php?topic=68337.0
CX500 Low budget Bobber : http://www.dotheton.com/forum/index.php?topic=43617.0
"Beer makes you feel the way you ought to feel without beer" -Henry Lawson
"Beer is proof that God loves us and wants us to be happy." - Thomas Jefferson

Offline Rick4004

  • Posts: 54
Re: Honda RS1000 - CB400F Mini Replica
« Reply #29 on: Mar 24, 2019, 17:22:14 »
Busy week, lots of moving stuff around in the shop getting ready for spring.

I did manage to get the front wheel/disk adaptor from a 3d printed part to a machined aluminum part.