1970 Honda CB450 K3 - Grey Ghost Build

Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Also, I apologize for my crappy cellphone pics. My Samsung Galaxy S3 doesn't come until July 10th 8), and I'm still using the original Droid with its crap camera.

I've got a boss Nikon D3 that I never bring into the garage when I'm working, it's waiting to take the glamor shots of the bike when its done... if it'll ever be TRULY done, that is.
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Got the forks finally together and on the bike Friday night - nothing like late night bike building sessions in the garage. I ended up sourcing a M6x12mm (+2mm OD than stock) from a washer set I bought on Amazon. It works fine, except that you can see the excess copper around the hex cap. For now, I don't care - I'm done fussing with these forks for the time being.

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On Saturday morning, I got back to work on the tank. Here is my 1st layer of bondo sanded:
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I definitely did not have enough hardener in the mixture. For my 2nd layer, I added more hardener than before and the color change was much more noticeable. It's a dark puke green, before, it hardly changed the straight Bondo out of the can. Here's the 2nd layer:

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Notice the change? Here it is after sanding:

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You can see that the dent area is definitely filled in. Now it's a matter of really fine tuning the shaping and smoothing it out by another thin layer to fill in the recesses.

Shaping it and smoothing it out is very easy using a handheld palm sander. You just have to mimic the lines you want in even strokes. And wear a dusk mask.
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Also, here's a pic of the front end looking good and finally back together... minus the brakes

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Maybe from sitting off the forks for so long (it wasn't hanging by its line), the brake caliper is stuck. I tried bleeding the line only to find the bleeder valve is rusted to oblivion. Doesn't turn at all even after a dousing in PB Blaster. I removed the whole unit from the bike from the connection at the lower fork crown.

I managed to get a few drops of brake fluid on the non-gloved part of my hands and pulled a "Get it off me!" move like i just got sprayed with acid blood in Aliens 2.

Does anyone have tips on removing a rusted on bleeder valve?
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build



I was able to make a lot of progress over the last two weeks on the bike, focusing especially on the tank.
Stripped down, patching, and refinishing the tank was nearly a Day 1 project, so I’m glad to see it finally done and mounted. It’s not perfect, but neither is the bike.. and I think it goes with the whole look. Needless to say, I’m impressed with the outcome.



On my last post, I showed you the tank that was just bondo'ed. Since then, I glazed, sanded and primed it. It took about 6 coats of priming and sanding with 800 3M Imperial. Dusted and wiped with alcohol.

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For paint, I went with Dupli-Color Perfect Match, since it comes in a huge assortment of colors. I wanted some in the grey color pallete, to follow my original “Grey Ghost” inspiration. The initial color I went with was Graphite Grey Metallic (a Nissan color). After a few coats, I decided it was altogether too dark. As you can see from the photos below, its nearly black, with metallic. I’d say its like the color of pencil lead.

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It went on thick and even with about 4 coats. Surpisingly, the small 8oz touchup cans covered the tank completely, with some leftover. For $6.99 a can, its not a bad deal. The metallic finish came out very nice, better than I expected from a rattle can. However, it was altogether too dark.

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I decided I was going to go a shade lighter, to find a more silver grey than this dark grey I had put down. I was initially going to just cover the whole thing, but then I had some vivid flashbacks of the Shelby GT Cobra from Gone in 60 Seconds.. My mind shouted “Eleanor! Eleanor!”. So rather than let this dark grey go to waste, I taped it off for a triple racing stripe!

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I used blue 3M painter’s tape, the wide kind for the thick stripe down the middle. I then used 3M automotive tape that comes in a thinner roll for the double stripes on either side. It made things much easier than having to try and cut 2 stripes the exact same size out of the thicker tape. As for laying it down, I could’ve measured and sketched out the lines, but I just eyeballed it. I’m right brained and have a good eye for lining things up. Setting it on a saw horse, I just looked down the tank and lined up the stripes with some on the horizon. Repeated it for both sides and then front and back. I had to make sure that the overall stripes stayed straight even though the tank is irregular in a few spots. The stripe maybe straight in one part, but it could look crooked in another just due to the metal. The tape also lays flat and will start to wrinkle if you go off course.

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The lighter silver grey was a Honda Phantom Grey Pearl. I thought that the pearl finish would help make the stripes stand out more….which it did.

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The tank came out great. I put 4 coats of Phantom Grey over it. When I pulled the tape to reveal the lines, it gives it a “ghost” stripe effect since its just a darker shade of grey. Also, the stripes look a little recessed and have an edge to them. I decided not to sand these down, because I think it gives a bit of a “crude” look to the bike. I don’t want this thing sleek and sexy. It’s a bruiser with some style.

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Dropped on 4 coats of clear coat and mounted it up. I also took the time to put in a new gas vent gasket that I had picked up from Dime City, along with new red polyurethane fuel lines & filters.

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Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Haven't posted in quite some time. Life, of course, has managed to get in the way of things. Landscaping, weddings, and staining a deck.

Fortunately, I've now got the bike up and running. The electricals are all done, after a couple weeks of head scratching and trial and error. I bought a connector kit from Del at Vintageconnections.com. I invested in a quality crimper tool, made my life a whole lot easier.

I pulled the old battery cage and made a low profile tray out of 22ga aluminum. I mounted it using the "strap" holes for the old cage. I mounted the solenoid to the inside, and a rectifier/regulator (the John Deere/Kohler mod) on the underside.

I also made new battery cables using 8ga wire from the (+) terminal to the starter, and a new 4ga frame ground for (-) terminal. I bought new rubber terminal boots from Remybattery.com.

New LED turns work, LED brakelight works (upgraded the relay and pulled the idiot light). I've got new LED lit gauges from DCC waiting for the winter to go on.

I got the bike to idle after some trial and error and a few recharges. Used starter fluid to get it going and had to adjust the throttle cables so it would idle properly. Make sure youre throttle cables are set to bottom out before starting the bike!! I made the mistake the first time of not adjusting them down. What i got was a bike that climbed towards redlining pretty quick upon starting.

The bike is still idling pretty high, at about 3K rpm. I think i may have some airleaks, maybe at the intake gaskets. I should also check the gap and points for timing.

Woohoo! Making progress! Now all I have to do is finish rebuilding the brake caliper I bought off eBay (bleeder valve and piston are frozen), weld on the cafe loop and build a seat, and hopefully be riding soon!

Here's how she looks at the moment.

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Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Been following on your blog since the inception of the build. You do some impressively thorough work, and I'm excited to see where you take this!
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Finally got around to welding on the cafe loop I bought off Cafegoose in the classifieds!

A couple nights ago, I brought the bike over to a buddy with a welder. We we pulled the back wheel and chain off the bike and cut off the rear of the frame – the notorious seat bump.

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Matched up and measured out the loop to length.

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Tacked it on, readjusted it a few times.
And he welded that sucker on in under 15 minutes.

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The result? See for yourself. I’m really pumped and love the look with the up swept bend. Now it’s time to design and make the flat double seat.

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Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Cool build man. Sounds like you had a hell of a time with your fork rebuild. Me too. Nice colors.
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Thanks bud. Yeah, the forks were a pain. I plan to do an USD conversion on them over the winter, or possibly hold that off until my next build.

I realize I haven't updated in awhile, partly because my build has stalled out a bit due to a Master's program, bowhunting season, and other obligations. I've managed to get a seat pan shaped up and padded. Here it is mounted on the bike. I wound up using two carriage bolts popped through the middle which mount through holes drilled through the frame brace in the middle of the bike. I plan to use some rubber loop clamps to hold down the back.
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to this

I had emailed Jared at Holiday Customs awhile back, he gave me the honest-to-god genius tip of just using a cut up Yoga mat for your seat foam cushion. As he said "its cheap, and feels good on your ass".

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Still need to figure out what I'm doing with the rear fender and how to mount my tail lights!
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

manualofman said:
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Front Fork

First off the bike looks great! As it's the off season now, when I get spare time it's bike stuff or tying flies so I love the theme and how you're tying the hobbies together!

Completely off topic: is that an old McCulloch on the right? I've got an old beast of that vintage that's missing a few parts here and there but I've got big dreams to get that thing running soon.

Little bit of an afterthought: If you were to do a graphic somewhere on this bike a dark outline of the Grey Ghost with the cafe "Spade" as the eye vice the junle cock outline could look pretty stellar. Had to do a quick sketch to show what I mean, couldn't resist.
 

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Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Dude! That's an awesome idea!

I haven't decided on any tank logo's yet. I was debating putting on new HONDA tank badge, or even these fly fishing emblems.
http://shop.kingsoutdoorworld.com/Fly-Fishing-Emblem_p_330.html

But the idea of incorporating the spade is a great idea, thank you.

And good eye on the McCulloch. I got that out of my girlfriend's late grandfather's workshop. It's a Super 10-10 from the 70's i think. Her grandpa had his hands in just about every manly pass time, including rebuilding chainsaws and building his own wood splitters.

I dug this out and a Mini Mac on one of my last visits to try and get it up and running when I had time, however, this bike showed up and took precedence on any free time.

Now that bowhunting season is over, I plan to really attack the bike again. I was really bummed that I couldn't ride it at the tail end of the season. With winter, I'm planning to tear the bike down to the frame and really get everything the way I like it. Most of the summer was spent fixing things just to get it moving before the warm weather was gone. Now that's there's no rush and it's miserably cold, I'm going to take my time.

I've found that my design inspirations are leading more toward making a cafe/brat bike. I'm planning on keeping the mid controls, raising the clip-ons above my top triple (or even selling them off for drag bars). We'll see.

Thank god I've got a propane heater in the garage!
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

After wasting a lot of propane heating my garage enough to work in, my girlfriend let me just move the bike into the finished basement. Victory!

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I got to work pulling off the old stock gauges to mount the 2.5" gauges I bought from DCC over the summer. Has anyone cleaned up the wiring for these, like putting them all to a pin connector and putting one on the main harness? I'm wondering if it's worth it to do, or just crimp on the standard bullet connectors.

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Found some nasty stuff under the old gauges, including several spider nests. After I saw a brown recluse scurry out of an old leather glove in my garage this summer, I've got an 8 year old's fear of spiders again.

I also pulled the top triple to smooth it done, glaze over the pitting and paint it gloss black. After about an hour of some mild buffing, Bondo glazing and sanding with 1200, I noticed this little hairline crack on one of my final washings.

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Glad I caught it, sad that there goes $130. Ordered it off DCC and also a new throttle body and cable. I pulled apart my handlebar controls to consider upgrading them to more modern ones and saw that my throttle body was pretty janky. As I unhooked the throttle body and cable, I checked along the cable and saw that part of it had melted where it was touching either the headers or one of the cooling fins. It was melted so I could see the metal ribbing on the cable, which was completely rusted out!

That stuff should be here today, so I'll hit with some paint.

One thing I'm confused about, and I may call up DCC about this, is when upgrading your stock control switches, what do you do about the headlight OFF/LO/HIGH combined with the starter/kill switch? I found one left hand control which has OFF/LO/HI but its fugly compared to the other one which only have a LO/HI setting.

Here's the less pretty one:

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Here's the nice one (IMO):

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I was planning on getting that one, since it has more of a modern styling to it, and then do a modern starter/kill on the right. Like this:

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That still leaves the headlight ON/OFF, which I'm wondering if I can do on a separate switch, maybe hidden under the seat?

I'm not sure if the wiring would allow that, I'll have to check the diagrams. Any advice would be appreciated.
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Nice I work on my stuff in the basement...it's not finished tho it still has that basement look,smell,feel,mess

As for Wiring...It is my Kryptonite ...I always end up calling my electrician buddy and he tells me every time..."why don't you trade like 2 or 3 of these for something that runs"
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

I've also stripped the bike down nearly completely to get the motor out. Carbs, exhaust, seat, and wiring harness are off. As I got the shift lever/front chain cover off, I found another surprise left for me by the 450's previous occupants (see video a few pages back).

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I'm hoping they didn't make it through the mufflers and into the top of the engine case, unlikely given the header bend and length, but you never know. The bike ran okay over the summer, so this should be the last of the birdseed.

Here's how she stands now:

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Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

DesmoBro said:
Nice I work on my stuff in the basement...it's not finished tho it still has that basement look,smell,feel,mess

As for Wiring...It is my Kryptonite ...I always end up calling my electrician buddy and he tells me every time..."why don't you trade like 2 or 3 of these for something that runs"

Haha. I dreaded doing the wiring when I first started, but found it got easier once I pulled the whole harness off the bike and really figured out how it all works. Plus, cutting, stripping, and crimping on shiny new terminals is oddly relaxing.
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Some updates:

Got the new billet machined triple from DCC....It's a beaut:

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I painted it gloss black with some Dupli-Color Acrylic enamel, I'll post a photo once it cures over the week.

Had a couple buddies over and got them to help me pull the motor. It sure is awkward for even 3 decently in shape guys. Since there were 3 of us, I had the motor put on a saw horse table at waist height. Should make working on it easier!

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Started working on the wiring harness: soldering in a new 15amp blade fuse, possibly moving key ignition switch to under the seat, and replacing scorched and crunchy old terminals with new ones from Vintage Connections.

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Some thoughts/tips on the wiring work:

The old plastic protector for the main harness loom is a bitch to get off, and mine was dried out it was cracking as I cut it. I replaced it with heat-rated braided sleeving and bundled the loom together intermittently with bands of shrink tubing.

Buy the crimper made for these terminals that VC sells. Yeah, pliers can make a crimp, but they are ugly and take more time than they should. These crimpers are solid, and once you dial them in, they make this work go by fast.

Get a chisel tip point for soldering battery terminals or wire thicker than 12ga. I figured this out after I started melting the insulation while waiting for some 10ga wires to heat up enough and melt the solder. The electrician I work with laughed his ass off at me and told me to get a thicker tip (i was using a pencil tip).

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Write down what terminals you plan on replacing, take stock of what you need, and order accordingly. I initially ordered the most basic kit from Vintage Connections, but wound up ordering an extra 5-pack of 2-ways, 3-ways, along with another 25 pack of males/females. The basic kit doesn't leave much room for error if this is your first time wiring.

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On these Honda 450's, the turn signals use 3.5mm bullets, while pretty much everything else uses 4mm. Either buy a pack of 3.5's or swap the them to 4mm with extra's.

The DCC 2.5'' mini speedo gauge (with the indicator lights) comes pre-wired with 26ga wires! I was debating making some 6-position terminal blocks, but didn't want to bother then having to splice together the grounds. However, I had to splice in thicker 18-20ga gauge wire so I could put the bullet terminals on them. Luckily, I was able to pilfer some colored wire from work that's close to the stock colors, but they range from 18-22ga. So it would've been the same work either way. In retrospect, I would've gone the route of using 6-12 pin block connectors.

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And buy an auto-wire stripper. It's the best $15 you'll spend on wiring tools.
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

Would you be willing to explain more about the tear down of the front forks. I keep putting the job off because I haven't figured out how to take them apart yet.
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

reesea17 said:
Would you be willing to explain more about the tear down of the front forks. I keep putting the job off because I haven't figured out how to take them apart yet.

Yeah man. The front forks caused me a lot of grief because I needed to get the tubes cut. If you just want to change out the seals or change the oil, the tear is way easier.

You can do this with the forks on the bike or off. It helps to drain the oil with them on the bike but its not a big deal.

You first have to drain the oil by removing the bolt at the bottom side of the fork. Oil will immediately start draining out but you'll need to pump the forks to get out all of the oil. Make sure you've got a wide pan to catch it, it can shoot about 6 inches.

Remove the top bolts and the nut Ian's crown inside the retains the springs on the thread rod. You should now be able to pull the fork tubes out leaving only the spring and rod inside.

If you want to change out the fork seals, remove the top circlip with some snap ring pliers. The seals can be a pain to remove, they can sometimes come out easily by using a thick flathead screwdriver with a rag wrapped around it and prying them off from underneath. If not, you can boil them by inverting them in a small pot of warm water for a few minutes. They come off real easy that way.

If you want to disassemble the lowers, there is a bolt that goes vertically up through the bottoms. If this thing doesn't come out easily, an impact driver does wonders.
 
Re: 1970 Honda CB450 K3 - Tentatively named "Grey Ghost" Build

manualofman said:
Remove the top bolts and the nut Ian's crown inside the retains the springs on the thread rod. You should now be able to pull the fork tubes out leaving only the spring and rod inside.

See I tried to do this and the top nut just spun while it was on the bike at least.
 
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