1981 CX500 : New Updates May 2014

[Dhalla]

First of all wanna just say hey to the forum. I have a build thread at another site, but I wanted to be part of this community as well so I'll be posting both. The post will catch the build up.
Day 1:
I've always been into the mechanical workings of things, but rarely have had the time for funds to do it. Well, it's not like I have the funds or the time either, now, but I am doing it anyways.

I had been checking Craigslist all the time for kawsakis, hondas, and suzukis, but all were over priced or overpowered. Then I somehow stumbled on to the CX and saw some potential. On Craigslist there were a couple for about 1200, and I almost bought them because I thought I'd never see a running bike for much less, until that is on my commute I paid attention to a bike that I had passed everyday- and sure enough it was a cx. It was an '81, but I figured for the price I could live without having a '70s bike. And that was that. I ended up getting a running bike in pretty good condition for 550.

The Budget: 1000
I am planning to do most of the work by myself. I have the resources and the help.
This will be for parts, paint, tires, etc

The Bike:
1981 CX500 Deluxe
36000 miles
Purchased for 550

The Idea:
There are a lot of builds that I like just from looking at pipeburn, bikeexif, the forum. You've seen them.
For this build I really want to create a ride that will convert from a once seater to two (god I hate that couch that is on it now).
Leather or canvas. I love the look of leather and the different use of textures on bikes. Not just on the seats either. Belts, straps, etc.
Bare/brushed metal and possibly wood. Again its a textSome ideas maybe far fetched for a first build but I can dream.
ure thing.

Rough Sketch:

Illustration *Updated*

I plan to try to document this process as much as I can that way since it is my first build yall can help on with the project, and give me pointers and advice because I'll need it!

Day 2:
Bike is in the workroom and started tearing down.

I stopped after frogging around with the airbox. I'm thinking if it is this ornery to get out how bad will it be when i try to put it back in. PODs are starting to sound good.

I am labeling all of the wire harness, and hoping I don't lose or scrap any parts I may need. That would suck. Any ideas on making sure I don't? zip lock bags? leaving everything in place?

Well. Off to work until the night. Hopefully I can get some good sketches of the bike soon.

Day 3:

Yesterday night I had a little bit of time and got the airbox and handlebars off. Tonight I did the gauges and started the de-wiring.

All the tear down pictures are deceiving on the forum. Everyone just shows their bike in a full state, then the pic of a frame and the motor separated. I wish it were that simple. I am a little weary of the the electrical harness. Should I just unplug everything from the engine and pull the entire harness out then drop the engine. Should i leave engine wires and general wires separate or together? Also, would it make sense to scrap the entire harness and replace it with new one?

On another note, I got my clubman bars today. It was amazing... I ordered them yesterday off ebay at like noon and they showed up at 4 today! Of course I had a trial with them on.

Recent Pictures (still the boring phase):

Day 8:

I didn't get anything done as I was away at Saratoga for some horse racing, and lake placid for a hike. But when tonight I went to town and didn't stop until I got the engine pulled.

Finally, some real noticeable progress.

Day 14
Had a good weekend with the bike thus far. I am still trying to see the design in my head, so I have been working slow until I can put my thoughts on paper.

The bike is completely apart now and have stripped the frame, and am working on stripping the tank (I needed more stripper but the parts stores all closed at 7 on Sundays). I think the frame looks great with a bare brushed metal look. I am contemplating keeping it that way and I like the imperfections and different tones that give the frame character. The only problem is I am not sure how a powedered clear coat would keep the frame from rusting. If not I am planning on doing a nickel or white bronze plating.

Also, my original tank plan was a nickel plate/bare metal look. However, I am having second thoughts and believe that doing so would create a overload of silver and bare metal if I did leave the frame and lower forks metal as well. So I am beginning the metal look would be better used as a subtly rather than the main course.

there will be two seats made: One seat will be a cafe style handmade from wood. The stain will be entirely dependent on the tank. The other will be a bench seat so I can convert from two to one person riding.

the other development is the table I built. So far I like it. It may be a little high and it might get cut down but it does the job. I didn't feel like inventing my own so I got it from Cafe Matty. I put two free spinning casters on and two straight, however, I don't like the maneuverability so I am going to put two more free spinning casters on from lowes.

For now that's it. I'll probably be mocking up the look and rebuilding the front forks soon as well. Until then, if anyone can help me. With these things:
Input on tank color, and seat stain.
A kit to spoke cx500 wheels (or a person who can do it) I have seen a couple thread on it but have lost them since.

Later.

Day 16:
I started to grind down the rear frame so I can get the looper built. Most of the existing frame will stay- I think-, whereas many bikes chop off the frame after the shocks.

I had some time to start a mock up of the bike seat. So a glued a couple blocks of wood and roughly sketched a seat. Right now I it is too thin, and the tail is too long and too boxy. However, I am pleased with the mockup and how the negative space is being filled. Getting the correct proportions to the seat so I can have a cafe seat and a bench that are interchangeable is going to be a design challenge.

Thanks for viewing.

Day 19:
Other then trying to the move to the front end and wheels I have started some fabrication. I made a hammer form to make a rear seat hoop. I have never done metal working so this was a first and I think I'll have to redo it with some gussets to prevent pinching.

Making the form
http://Coming along
[img]http://cx500forum.com/forum/attachments/cx-customization-modifications/3698d1376276288-my-first-build-cx500-screen-shot-2013-08-11-10.47.20-pm.png

Pretty rough, needs some more work

Chopped the rear end, and surveyed my mockup.

 

[caferay]

Re: 1981 CX500

wow.. you're going all in on what the British called, "the plastic Maggot".

These bikes were advanced in their day: water cooling, shaft drive, engine as stressed frame member, and the engine was bullet proof-they bored it out to 650 for a Cx650 in Europe and Canada, and used the block as the basis for the Cx650 turbo. It then when on to be the GL500 engine for touring bikes. The inherent design makes for a short wheelbase bike.

I might suggest a tube or rod across the back near the suspension mount points. That hoop you made may not provide enough stiffness and the rear frame will flex putting stresses on the drive train. You can see how Greg Hagman did it on his cx500s.
Or, buy a bent tube and weld it in. that seat bracket you removed was beefy -not just to support the rider, but give the frame support near the rear suspension mount points.

 

[caferay]

Re: 1981 CX500

Some nice parts for this here:

http://www.caferacerkits.co.uk/order-online-2/universal-parts/

stainless headers and muffler, baffle, etc.

 

[BigBSBusa]

Re: 1981 CX500

Look forward to what you have planned. Keep the updates coming.

 

[Dhalla]

Re: 1981 CX500

Day 20:
I took a different approach to the rear hoop today. Tried to hammer the tube then bend it. Didn't quite work yet. Plan C formulating in my head. I am thinking about starting the read from scratch, and using my own rectangular tubing.

I took a brake and finally got my thoughts on "paper". Here's my illustration.

Thanks CafeRay for the good info. I was weary of the rear looper, and I'll take your advice. As a mock up it works, but it really is important to have the rigidity. And that parts store is spot on, I was looking for spoke wheel conversions.

 

[cxman]

Re: 1981 CX500

remember that a cross bar in the rear hoop also acts as a bump stop to keep the rear tire from hitting your butt

if you hit a pothole

 

[caferay]

Re: 1981 CX500

And that parts store is spot on, I was looking for spoke wheel conversions.

Not sure if that conversion will work on your hubs -they didn't get the custom in Europe.

Consider a 2 to 1 pipe -the CXs have an unusual gear lever that loops over the exhaust, makes rearsets near impossible. If you are considering rearsets, 2 to 1 could save big headaches.

 

[AceCR]

Re: 1981 CX500 -- *NEW ILLUSTRATION*

cool idea what you did on the loop

 

[caferay]

Re: 1981 CX500 -- *NEW ILLUSTRATION*

Another trick, from the racing days. We had a problem at tech inspection at a race with the roll bar being too low for our taller driver.
The Italian mechanic found a tube about the right length and diameter. He brazed on a washer at one end and filled the hole with bronze, he then packed fine beach sand in the tube , and sealed the other end with brazing.
Then with the torch, we got the tube red hot and bent it around a wood form I made quickly to a U shape, he then cut off the ends, got the sand out and TIG welded the tube in place. We made inspection a few hours later. Could have been an episode of McGyver.

 

[wowbagger]

Re: 1981 CX500

I was looking for spoke wheel conversions.

Not sure it's worth all of the time but this guy did an amazing job converting his comstars to spokes:
http://motosynthesis.blogspot.com/p/products.html

He also did a decent cx500 cafe build:
http://motosynthesis.blogspot.com/p/cx-500-cafe.html

 

[Dhalla]

1981 CX500

The frame and wheels were at powder coat and sandblasting forever. So nothing got done til today.
Today I was able to rebuild the front forks, and change all the bearings. Yesterday, i got the tired mounted so today I have a roller!

 

[Dhalla]

Re: 1981 CX500 -- Frame Rebuild Update

Whew. It has been a long time since I a updated last. Or at least it feels like it. Since powder coat took a while I could make much headway before going to school. So I am now at school and trying to get some progress done on the weekends when I have a chance. So the big news is I got the rear frame rebuilt. I originally was unsure if this was task I wanted to undergo, but since the build was going to take longer, I figured I amy as well do the full treatment. That means my renderings are a little obsolete now. Sigh.

So since I don't trust my welding on the frame I took the bike to a local builder. Mat Seely is the name. Great guy. Awesome work and attention to detail. We started out mocking the frame lines

Then Cut the frame to bend up the frame rails with a torch and some leverage

Then plugged the frame. (we lathed the tubing to get the right, snug fit)

Checked the proportions for the length of the tail section (do we go short and stubby or longer for 2up)

Then mig'd her up

Detail in the looper. Not a perfect 180 degree bend. Mat hit the design I wanted spot on. Then rasped the welds so you can't tell. Simply perfect and spot on.

Lathed the old shock mount studs. and built the new mounts.

Mat ran in to the problem of holding the tabs straight, even, and perfectly spaced. So he made up a jig from some bar, and machine screws to hold the inners while he welded them, and then the outers when the time came to put them on. Pretty clever if you ask me.

Finished shock mounts.

And the final product! So happy how it turned out.

That's all for now. Until the next time.

 

[Finnigan]

Re: 1981 CX500 -- New Frame Rebuild Process Pics

Looks great, will be watching

 

[jwdmotorsports]

Re: 1981 CX500 -- New Frame Rebuild Process Pics

I'm working on a similar project. Any updates?

 

[Dhalla]

1981 CX500 : Updated May 22

Well, it sure has been a while. School has taken up most of my time and winter break i was in Oregon. Thus, no work was done til spring break. It felt good to just hang at home and turn a wrench.

So since last time I have been able to:
paint the engine
fully reassemble the front assembly
send valve covers, engine mounts, etc to powdercoat
fabricated a seat pan for one of my seats

Some updated pictures:
New Paint, Valve covers are at powder coat now.

Seat pan construction:

May 2014:
School is finished and I have much more time to work on the bike. I recently received my new headlight with integrated turn signals and some gaskets. Currently, I am mocking up the final look and though my design has changed quite a bit I am happy with the way the bike is coming along.

 

[Roar]

Re: 1981 CX500 -- New Frame Rebuild Process Pics

Very nice work, what an improvement over the original!
I think if you move the headlight down about 3" it would look even better!

 

[Dhalla]

Re: 1981 CX500 -- New Frame Rebuild Process Pics

I think if you move the headlight down about 3" it would look even better!

Oh for sure. I haven't a mount yet, but I can assure you it will be lower. Nothing will be higher than the ignition.