Re: '76 cb360 cafe:ROUND 2!
So, this bike has quite a history among friends already.
Where checko left off on the previously is how he traded away the bike for a set of Ronal Turbo wheels for his mk2 GTi project.
He sold the GTi, and Daryl (who got this cb360) decided he didn't want a cafe'd one so he offered to trade this rolling chassis with Luke for his mostly stock cb360.
story on that bike was luke's uncle gave him the bike with a locked up motor...which we free'd and got running....he got a lot of checko's take-offs to make it a ride-able bike and enjoyed a full season of riding before a valve let go.
Luke sat on the project all this time and checko took a mk3 jetta as partial trade on selling his mk5 rabbit. He offered luke to trade for the 360 project back and luke now has a winter-beater Jetta.....and Checko and I have gone hard on this project again to sell it upon completion for some shared profits. Best part is....through all the trades no-one re-titled it....so it's still in checko's name LOL.
So, let's examine the parts list of thing's we're working with here:
-1976 cb360 frame, with custom subframe and converted to monoshock using ninja250 swinger and zx6r shock/linkage.
-1974 12k mile beautiful condition running motor and carbs
-luke's blown up half disassembled cb360 motor for mockup
-cb500T front wheel, previous converted to a 19mm bearing/axle instead of stock 17mm
-cb750 rear wheel
-1995 zx9r complete front end
-some 90's ducati front brake rotor
-cb350f supersport tank
So, when checko last "owned" the bike, he'd never made it to working out the rear axle. the ninja250 actually uses a smaller diameter rear axle than a cb750, and the cb750 rear axle is too narrow for the arm.
We started out by having a buddy bore the swingarm's internal axle adjusters to match the cb750 bolt (I didn't even own a mill yet). Then we figured out that a cbr1000f hurricane uses the same diameter rear axle we needed, yet definitely long enough (too long, in fact). So we tossed the bolt in the lathe to cut the shoulder back a little farther to add more threads to shorten the bolt later
after turning and threading, we have this:
cool, so now we have to get the wheel centered in the swingarm. What was odd, is the sprocket lined up great, but the wheel wasn't in the middle. so we shaved 8mm off the spacer for the axle on that side, and then had to come up with a way to chuck the cush drive in my lathe and take 8mm off that as well.
here's after we took care of spacers:
Checko had a stroke of genius after we spent over an hour trying two different sets of jaws on the lathe chuck and various ways of mounting it.....DURRR, flip the sprocket to the back and use that.
ahhh, there we are!
Then Checko made up some gussets for the area's around the shock mount (they got fully welded, didn't snap a pic though)
and he designed and made up a battery box to go just at the rear of the tank above the carbs
Time to move on to the front. Originally, the plan was to cut custom triple trees for these zx9r forks to retain factory geometry.....but we realized the back is now longer, wider, and mono-shock....so factory geometry is kind of moot here.....so we spend a good bit of time measuring and calculating and as it turns out, trail with the zx9r trees is 4.47" which is pretty acceptable.
so we pressed the stem out of the zx9r tree assuming we'd have to make a collar to adapt the stock cb360 stem.....as it turns out, the I.D. of the zx9 stem was only 1mm smaller than the O.D. of the cb360 stem....so what we did was cut the zx9 stem flush with the top of the lower triple, then chucked it in the lathe, and bored it to press-fit the cb360 stem into it, then welded the two together at the bottom. Quick run to Buffalo Bearing for some stock-sized tapered neck bearings and bob's your uncle.
Now that the forks fit the frame, time to make the wheel/axle fit the forks....
We had the zx9r axle to be able to replicate the ends, measured for what spacers would be required....and combined that to make the axle do both jobs in just two pieces. We cut spacers to run with a suzuki VZ800 front axle that was previous on this bike....but Luke traded away the VZ800 front end. Since the axle was still around and checko previously already swapped the bearings to fit that....here's how it went.
Next checko made up a new seatpan from some stainless he snagged out of the scrap bin where he works, complete with blind hardware
And in some ebay searching, he snagged a yamaha blaster headlight, some Renthal Twin-Wall bars, and some 1-1/8" bar clamps. some measuring/drilling/hardware later we have this:
Next we decided to start planning out exhaust. We both liked the idea of scrambler style pipes to fit the dual-sport look/theme we're kind of running with so far..... Found some U-bends from a previous exhaust build while rummaging in our parts room and started mocking up a left side pipe
then, we were able to grab some cardboard to draw up how we'd be able to get the right sid to hug the front side of the frame down-tube and loop through this u-bend.
Set a 10' length of 1.5" pipe up on saw horses and struck two chalklines 180* apart. set the bandsaw to 7.5*, and made cuts alternating 180* to achieve 15* per seam over an 8.5" radius to pie our way to greatness.
Checko laying the sparks
Then we both went to work the next day and did some non-work things at work.
Checko took a sketch in and made up a heat shield for where your leg would lay across the exhaust.
I made up drawings for a collector, and that night we made up a jig from some scrap box steel to make the cuts on a chop-saw
We put some bends on the top and bottom of checko's heat shield to get it to roll over the edges of the pipes, and welded on some nuts to hold the pipes parallel while we welded on our collector. Borrowed a muffler from one of the pitbikes for mock-up.
That pretty much brings us current. Checko grabbed an FMF can on ebay to finish up the exhaust, and we're pretty much to the point of adding some gussets to the frame, and sending out a bunch of stuff for blasting so we can have our buddy lay some nice powdercoat for us. Checko plans to order some dual-sport tires later this week, and we'll probably break the bike down over the weekend to get upholstery and powdercoating taken care of, and bodywork/paint on the tank.
Current plan is a cream/off-white on the tank and rims, with brown frame and hubs, black spokes, and a tan seat.
