Green Hornet CB 550/650 Hybrid #2014 Footage Compilation

[Oette]

Hello Ladies and Gentlemen!

With this Post I am starting my blog, which is actually a building diary about my Cafe Racer, based on a 1978 Honda CB 550 Four.

I found your forum here and decided to post everything up to the current building progress via "copy and paste".
Please don't be confused about all the old dates and places, I started the build nearly exactly one year before.

Some facts about me:
I am a 20-year-old student (studying Electrical Engineering) and at the same time a trainee for plant mechanics.
Well, enough of that. Here are some facts about my project.
After a short period of time i began to search for an old motorcycle which did not have to be comlete or running at all, because i was about to change it either way.

On Friday 18th March 2011 I inspected an old CB 550 Four about 25 miles from here.
You can't imagine just with words, so I uploaded some photos for you:

Well, it is not complete, but the most parts are convenient or perfectly o.k. Here are some detailed shots:

All in all:

-front wheel and rim are perfectly o.k. (chrome is shiny)
-rear wheel and rim are convenient (the chain added scratches to the rim's side)
-brakes are as good as new
-front and rear fenders are super
-fork o.k.
-tachometer o.k.
-swingarm super
-stands o.k.
-chainguard perfectly o.k.
-shock absorbers o.k
-frame o.k.
-wiring harness super

Fuel tank, tachometer and saddle will not be used, because they are going to be changed, too.

There was a Suzuki GS 550 E available for nearly 1000$ but in a quite bad condition.
Moreover, my family owns a nearly complete engine, another frame and many, in some cases new, spare parts.

Today i got an offer for an complete running engine for about 320$, but let's see what the next days will bring.

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

Last evening I brought the bike to my garage. After a distance of 50 miles "she" found her new home.

The inspection of the new engine will be on monday, but I have just begun to disassemble the bike. Of course I took some photos for my followers ;-).

Furthermore I checked if the fuel tank of an CX 500 D would fit on the frame and I am convinced that it would be looking great. With the notch for knees it really looks like a true Caferacer!

Unfortunately the tank lay a bit too high at its rear end and I forgot to took some new photos when it finally fitted.

Regrettably the hole for the screw holding the tank does not fit on the 550's frame. Because of this I have to think about a proper solution for this problem. Maybe I will get an aluminium tank, so the CX's tank may be just a temporary solution.

Meanwhile the tachometer, fenders, wire harness, brakes, handlebars and the chain are disassembled.

At the weekend I will go on disassembling the bike until the frame is naked. I will document the progress here.

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

I went on disassembling the bike and finally finished it. Today I focused on polishing the rims and the other chromed parts.
As you can see, old and dirty changed into shiny chrome. As always I took some pictures so you can have a look on my work and the "before-after"-effect.

After quite much work an a pair of weakened arms it looked this way. Though it is not highly polished yet rust and dirt disappeared.

Unfortunately the scratches added by the chain are more visible now, but maybe I will find another rim to replace it in some time.

The worker's meal: Orange-juice! Who would waste time on eating some consistent food?

Halftime: There are still some things that have to be disassembled

Finally admiring the shining rims while the 550 lies completely disassembled in my garage. I wonder if I will do something tomorrow. With my sandblaster box I could release some parts from rust and dirt to conserve them for coating.

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

After a short pause I am back again with some news:

-the tank sealing has arrived

-my thoughts about the mounting of the speedo and tacho led to a result

-the fork brace is bare now

-I purchased carbs which are as good as new

I took some pictures again, so here they are with fitting comments:

These are the new carbs with some chrome, which is actually not really my taste, so I think of changing this. In some time I will clean them in my ultrasonic bath to make them shine like new carbs.

With my CAD program I printed a pattern for the mounting of the instruments. I used 3mm aluminium for this.

After some drilling and filing the mounting was finished, it just needs some surface treatment now.
In fact, I am not sure if this one will look good enough in the end, but I'll judge about this later.
When there is a bigger budget available I may be able to get something better looking.

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

-The adapters for the CX's tank are finished
-I prepared the tank for welding


As usual I took some photos for you:

The tank with cut off mountings

The new mounting which will be welded within the next days

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

Today the seat arrived and I stripped it down.
The cover was raddled so don't worry about destroying a good one. I took the rubbers off so I can use them later when the seat is finished. Furthermore the seat is quite rusty so I have to weld a smaller crack later when the hump is finished.

These sheets shall reinforce the seat and close the crack when they are welded onto the seat.

Yesterday I spend some hours to overhaul the carbs. My work consisted of: Disassembling, an ultrasonic cleaning treatment, new greasing and reassembling.

The results are looking pretty good now, after reassembling had taken much of time and nerves.

Disassembled and sorted by each's carb parts.

Many, many screws.

Our "little" but useful 4 litre ultrasonic bath.

Right one: Before / Left one: After - looking better, isn't it?

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

Here's the next conception. Got an boxed swingarm for my CB today. I think I will have both, the original and the boxed one coated to decide about which one I'll use later.

I also welded the seat, using a moped's tank and the original seat.

Pics are self-explaining.

That's the progress so far. I hope I'll find some time this summer to get her running before 2013.

By the way:
-Exhaust is from Benjies Cafe Racer, shortened by 3 inches
-Meanwhile I got new aluminium rims. After some polishing they will be assembled with new stainless spokes.


If there are any questions, feel free to ask.

Regards,

Oette

 

[axeugene27]

Re: CB 550 K Cafe Racer Conversion

My first thought when opening this thread was that i really liked the original paint job on that bike only to quickly find you abandoned it. lol. How is the paint/condition on that original tank.. are you interested in selling it?>

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

Haha. No I'm sorry... In fact I told the original owner to keep the tank in order to get the price another 50 $ down. I already had the CX 500 tank at home and simply thought of using it anyway.

It all has begun with this video here, which brought me a clear image of what I am going to do on that bike. That includes using the CX's tank.

http://www.youtube.com/watch?v=pTsY4ALm8C0

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

I adapted a modern clear glass headlight into the classic headlight case. Took some time, heat and nerves!

 

[03rangerxlt]

Re: CB 550 K Cafe Racer Conversion

i like how this one is turning out and really like how you did up the seat.

 

[Modgod1]

Re: CB 550 K Cafe Racer Conversion

Looks like its coming along nicely, any idea what kind of front fender/mudguard that is, I don't think it's original?

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

Thank you guys, I am doing my best.

Regrettably I don't have any idea of which bike this fender is.

 

[rock2d2]

Re: CB 550 K Cafe Racer Conversion

Coming along great. Following!

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

Hi Guys,

I need your help, because I'm quite indecisive. Shall I leave the frame as it is or shorten it like visualised by the black line?

I know it's a personal estimation, but maybe this dilemma can be solved by one or two good arguments for or against this measure.

Regards...

 

[kwazykid]

Re: CB 550 K Cafe Racer Conversion

I think you should cut it to follow the bottom edge of the frame from the shock mount back. Make it flow right into the cowl. Sorta like what you've got drawn but a little bit flatter.

 

[03rangerxlt]

Re: CB 550 K Cafe Racer Conversion

i say do some work to blend the lines of the frame into the bottom of the seat. Maybe even weld up some kind of extension to better get the shape that will flow.

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

FIrst of all, thank you.

The problem is, I used the original seat plate and will stick to it. The consequence is, that I have to use the stock mounting points like the bail at the rear frame. Cutting the frame right behind the shock's mounting means to abandon the whole setup.

Moreover, I really want a clean tail. Welding some extension on it might not look as good as it does now...

 

[Oette]

Re: CB 550 K Cafe Racer Conversion

I think you should cut it to follow the bottom edge of the frame from the shock mount back. Make it flow right into the cowl. Sorta like what you've got drawn but a little bit flatter.

Ah, sorry. I misunderstood your post. That sounds good, but for road use I have to avoid sharp edges. It's a requirement for road use here in Germany. But I'll see what I can do!

 

[03rangerxlt]

Re: CB 550 K Cafe Racer Conversion

WHat I'm talking about is welding and shaping the frame to fit to the bottom of the seat in shape. Kinda like Ringo's Gulf CB550.

(Damn, I love this bike!)