My first project. CM400 style.

[memphis]

Before we get too far, let me give you some background. I got my CM400E as a gift from my wife about three months ago. She knew I've always wanted a bike, plus since gas is the way it is...it was a practical choice... ;D yeah for practicality!!!! ;D So, I rode it around for barely a couple of weeks before I realized I NEEDED to do something with it. At first I wanted to make it more of a cruiser, so I through some saddlebags on it and almost through some crashbars on it. But, after some www searching I found the cafe racer style. I knew immediatly that this was what I wanted to do...why make this bike something it's not. I figured i should play to the bikes' strengths. It's a small cc bike, what did the rockers do with a small cc bike? exactly...cafe racer

So I took off those evil saddlebags and threw on some clubmans, that alone dramastically changed the look of the bike. Then I took out that HUGE air-box and through on some pod air filters,-hence the other thread about adjusting my carbs.

so here is what the bike looked like after that.

After some searching and asking around I found a nice, bigger tank on fleabay. Seller states that it's off a 750. I have no idea which honda bike or year it's off of...any clues?

I stripped off all the paint. I tried spraying on some aircraft remover bu that didn't seem to do the job. I let it set for a few hours, the can only said 30 minutes. So, unsatisfied with the results, I took some sandpaper to it and viola'

a nice shiny, bare metal tank...AKA empty canvas.

I thought, instead of finding a oem lid I would just weld a piece of sheet metal over the space where the lid would go. cut a hole that lines up with the original, then get Carpy's cafe style gas cap and place into the holes. I would weld a piece of metal tubing that would connect both fuel holes, to keep fuel from spilling into the covered cavity that the new sheet metal "lid" would create. By the way....ANY critics are welcome, incouraged even!! 8)

So, that is what we have so far...gotta figure out a new seat and how to mount it.
Someone gave me a great color suggestion today, flat matte burnt orange.
Again, suggestions and CRITICS are encouraged. I'll post more as the project goes.

 

[kneedragger]

Nice to see the start of your build; we'll be watching your progress...

That tank is from a mid-70's Honda, though I'm not sure which model. It LOOKS like a 750 tank... Just a reminder... how clean is that tank on the inside? Got any rust or pinholes to deal with? Make sure the tank is road-worthy BEFORE you put a lot of time and effort into it...

OK, since you're looking for both criticism AND advice, here's some input for you to consider: Don't simply weld a "lid" over the space where the original fuel filler door was; all kinds of crud will build up in there, including condensation, which will occur simply as the top of the tank heats up in the daylight, and cools down at night. Rust never sleeps, so bad things will be happening, and you won't know about it until too late.

You might want to think about using the space as a holder for the gas cap when you're filling up; of course, you'd want to make it a bit smoother for that. Conversely, you might simply want to fill that space with epoxy. In that case, just put some thin layers of epoxy in the space, and build it up level with the rest of the tank. If you happen to build it a little too high, you can always sand it down pretty easily, so don't worry about getting it exact until you're almost ready to paint the tank...

Judging from the discoloration on the headpipes, it looks like the engine was run lean (stock jetting will do that); if your carbs are dialed-in now, you might want to get some Blue-Away, or another fine metal polish, and see if you can bring up the lustre in those pipes. For a good example of what you can achieve by polishing, see these two photos:

BEFORE:

http://i14.photobucket.com/albums/a332/bmx_v_dubdub/Yamaha650/DSCN5333.jpg

AFTER:

http://i14.photobucket.com/albums/a332/bmx_v_dubdub/Yamaha650/DSCN5338.jpg

They appear in this thread:

http://dotheton.com/index.php?topic=3495.0

Others might have more / different ideas / suggestions for you; feel free to disagree with me. This is your bike, and your build; thanks for letting me put my .02 cents in. I hope you plan to black-out that shiny chainguard, or maybe fab a new one, and lose that obnoxious chunk of chrome-plated trash... you could always use it to fab a new gas flap for the new tank; just use your original tank as a model...

Lastly, POST MORE PHOTOS! Let's see the other side of that CM...

 

[memphis]

Awesome advice!. I never thought about "crud" build up. A buddy had the idea of finding someone to simply cut out that area of the tank and then weld on a piece to cover. As far has the inside goes, it's clean.

Here's what I've still got to do.

wrap the pipes
tune in the carbs
polish or paint all the chrome (black out)
make a seat
lower the forks
relocate the battery and electrical
move the taillight and plate mount
lose the rear fender
much, much, more


here's the other side

 

[Gordon]

They appear in this thread:

http://dotheton.com/index.php?topic=3495.0

Its opening a "Roll Call" thread.

 

[kneedragger]

Its opening a "Roll Call" thread.

Hi Gordon; you're right, those "before" and "after" photos appear in the "Roll Call" thread, on the SECOND page; here's the DIRECT link to the second page:

http://dotheton.com/index.php?topic=3495.15

I used the link to the first page to give everyone a chance to start reading at the beginning of the thread; I dislike jumping into threads beyond the main page, and I guess my bias is showing... sorry if I've caused any confusion...

-- kd

 

[Gordon]

a good example of what you can achieve by polishing,

Is there a link showing how to go about doing it?!

I'd like to do the same to my Yamaha tree.

much, much, more

Indicators

 

[memphis]

;D Yes, Gordon Indicators too ;D

Well, second night after deciding to really get busy. All day today while my wife and I were driving around town in this rainy july 4th, all I could think about was gettin' back to by bike...get some more work done.

Since I don't have a bike lift I had to jimmy rig one. It's a wonder what a piece of wood, an hydraulic jack and some stands will do.

Once i got 'er up I started tearing into her. I took off the tank, chain guard (KD ;D), and rear tire. I'm hoping to get new tires this weekend if I can get them for the right price from the local shop. if not, then online I will go.

I went ahead and took off the rear fender, taillight and, yes, indicators. I relocated the license plate to the left side using a bracket off an old CB radio mount.

I needed to tune my carbs so I decided to go ahead and take them off and see what I could do. This is what slowed me down. Now, like I've stated before this is my first project. When I worked on cars I alway worked on ones that were fuel injected, not carbed. So, when it comes to carbs, I'm a little lost...ok BIG lost. My book isn't very clear on which needles I need to adjust to better my mixture. So, maybe my DTT family will be able to clear up the fog in my head.

When I take apart the carbs I find more than a few needles and I don't know which to adjust. Do I adjust/change the needles in here...

or these?

forgive my ignorance.


So, there you go. Heres a nice mock up with the new tank on. I can't wait till this bike is done!!!

more to come

 

[kneedragger]

Hey memphis, check out the links on this webpage:

http://www.xlintperformance.com/Tech.htm

LOTS of good information there; more good links you should see... first, download and read this .PDF file (just right-click and SAVE):

http://www.motorcyclecarbs.com/carbs101.pdf

Carb jetting and tuning for LOW-RPM engines (such as most thumpers):

http://www.factorypro.com/tech_tuning_procedures/tuning_carbtune,CV,lower_rpm_engines.html

Carb jetting and tuning for HIGH-RPM engines (redlines at 8K RPM and above):

http://www.factorypro.com/tech_tuning_procedures/tuning_carbtune,CV,high_rpm_engines.html

Another good article:

http://www.dansmc.com/carbs2.htm

There are countless THOUSANDS of more articles available on the 'net, but those should help you ramp up your learning curve.

Check out this cafe racer; is this the type of color / paint scheme you're considering?

http://losangeles.craigslist.org/lgb/mcy/737516507.html

Don't worry; if the ad is taken down, I've already saved the photos, and I can post them somewhere for you to check them out...

-- kd

PS - - Thanks for yanking that obnoxious chainguard; I'm actually trying to design one, so if I like the results (I'm working in cardboard), I'll let you see it, and you should be able to fab it in flat aluminum stock pretty cheaply... you'll need a Dremel, or something similar to cut aluminum with, and maybe some epoxy such as J-B Weld...

-- kd

 

[memphis]

thanx for the links KD, I now know ( at least a little) what I'm lookin at!!!

the color on the bike you showed me is close...it as too much yellow in it. This is closer to what I mean.

basically a flatte version.

KD, you seem to be the only one willing to comment on my bike, do you have any suggestions on the seat?
I've looked at all the seat making threads, but all seem to have a slat frame. My bike, as you can see, as a frame for a more "cruiser" style seat.

 

[kneedragger]

Well, don't overlook the input you've had from Gordon, and keep in mind that most of the members are probably spending this weekend with their families, so it isn't likely you'll get any other comments until our DTT brethren have the chance to get online again, and do a LOT of reading to catch up...

To be honest, I'm not crazy about how Honda built the back of that frame, but as with all things cafe, consider it an opportunity to fabricate a solution. Your BEST option might be to use your existing seat pan as the platform for the new seat, and work with the existing layout of the frame; otherwise, you might have to get a smoke-wrencher to modify the frame with some additional bracing, which would provide a level surface for whatever seat you build.

Whatever else you do, do NOT make a decision about that yet; the seat should be just about the LAST thing you focus on. As has been said before, the only way to eat an entire elephant is ONE BITE AT A TIME. Don't settle on a seat design until you've got everything else done; I'm not trying to create any work for you, just make helpful suggestions, but from the looks of those photos, you might be trying to do everything RIGHT NOW, and that approach will only frustrate you.

SO, one thing / one bite at a time, OK? You've done so much already, it's overwhelming ME, and I'm just sitting at a keyboard, looking at PHOTOS! I had NO idea you could work so fast... let's hope I can keep up!

First off, get the engine / carb work completed; if it won't run right, you won't be able to ride it.

Once the engine and carb are taken care of, take stock of where you are; decide what else needs to be done, and the order in which you need to complete it, but keep the paint and seat for LAST, to avoid last-minute changes.

I realize how frustrating this must be for you, but remember, you have to eat the WHOLE elephant, so you CAN'T rush this. Let us know where you are with the engine / carbs, so we can help you get those items out of the way, and THEN you can move on to the next logical point of attack. Have you detailed the wheels yet? If not, decide what level you want to bring them to once you've got the engine completed, and work from there. BTW, thanks for posting that block of the color you want; I don't know ANYTHING about color beyond the eight basic Crayola colors I grew up with, so I'm thankful you're not asking my advice in that arena...

I do hope you'll consider blacking-out the fork legs; I think the contrast between the orange and black would be ULTRA cool (Orange and Black! Harley-Davidson and Halloween immediately come to mind), and you might want to consider adding fork gaitors, which will make the front end look much more "muscular", if you know what I mean. The forks of that era were always a concern; gaitors will provide an authentic cafe look to the front end , without running into $$$$ territory. Think about painting the forks and installing gaitors, and let me know what you decide to do. As you know by now, I am NOT a fan of chrome on cafe bikes...

Lastly, remember that quality work is worth the time and effort it requires; what you learn during this build will prepare you for the next one. You're off to a GREAT start, so now you need to focus on getting the details correct, while working with what you have close at hand. Sooner or later, you'll hit a sticking point (probably with the seat, if not before then), and at that point in time, you can ask the brethren to help you brainstorm a solution to help you move forward. I really wish I lived within a thousand miles of you, because I'd be there tomorrow with my sleeves rolled up, ready to work. Keep punching, and remember not to rush this; if you need time to have a few brews, or just to relax with your wife, then be willing to walk away for a few hours to decompress. The project will wait for you, and you'll have a fresh perspective when you return to it.

One more thing; even the best boxers in the world need to rest between each round, so take frequent breaks, and don't forget to duck every now and then when you get back into the ring...

-- kd

 

[memphis]

yeah, sorry gordon, I hope nobody takes that the wrong way...my patience SUCKS!!!!!

sound advice. Yeah,  patience......I never really do anything half way. When I've got the wrench out, it's one thing after the other. I think I'm a little ADHD.... oooh shiny thing!!!

I only really get to work on my bike every other weekend so I try to cram everything into it. I won't get the chance to do anything all week.

I tried cleaning up a little today after church. Figure it's time to do a little shopping for the "this and that" stuff I need, i.e. taillight, inicators, bar end mirrors, gaitors, etc...

 

[Gordon]

Whatever else you do, do NOT make a decision about that yet; the seat should be just about the LAST thing you focus on. As has been said before, the only way to eat an entire elephant is ONE BITE AT A TIME. Don't settle on a seat design until you've got everything else done; I'm not trying to create any work for you, just make helpful suggestions, but from the looks of those photos, you might be trying to do everything RIGHT NOW, and that approach will only frustrate you.

Its true. I've noticed this. You've to go step by step for results.

What I've planned on my Yamaha is that I'd get the bike opened up, make each part at a time. For now, the handlebar and tank are ready. The engine and works are in proper condition. Will have to make seat and rearsets. Now the only logical thing for me to do is make the seat first and then depending on my seat posiition and height of the seat, I'd have to make rearsets. So rearsets are getting delayed since the seat is getting delayed.

The tank looks good, I quite like the chrome or polished look. Are you changing the front fender or shortening it?! If its the same size, try getting those brackets that are connected to the lower fork. It gives a nice classic look.

Your bike has almost the same style of frame like an Enfield. The seat area curves. This does give a good comfortable position. Now for a cafe, you'd need to make it a straight seat. If you use a flat seat base, then there will be a gap between the seat and the frame of the bike. If you use the existing seat base, you could cut the foam in such a way that the top section would be flat.

 

[stuco]

If it were mine, I wouldn't touch that seat or rear fender. The bike has really good lines and the rear of the seat already has a cafe-ish shape. Also, it looks like a damn comfortable seat.

 

[chrisf]

Here is what we did on Sam's bike. He's doing a bratstyle seat. If you look through the pics, the rear grab handle looks over the top. It is. We're going to chop it down when he gets back from vacation...

http://dotheton.com/index.php?topic=3983.45

It looks like you're on the right track. Keep at it.

--Chris

 

[memphis]

Yeah, the seat is comfy, it just won't fit with the new tank. I'm thinking of buying an old stock pan and doing some hacking.

 

[memphis]

OK so, today in between taking people to the hospital, I was able to order some new tires. Kenda challengers, $41.95 for the front, $51.95 for the rear, and $15 each to put them on the wheels. Gonna go tomorrow and get them changed over. So, when i got home I went straight into the garage and took off the front tire. I also decided to clean the tires up a little. I took a tooth brush and some carb cleaner and washed each spoke till they shined. I wasn't really prepared to get wrenching so I didn't grab my camara...sorry :-\

Ordered a "new" seat too. found an old tore up one on fleabay for $15. seat pan is all I want, so I didn't care that the vinyl is tore. I would really like to get this thing atleast half-way done before I go to ATL next weekend.

 

[memphis]

Well, I've come to a halt on carbs...check out this thread for details
http://dotheton.com/index.php?topic=4820.0

so I decided to work on the seat. I got this delivered yesterday. It was in pretty bad shape as you can see.

I took out some foam. Figured I'd take a stab at shaping it. I really needed to take time away from the carbs....be a little creative.
I don't have any pics after I started carving. But, here's your before shot

I also got my wheels and tires back yesterday.

So, yesterday wouldv'e been a GREAT day, since I got the tires on and my new seat in...but since I can't get the bike to start, it's no good.
I hope I can get this stuff figured out.

more soon.

 

[memphis]

Hello there. It's been a LOOOOOOOOOOOOOOONG while since I've been able to make ANY progress on this ol' gal. But, I'm glad to report I've gotten it back from the shop the other day. First, let me apologize for my lack of progressive photos. I get to working and forget to snap any pics. so, when you do see some shots, there will be a big change in the look of the bike.
I was having some trouble, has you've read on some other threads, with my carbs...so, I took it to a local guy who ( seven weeks later) fixed my problem!!!
I've got the new tank on, and I was able to make a new seat out of the old seat pan. I had ordered a "new" one and butchered it cutting away to get it "just right"! But, I learned how I needed to do it an was able to use the original. I think it turned out pretty good! I cut up the original gas tank to make the rear cowl. I'm still tweaking it, so, it will be a while. I was able to get an intigrated taillight/turn signal from a parts bucket at the local shop for $10. I'm having a little trouble with the wiring though...so, if anyone has done the same, let me know how you did it?! The original wiring had two wires for the brakes, one for each indicator and a ground. the new tail light only has three wires...so, you see my problem!
Any way...tomorrow's a build day, so, I'll take some pics.....promise!
Later

 

[colpumpkinnuts]

I'm looking forward to seeing some pics.

 

[memphis]

Has promised...pics!!

gimme some feedback...remember, it's NOT done....just "road worthy"!

I couldn't figure out the wiring for the integrated tail light. I figured I'd use the old lights untill I could get things together. I can't figure out my headlight though...for some reason my high beam stays on. I don't have a clue how to fix it. Help would be nice. hint hint wink wink
The cowl is made out of the old original tank. My seat is made partially out of the original foam and that floor tile foam stuff that locks together, same with the "bum stop". I plan on re-opolstering it with leather soon. Now it's just vinyl. Like I said, it's still a work in progress.