Nixon - '72 CL450 - Updates and Upgrades

[Flugtechnik]

Re: Nixon - '72 CL450

So i finished up the wooden form. I tweaked the CAD design shown above and used that to make templates to cut and shape the wood. It took a little while, but at least the tank and seat will look exactly how I want them. I will be dropping them off at the welder's today so he can start working on them.

Making the Buck
My dad glued up some pine boards and then we cut out the general shape (using templates from my CAD model) using a really big band saw. I then used a large file and a sander to get it to the final shape. I made cardboard templates to help be get the corner radii right and keep things consistent.

The Finished Product
The final tank won't have a pointed front because it will be cut out for the frame tunnel. Also, the seat will be trimmed to match the profile of the tank where they meet. The flat part of the seat buck is actually a little long so we can trim it to fit.

and here is the lonely engine waiting for a bike to call home....

and the three tanks that didn't make the cut.

 

[sxecafe]

Re: Nixon - '72 CL450

That looks great, man! Im really impressed. Now get to hammering some metal!

 

[Flugtechnik]

Re: Nixon - '72 CL450 - Tank/Seat Forms

Thanks. It was actually easier than I expected. All the pre-planning helped. I'll let him hammer the metal. I have no idea how to do that.

 

[Flugtechnik]

Re: Nixon - '72 CL450 - Tank/Seat Forms

Tank and seat fab work is done!


We finally got everything looking the way I wanted and the mounting scheme worked out. There are a few details to work out. Currently my triple tree hits the tank so we are going to have to modify the stops somehow. Also, I'm still waiting on my tail lights to come in so those still need to be mounted.


We are currently working on the rearset mounts. We are going to have to make some standoffs so the the rearsets stick out far enough so that my leg clears the high CL exhaust.


I still have a lot of work to do before the GTG at the end of July. It will be a sprint to the end.

 

[Maritime]

Re: Nixon - '72 CL450 - Tank/Seat Fab Work Done!

Shit Fluge, makes me sad I won't get to the GTG this year.

 

[Flugtechnik]

Re: Nixon - '72 CL450 - Tank/Seat Fab Work Done!

Ugh, I hope I have it done by then. It's too bad you can't make it.

 

[Flugtechnik]

Re: Nixon - '72 CL450 - Painting Complete

LOTS and LOTS of work done this weekend. Spent 3 solid days getting everything done. I paid the welder and got everything back. Installed the tail lights in the seat. Cleaned and painted a bunch of parts. Got the fenders done and painted. Cleaned up some stuff on the frame (tabs and such) and made some slight mods to accommodate the electrics. Cleaned and stripped the frame, which took a LONG time. Primed it and then painted is satin black to match the rest of the painted parts. The paint turned out really well for a spraybomb job.


Tomorrow, I start reassembly! I should have it mostly back together this weekend. I will have to modify some of the wiring since I moved stuff around and I still need to work our the rear brake rod and the shifter so those will take some time. I also still need to apply the brushed finish to the tank and seat. 3 weeks left! Hope I make it.


Front Fender Body Work






Frame Primed






Frame Painted

 

[Maritime]

Re: Nixon - '72 CL450 - Painting Complete

Getting there, will it be done by GTG? Looks like you are close.

 

[Flugtechnik]

Re: Nixon - '72 CL450 - Painting Complete

I think it will be done in time. The main hurdles are the wiring and the foot controls. There are some things that can be put off until after like applying the finish to the tank/seat and repainting the rims.

 

[JustinLonghorn]

Re: Nixon - '72 CL450 - Painting Complete

Keep it up, sir. I am sure she will be rideable come the end of the month.

 

[Flugtechnik]

Re: Nixon - '72 CL450 - Assembly and Wiring Complete

It took a lot of beers, but she is 99% assembled! Everything is on except for the rear brake rod which needs to be shortened since I have rearsets. The wiring took FOREVER! Sinced I moved all the electrics to the seat hump, all of those wires had to be extended. I also moved the key switch to the dash so I had to extend that too.

When I got the tank on, I realized the bungs for the petcocks where in a bad location. When the tank was built, I didn't have the engine in the frame so we didn't know exactly where the interferences would be. I dropped the tank off at the welder's house and he had it back to me the next day with the bungs in the right spot.

Also, when we were assembling it, I had to take the back wheel of for some reason. When I did, it became imbalanced on the platform......err cooler, and started to fall forward. My dad tried to catch it and it fell on him. The only real damage to the bike was that the rear brake stay that was hanging down got bent. Most importantly, my dad did not get hurt. We bent the brake stay back and got everything put together.

Next step is to sync the carbs and adjust the set the timing so I can get her running. Then take her over to the welder's to modify the brake rod and shift lever. If I have time before the GTG, I still need to apply the brushed finish to the tank. The seat is done though.

Haha. No pics of the final product though. Just these teasers. I'll post some up after the GTG. Or you can just see it there!

The engine is in!





Suspension and wheel on!





Oops, that isn't going to work.





The electrics under the bump.





She's ready to roll!

 

[clutch]

Re: Nixon - '72 CL450 - Assembly and Wiring Complete

Fantastic work with that wooden buck and metal-work. Pic from the front is a tease!

 

[Flugtechnik]

Re: Nixon - '72 CL450 - She Runs!

I finally fired her up on Sunday. I had gotten a new throttle cable and a new set of points so it took a while to get both of those adjusted properly. I still don't think I have the timing quite right. I put the tank on and put a little gas in there. I opened of the left petcock and nothing leaked. Yay! I opened up the right petcock and almost immediately gas started dripping all over my freshly painted engine. Nooo! Turns out the o-ring on the bowl drain was bad. $1 at the parts store and that was fixed. However, when I got back from the parts store, I realized the petcocks were leaking where they screwed into the tank, very slowly. I couldn't wait anymore so I stuck some paper towels under the petcocks and started her up. It took a few tries because I had the idle screws set too low but she finally started and kept running. A bunch of black soot shot out of the exhaust. I'm guessing that was from the assembly lube (I did rebuild the engine). That cleared up pretty quickly and she just kept running. I think one of the cylinders might be missing every once and awhile so I've got some work to do, but I am very happy at the moment.


After letting the bowls run dry, I took the tank off and took out the petcocks. I got some fuel safe thread sealer and put that on there. I'm letting that cure overnight and will put the tank back on today.



Now that she is running, I have to ride her over to the welders house (about 1/2 mile away) to get the rear brake rod and shifter modified. Hopefully I can get that done today. I am going to try and get some tuning done on Wednesday and then take her for a shakedown run and hopefully a long ride this weekend. I want to make sure she is going to make it to TN.


*Yes, I have two petcocks. One on each side feeding it's own carburetor. No I have no reserve. I'm living life on the edge!*

 

[SHINFO]

Re: Nixon - '72 CL450 - She Runs!




Super sick build Flug! Your engine job is gorgeous and the same look I'm sort of going after. I noticed your fork tubes were painted black, I didn't
read about it in your build unless I may have missed it but what paint did you use for them?

 

[Flugtechnik]

Nixon - '72 CL450 - She Runs!

Thanks Shinfo! I don't think I mentioned that. They are only painted down just below the lower triple tree with the same satin black epoxy paint I used on the frame. They were VERY rusty and couldn't be cleaned up.

When I painted the trees, I cleaned out inside the clamps with my dremel tool. Then when I assembled the forks, I had my friend hold the lower tree clamps open so they wouldn't scrape the paint off.

 

[Flugtechnik]

Re: Nixon - '72 CL450 - She Runs!

BALLS! The tank is still leaking where the fuel valves screw in. I can't tell if it is from the threads or a bad weld. I took the tank back to the guy that made it to see if he could figure it out.


Time is running out.

 

[el_simo]

Re: Nixon - '72 CL450 - She Runs!

Hey man,

Project looking great, I havent posted here before. Im polishing hubs at the moment & am aiming to get a finish similar to yours. What clear coat did you use if ya dont mind me asking ?

Cheers

 

[Flugtechnik]

Nixon - '72 CL450 - She Runs!

The clear I used is a high heat engine enamel - clear. I can't remember the brand. It is a common brand like rustoleum or something. I've heard all these clears will yellow over time. I guess I will see

BTW, my hubs and such are not polished. They are brushed. Just making sure you saw that. The clear has a gloss finish.

 

[el_simo]

Re: Nixon - '72 CL450 - She Runs!

Thanks flug,

Rushed into the questions there, just finished reading your thread so I'm more clued in now. Thanks for getting back to me. Great original work and dedication on your project man ! Cant wait to see more pics of finished bike, well done !

Si

 

[Flugtechnik]

Re: Nixon - '72 CL450 - She Runs!

Got the leaks at the threads fixed. The shift lever and brake rod are done. However, we had to put such a big bend in the rod that it flexes when I brake. This is not a permanent solution and will need to be reworked after the GTG. Sorry, forgot to take pictures.

I got the tank on and did a quick shakedown run to get the shifter and brakes adjusted. Put about 8 miles on it running around the neighborhood and going to the gas station to fill the tank. It ran pretty well but the idle wanted to start racing at stop lights. I got it home and was adjusting the idle when I noticed gas on the outside of the tank. Apparently there were some pinholes in some of the welds where the guy had to move the bungs. So the tank is back at his house and he is working on it. Doing some pressurized leak tests. Hopefully it will be done tomorrow. I still need to balance the carbs and get the timing dialed in. Shooting for a long shakedown ride on Wednesday.

Going to cut this one close.