The not-so-rare '77 CB200 build

RENO.HOOLIGAN said:
Did you use spray paint for all the paint?
Yup, expensive self etching primer, off the shelf black, custom blended orange from lordco, and an expensive two-part clear.
 
Started to cut polish the clear coat today. The objective was to smooth out the orange peal finish.
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So here we go. Sand paper grits 600, 1000, 1200, 1500, 2000, and 2500. Then three levels of cut polish.
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Two hours of elbo grease and she's smooth as glass.
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The fender had a dent in it that I couldn't bang out. The chrome was too nice to completely paint over so I just filled the den and painted this stripe over it. Not bad, not perfect, but I like it.
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Total Balls!!!! Well the fun has come to a grinding halt. I was bolting down the exhaust and the header bolt stripped out in the head. Now what? Retap it for a #7 or maybe a #8 bolt? Any suggestions?
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Retap to #7 and if you feel that it has given a full depth thread, winner winner chicken dinner, if not the full depth you'll have to go to the #8 unless you can get half sizes? but surely #7 will be fine.....
 
I couldn't find a M7 so I just tapped it for a M8. Done.

On to the next tragedy. While hanging up my latter I knocked something off the wall and it landed on my gas tank. Balls! Four chips in the paint.
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Did some dremeling to my new VM20 carbs to line up the ports better.
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"Modded" the filters to fit around the frame.
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Got most of the wiring done on the back end of the bike. New electronics tray worked well.
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I mounted this electronics box under the gages to house all wiring that was originally in the headlight. Hopefully it will all fit in there when done.
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After a week of wiring I got it all done and crammed into the box.
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Wired up these swiches I got from DCC. Had to do some minor mods and add an extra relay to make them do what I wanted them to do.
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THe HID lamp came with four different black boxes to mount..... somewhere. I ended up jamming one of them into the headlight case.
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I had to wire these diodes to make the blinker indicator work with the LED signals. I don't how it could of worked before without it.....
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I made this kill switch and high beam indicator.
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All buttoned up!
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Did some soldering. First time making throttle cables. I think it went well.
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New throttle from DCC. Looks and works sweet.
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Got the carbs mounted.
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Used some shrink wrap to cover up the ugly old brake and clutch cables.
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And I'm done!

Looks sweet - check
More horse power - check
Dreadfully uncomfortable to ride - check

I'm not impressed with the performance of the HID head light. I was expecting super bright, but it's more like super not bright.... not sure why yet. It's leaking a little oil from the left case cover so a little work there is still required. Besides that, it's time to ride! (to work and back :-\) More pics to follow.
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