"Traveler's" 1977 CB550K Cafe build

[Traveler]

Today, I worked on the bracket and mounting of my electric panel. I started by cutting some angle iron down to size and drilled two holes to mount it.

I then cut a piece of 16ga. steel and drilled some holes to mount the panel to the "L" bracket. To space it off where it needs to be, requried using some 1/4"dia. 3" long bolts, nuts, and washers.

Granted, this is the mock up stage, so the cuts are a little rough, and some cleanup will be necessary, along with painting.

Anyhow, here are a few pics.

And...when I came inside, I found that my New Clutch and Throttle cable from Motion Pro arrived.

~Joe

 

[JRK5892]

looks good! Ya the air box sucks huh, and those boots even a small rip will screw up your tune, it is unreal how pickey this 4's are. I found that by soaking them in hot water for 20 min then putting it on helps alot! i am stoked to see how the air box works out, from what i have read i think it will be great! i love that idea, looking good man, i really like those mirrors as well!

*got your fork bag in the mail today. Ill PM you some details

 

[Traveler]

Today, I decided to clean up and get the electric panel the way I wanted it. ALOT more work than you would think....took some time with a die grinder, file and saw, but I got her done. The nuts I am using for spacing are currently threaded down with red locktite to make them permanent. Tomorrow, I'll go ahead, take it apart and paint. Anyhow here are (probably too many) pics of the end result.

The bike is starting to look like a racer....

~Joe

 

[Big R]

Joe I've said it before and ill say it again, you are making some great progress!

Don't wanna get it done too soon or else you'll be tempted to drive it in the snow!

 

[Traveler]

hehe...hope not!

~Joe

 

[JRK5892]

looks good Joe, did your talk to roc city to make sure that bump is where it needs to be, any idea what you are going to do on a battery or where you are going to pop that thing?

 

[Traveler]

Yeah, gonna spluge and go with a A123 cell battery, which is like 1 inch wide, 2 inches tall and 4 inches long. The smallest one is 120 amps, which they recommend for bike 750cc and smaller. It is TERRIBLY expensive, but it is worth it....I don't want a heavy, big old battery cluttering up all the work I've done to minimalize the bike...and the weight difference is HUGE. This battery weights ONE POUND.

Here is a link.

http://www.orientexpress.com/Universal+Parts+%252526+Accessories/Battery/SpeedCell+-+Supersport+2.3+-+120+Amp+Battery%25252FSuper+Lightweight%25252FExtremely+Compact%25252FIncludes+Quick+Disconnect+Terminals+%252526+Harness%25252FSee+Details+Inside.html?osCsid=3febfdc1e1903f2b2a63c304cc093810

It recharges off of the factory charging system. I went out and did some "google-ing", and everyone that has used this setup is happy with it!

Too bad it is so expensive. But, it's what I have to have to keep the bike a "fly-weight".

@ 550cc...power to weight ratio is what will make this work for me....so excess weight MUST go!

P.S. Me and Sean @ Roc City are on the same page here...this will fit!!! ;D

~Joe

 

[JRK5892]

i figured, Sean has his shit together... great guy to work with... i think 160 is not too bad for that battery man, hell i would pay it, that sucker will last at least 3 - 4 years well worth it! sweet find!

 

[hedrives]

Great find on this battery and agree about Sean at Roc City. I'm moving my electrics under my Roc City seat on my 82 dohc 750 project and this will be perfect.

 

[Basement rat]

Hows it comin?

 

[cgancos]

Looking good! I'm really diggin the way your handlebars and all the attachments are looking.

 

[Traveler]

Well, Sean at Roc City Cafe sent me this photo showing further completion on my tank and seat. He has a 550 frame that he is using for mockup.

Looks pretty good so far, I think.

~Joe

 

[Traveler]

Got my electrical all done today. Only have to lengthen two large electical cables and tie them up. That and tie in my micro battery when I get it. All else is done. This took a long time....as I had to put it in how I wanted it to look.

Here are a few pics of the completed product.

(Yes, the rectifier is just tied out of the way. I will mount it after the seat arrives)

The nose all buttoned up, with my new headlight isntalled. Also had to get a new chrome outer ring, as the original was scraped and gouged up.

Looks like I need my tank and seat, huh?

~Joe

 

[Traveler]

The guy who owned this bike before me decided it would be a good idea to mask off the engine and put on a coat of silver. Well...long story short, it really looked bad.

As I mentioned earlier, I cleaned the case area below the carbs, and today, I started on the head and block fins. I sanded them up, and then I filed the fins to make them look more sturdy. It was also a chance to remove the casting marks.

I will continue to work on them, smoothing out some of the fine scratches.

Here are a couple pics of the progress.

~Joe

 

[JRK5892]

tank and seat look insane! you going to pull that motor for paint? or just keep going up in grits to smooth and semi polish what you can?

 

[chrisf]

A few things...Keep the individual pics coming. I think someone said to knock it off, but I think the detail pics are important--especially to first time builders.

Also, that battery is a great find. I think all my projects moving forward will use that battery pack.

The RocCity Cafe parts are the shit. Sean is getting better and better at alloy bits; you really can't go wrong with them.

I would be very surprised if that filter works on that airbox. Visually, it looks way too small. My RD400 2-stroke has a single filter and it's HUGE--like 2" opening and 5" tall. You might need something significantly larger. Of course, you'll find out quickly if you run out of air at a specific RPM. If you did the math and know this will work, please ignore the above statement.

Finally, thanks for serving over there. I know I sure as shit would not want to do it, and I have a lot of respect for those that serve over there. I know it's their job, but I suspect they would rather be home with their family's.

--Chris

 

[JRK5892]

+1 on the pics man... i love posting every little thing that i do on bikes, shows the attention to detail, and i know from you past chop and the dyna that you are picky like me on the little details!

 

[Traveler]

tank and seat look insane! you going to pull that motor for paint? or just keep going up in grits to smooth and semi polish what you can?

Raw and polish what I can on the heads and cylinders....paint case underneath black.

I know it may not sound like a good idea....but I like raw fins.

~Joe

 

[Traveler]

A few things...Keep the individual pics coming. I think someone said to knock it off, but I think the detail pics are important--especially to first time builders.

Also, that battery is a great find. I think all my projects moving forward will use that battery pack.

The RocCity Cafe parts are the shit. Sean is getting better and better at alloy bits; you really can't go wrong with them.

I would be very surprised if that filter works on that airbox. Visually, it looks way too small. My RD400 2-stroke has a single filter and it's HUGE--like 2" opening and 5" tall. You might need something significantly larger. Of course, you'll find out quickly if you run out of air at a specific RPM. If you did the math and know this will work, please ignore the above statement.

Finally, thanks for serving over there. I know I sure as shit would not want to do it, and I have a lot of respect for those that serve over there. I know it's their job, but I suspect they would rather be home with their family's.

--Chris

Thanks, Chris.

On the Airbox. This is a trial and error deal. If it dosen't work, Ill take the bracket off and make a bracket that is just a 1/8 wide surround with mesh, and bolt that on. Kind of like the mesh filters on individual velocity stiacks, but this will still keep the airbox, which these small 4's seems to like.

I'll probably put some hooks around the edge to put on a thin piece of foam that can be readily taken off and washed. The idea here is to keep the "triangle" open...and keep this bike LIGHT! ;D

As for the service....I appreciate your support. On behalf of all those in the service, I say "Thanks".

P.S. I have a serious crush on the brunette on your website with the writing on her hand. Those big brown eyes are doing me in!

~Joe

 

[jay_kent]

Raw and polish what I can on the heads and cylinders....paint case underneath black.

I know it may not sound like a good idea....but I like raw fins.

~Joe

I'm with you on raw fins, only going to let the engine cool more. As for that seat and tail...unbelievably amazing.

Jay