'81 Honda CX500 in the works

Re: '81 Honda CX500 in the works - 5/3/09

I get irritated at myself sometimes for saying that I'm going to do something a certain way (and spending the $$$ and time), then eventually decide on something totally different. But I guess that's just how these projects are...you just keep trying things until it works.

Here's just a snapshot of where the project stands as of this past weekend.

SEAT: I thought of mocking up a totally new electrics tray and seat pan combo (as seen on previous posts), but I decided to use the original seat pan instead because it's strong and has all the mounting points (plus that upswept look isn't all that bad. It will still be trimmed down and shaped/fiberglassed to something more desirable). I'm also a stickler for recycling things as much as possible.

HANDLEBARS: You can't really see it, but I decided to use a drag bar that I had laying around instead of the clip-ons I purchased. I just couldn't get clearance and the right look (it seemed too messy); whereas the drag bar looks much cleaner and it clears the tank (just barely) after I got the controls where I needed them.
<img src="http://farm4.static.flickr.com/3586/3501876610_a2295a578d.jpg">

Also, my cousin donated a pair of CRG Bar End mirrors.
<img src="http://farm4.static.flickr.com/3374/3501109695_f929379ce9.jpg">

TACHOMETER: Thought about modifying the stock tachometer and embedding the indicator lights in the face. Instead, I'm recycling the much smaller tach from my '71 CB350 and polished it up (but only up to 400 grit so far). The great thing is, it already has the indicator lights for Neutral and Turn Signal (which I'll be using for Oil Pressure instead). Now all I need is to modify the stock mount to accomodate this tach.
<img src="http://farm4.static.flickr.com/3414/3501932620_776ae8a61f.jpg">
 
Just checking what it looks like with bar-end mirrors and turn signals. Want to paint them black though.
<img src="http://farm4.static.flickr.com/3386/3506674444_180fe7e39c.jpg">
 
Hey where'd you pick up thise signals from? I've seen'm before but only found cheap junk when i looked.....
 
are you gonna have room for your grips? I thought about doing the same on my CX but found that I just didnt have the extra room on my clipons for bar mounted mirrors. I'm prob gonna end up mounting mine on the forks.
 
Swagger said:
Hey where'd you pick up thise signals from? I've seen'm before but only found cheap junk when i looked.....
Click to expand...

They're made by Emgo...decent enough, but not exactly "heavy duty" by any means. But I also wouldn't consider them "junk" either.
http://www.caferace.com/Merchant2/merchant.mvc?Screen=PROD&Store_Code=C&Product_Code=60-14550-1
 
CaTacl1sm said:
are you gonna have room for your grips? I thought about doing the same on my CX but found that I just didnt have the extra room on my clipons for bar mounted mirrors. I'm prob gonna end up mounting mine on the forks.
Click to expand...

Even without the mirrors, i'm gonna have trouble with the grips. You've noticed from your own CX that mounting almost any non-stock handlebar makes it extremely difficult to clear the tank at full turn. So, I've had to move my controls outward so they don't hit the tank, but leaving way less room for the grips. I'll figure something out, but if you have any ideas please knowledge share.

But to answer your question, the turn signals will be let out juuuuust slightly and then the mirrors mounted to that. Fortunately the turn signals lock in really tight inside the handlebar. I have yet to really try this, but hopefully it all works out.
 
Re: '81 Honda CX500 in the works - custom baffles

Since I'm running straight pipe or Emgo shorty mufflers, I'm anticipating losing necessary back pressure (i'm not so concerned about having a very loud bike). so i went with this idea, a tunable baffle: http://www.nightrider.com/biketech/exhaust.htm

here are the results:
perpendicular to pipe = more back pressure
<img src="http://farm4.static.flickr.com/3369/3509756306_32a61f41c7.jpg">

parallel to pipe = less back pressure
<img src="http://farm4.static.flickr.com/3380/3508946015_d39051a4cb.jpg">

I'm planning to just have it at a 45 degree angle to the pipe. Granted I won't know until I start riding if this has any effect.
 
In response to your tank problem, I have a suggestion from the 800 help page. There is a thread on polishing aluminum where home made "sanding mops" were discussed. I made my own, and for fun, I made miniature versions for my Dremmel tool. It works very well in tight spots. You might give that a try?
 
Re: '81 Honda CX500 in the works - custom baffles

GoBears0305 said:
Since I'm running straight pipe or Emgo shorty mufflers, I'm anticipating losing necessary back pressure (i'm not so concerned about having a very loud bike). so i went with this idea, a tunable baffle: http://www.nightrider.com/biketech/exhaust.htm

here are the results:
perpendicular to pipe = more back pressure
<img src="http://farm4.static.flickr.com/3369/3509756306_32a61f41c7.jpg">

parallel to pipe = less back pressure
<img src="http://farm4.static.flickr.com/3380/3508946015_d39051a4cb.jpg">

I'm planning to just have it at a 45 degree angle to the pipe. Granted I won't know until I start riding if this has any effect.
Click to expand...

that is what i have in my harley... you are going to want to drill a hole in the thumb screw though bud... without it the exhaust will not flow right
 
Re: '81 Honda CX500 in the works - custom baffles

JRK5892 said:
that is what i have in my harley... you are going to want to drill a hole in the thumb screw though bud... without it the exhaust will not flow right
Click to expand...

Sounds like a plan...I'm guessing 1/4" hole? Was there a noticeable difference when you changed the angle of the thumb screws on your harley?
 
biker_reject said:
In response to your tank problem, I have a suggestion from the 800 help page. There is a thread on polishing aluminum where home made "sanding mops" were discussed. I made my own, and for fun, I made miniature versions for my Dremmel tool. It works very well in tight spots. You might give that a try?
Click to expand...

I did see your post about making a miniature dremmel version of the sanding mop. So, i have since tried it myself, and yes it does work very very well.
 
not at all... there was a HUGE diff the deeper in the pipe i put it though... i ended up tuning my bike with it flat, and 7.5 in inside the pipe... runs like a rape ape now!
 
I really hate not having a garage, shed, or anything that allows me to work at night. So I took advantage of the 1 1/2 hours of daylight I had left after work and trimmed the old seat pan. Hoping to shape the cowl this weekend.
<img src="http://farm3.static.flickr.com/2115/3532878868_5f0580f3ce.jpg">

<img src="http://farm4.static.flickr.com/3403/3532064361_cb7d2b2fc0.jpg">
 
A few things done today:
Shaved down my old seat foam from this:
<img src="http://farm4.static.flickr.com/3384/3537138663_f30a575644.jpg">

To this (as well as chopping off some of the back-end:
<img src="http://farm3.static.flickr.com/2264/3537951504_d7203411d6.jpg">

Finally decided on the clip-ons (as opposed to the drag bar). Chopped a bit off the headlight ears and mounted the headlight.
<img src="http://farm3.static.flickr.com/2178/3537171213_8f5849618e.jpg">
 
I really dig the use of to stock seat pan in this case. One problem with the CX is that dip in the frame and trying to work a typical cafe seat into the mix. I love the idea of embracing the idiosyncrasies of the bike rather than trying to force something to work.
I think you're going to be way ahead of the game amigo.
Can't wait to see how this turns out!
 
Swagger said:
I really dig the use of to stock seat pan in this case. One problem with the CX is that dip in the frame and trying to work a typical cafe seat into the mix. I love the idea of embracing the idiosyncrasies of the bike rather than trying to force something to work.
I think you're going to be way ahead of the game amigo.
Can't wait to see how this turns out!
Click to expand...

Thanks...much appreciated. My limited tools and resources force me to be creative with what I have. And plus, the seat pan is already so damn strong (even after the chop) and the foam is very comfortable; it would be a shame to let it go to waste.

The next step is to fabricate a seat cowl out of fiberglass that will finish off that back end.
 
Mighty I recommend a cut down gas tank? Since all you're using it for is essentially 'trim' to shore up the appearance of the tail end of the bike, you could grab just about any tank you like the shape of and start trimming. Just a thought as I sit looking at the CX sitting here waiting for it's turn. FYI: I intend to rip off your seat idea!
 
Re: '81 Honda CX500 in the works - Command Central

Finally got around to center-mounting the tachometer (an oldy from a '71 CB350...i like that blue face).

Here's the first attempt at the mount. The holes were rough and not in the right spot, so i tried again after getting the right size bits from my tool lending library (yes, i have a library around the corner that lends tools for free). I'd show you the final piece, but I'm too lazy to take it off the bike.
<img src="http://farm3.static.flickr.com/2076/3547441670_a4e47caf65.jpg">

Second time around, holes were right where they should be and the tachometer was perfectly centered. And this sucker isn't going anywhere. The ignition was just moved to a mounting point that previously secured the old tach/speedo mounting plate. Looks pretty nice if i do say so myself (sans the hacked fuse holder...a sacrificial lamb since i have another one in perfect condition that will be installed later.
<img src="http://farm3.static.flickr.com/2019/3547439802_0be275afb4.jpg">
<img src="http://farm4.static.flickr.com/3343/3547440450_9d8d4d8087.jpg">
 
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