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Hello all at DTT -
New here, but been lurking around a while. Also known to frequent other honda related hangouts.
Wanted to post a build thread here... Promised i would, so here you go.
I have rebuilt and worked on motorcycles as a hobby for a while. For this one I got really ambitious and wanted to build something from scratch. Here's my start:
Motor, frame, wheels etc. all came separately. Spent a couple months researching and procuring, and ultimately wound up with a garage full of parts, two motors, and lots of cardboard boxes with parts from all over. Some of the neater (and more expensive) parts are: Tank from Roc City, Seat and Swing arm from Steve Carpy, and a "power-up" kit from cycle x. Those three orders alone took close to half the budget. I also scored a really cool vintage Akront racing rim from a friend and found a bunch of vintage aftermarket stuff on old bikes at a salvage yard.
Here are some shots of tearing down the two motors:
And here are some of the frame mods I did. I really love my angle grinder. ;D
That little guy shows my modified steering stops. I drilled and tapped the triple tree and added some cap screws. Keeps the clubmans from touching my tank.
This has been a work in progress over several months. I'm not the fastest builder out there, but I have been pretty happy with the process. In the engine I put in .75 overbore cylinders, new rod bearings, new cam chain & rollers. I painted and polished everything myself, and did all my own top end work.
While I was rebuilding the motor, I had about 30 pieces powder coated black. Then I put the motor in and started working on suspension, chain and brakes. From the start, I wanted to do a dual disc mod, and I finally got that squared away:
Here is the most recent mock up with the motor in the frame:
Since then, I have done almost all the wiring, got my cables sorted (for the moment) and added oil and brake fluids. I also rebuilt my carbs and did a little fiberglass work on the cheap side covers I had:
I 2nd that, awesome job on the engine. I like the colour scheme. A suggestion: you may want to rotate your clubmans until the angle of your grips evenly distributes pressure on your hands when you're sitting on the bike. From the pics, it appears they're kicked up at the ends which I find quite uncomfortable. Also, you might get back some of your tank clearance by doing this. Looks like you have the makings of a nice machine and kudos for supporting Carpy. He's definitely one of my favourite builders.
I have a question about how you split the crank case apart. I'm having a whale of a time getting them to separate The Clymer is saying to pull the rotor and the clutch plate etc but I noticed that your ride has all of those still in tact. Did you just have to beat it mercilessly like a red headed step child (sorry if you are one)?
Thanks for all the positive comments. I spent the weekend out at my grandfather's house painting. It was my first time using a spray gun, and I have to say that I am really happy with the results. A couple pieces had a run or two, but overall I think it turned out pretty awesome.
I used a urethane base coat/clear coat and a spray on automotive primer. Here is the base coat:
And here it is with the clear:
The dog licking his balls in the background is named Pete. ;D
jlgace - thanks for the tip on the clubmans. I'm still tinkering with the angles. So far, I like them back like that because it allows me to be a little more upright on the bike and its closer to where they would be if I was using clip-ons. Kinda wish I had used clip-ons...
sxecafe - You're right, I did leave my clutch basket and alternator rotor on. Last time I split a case I did remove both per the manual and remembered it to be an unnecessary hassle. Unless you need to change the bearings, I don't think these need to come off. Disclaimer: I'm not an expert, this is just how I did it...
As far as actually cracking the cases, I just used a rubber mallet. As tempting as it may be, never stick a screw driver in between them and try to pry them open. That will cause oil leaks for sure.
Yeah, sorry 'bout the italics. Didn't even look at my own post. :
I'm afraid to say it out loud on this site, but I've had to move away from clubmans for the same reason you stated. LOVE the look, but got tired of feeling like I was doing a pushup while riding in the city and needing to ice my lower back after a lengthy ride. I'm not 20 anymore tho...
Had the day off yesterday and finally rounded up the last of the electrical components I was missing. Thought I would give it some gasoline and see what happened...
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