Long awaited CB200 Build

bex

Been Around the Block
Some odds and sods going on...

Tapered bearings in, will have to remove for powdering the frame, but I needed a measurement for the new stem:


Forks rechromed:


Speedo at the ready:


And a new yoke/clamps design I've been working on with Fastec, who also did the 3D (and have had oodles of patience with my fussiness):


And Hagons arrived!
 

bex

Been Around the Block
Since had wheels refurb'd and fresh rims.




And today my yoke designs arrived. Delighted with these, beautifully made by Fastec.
Old and new:




 

bex

Been Around the Block
Started putting some parts back together today after collecting some vapour blasting yesterday. Good to see a bike again rather just boxes of bits! Now starting to think what paint schemes might work.

Rear drum


Rear wheel and swinger


Yokes fitted and front wheel and forks rebuilt




 

BazookaFiero

"Now I am become Death, the destroyer of worlds"
Looking great! I'm in the process of rebuilding a CB200 as well, but I'm not being nearly as ambitious as you are! I bet she will be a sight to see when done

Love the triple tree, that's gonna give it a real clean look up top
 

Erskine

Over 1,000 Posts
Triple tree hotness! I'm in. Cool fabrication skills.
I'm afraid I may have to agree with xb33 about yr compression issues out back, however with your capability it will be a breeze to sort.
 

bex

Been Around the Block
Have checked the back and the clearance is ok, shocks have a stroke travel of 3.2" and I'm beyond that so I think it's ok, or at least I hope... :)
 

Erskine

Over 1,000 Posts
bex said:
Have checked the back and the clearance is ok, shocks have a stroke travel of 3.2" and I'm beyond that so I think it's ok, or at least I hope... :)
Cool, must have been an optical illusion from the camera angle.
Are you in the uk?
 

bex

Been Around the Block
Figuring out headlight and some mounts using bicycle seat post clamps. Saw someone (on here?) somewhere do this before and thought it was clever. There isn't much around at 31mm. Will come up with a nicer bracket now that I know it will work.

Working on a hydraulic brake conversion at the min, will post pics soon.





 

bex

Been Around the Block
Started pulling together parts for hydraulic brake conversion. Waiting for a caliper to show up.

In the mean time got some bargain used parts off eBay, brake master cylinder and cable clutch. Smaller reservoir on the way as this one looks a bit big for the little CB.

 

bex

Been Around the Block
Been mocking up a bracket in card and then wood to take the Brembo caliper I've picked up for the front brake conversion.

It's not quite right yet in terms of shape and probably needs a bit more meat on the skinny bit up top, but here's the progress so far. It'd also be good to get some holes or slots in there to lighten it up visually, but I suppose I need to tread carefully or I will risk weakening it.

Some alignment issues to be sorted out with the wheel spokes and mounting points too.







 

bex

Been Around the Block
Round 2, and 3...

Going to get one laser cut in the correct thickness metal as it's difficult to fully appreciate alignment / any clashes otherwise and for now I'm happy with the fixing points, bottom mount obviously needing a good spacer. Also a friend suggested drilling out and retapping the mounts to take bigger bolts, which sounds like a good idea, providing there will be enough metal left around the holes.





And with a slightly fatter top curve, perhaps still too thin. May resort taking a straight line from top mount to upper Brembo mount in the end. Will see how the metal version turns out first.

 

xb33bsa

Over 1,000 Posts
looks good but the bottom bolt is only an m6 for a fender and having the spacer means it is depending upon the torqued up fastener to keep the assembly mimicking the diameter of the spacer as to shear loads
you want to make sure where the spacer plants is a true square surface and relieve the ends of the spacer so they plant down as if they were made of medium walled tubing however i think m6 is kinda small to get the desired effect m8 would be much better
i think it would be better to have the plate attach more outbored on the brembo like right under the bolt heads
this would shorten both spacers considerably
 

xb33bsa

Over 1,000 Posts
and i dont like strengthwise the way you have scalloped out at the top below the bolt
we would rather see that as a full section ,it ie under twist/shearloads and being aluninum flexing must be kept to an minimum
you could atrfully do like 2 speed holes up there but not big ones like a 1/2 and a 5/8 no more no bigger
but you want to leave at least a holes worth of margin either side of any speed holes in this app so go by that
 

bex

Been Around the Block
Thanks for the comments - I did mention above about the scalloped area perhaps being risky, so I haven't quite decided what to do about that yet. I'll probably straighten it off in the end as you say. Similarly about drilling out the both mounts to take bigger bolts if possible.

I looked at putting the plate on the outside of the brembo but this would mean machining off a substantial chunk off the fork casing at the upper mount, more than is available to me I think, as this mount is much longer - no spacer currently needed at the top. And without machining it would push the caliper much closer to the wheel which is a no-go, it's already a little too close and is clashing win some of the spokes, so I need to be pulling it the other way a few millimetres.

Lots of fiddly things to figure out with this one! :)
 

bex

Been Around the Block
Getting the brake bracket cut in ally to have a real thickness mock up. In the meantime I was mocking up a headlight bracket today. Could have been the final piece but the ally I had kicking around is only 1mm, and it's a bit weak and bendy of course, so I will remake in 2mm soon.

 

xb33bsa

Over 1,000 Posts
thats bitchen man
if you dont mind ne saying the hole is too big relagating any strength to the cross sections of material left
if i was doing it i would look at 2 other options for holes
3 holes 2 of them stacked vertically closest to the stanchion
then a 3rd larger hole closer to the light bucket
or just a large cutout leaving a very generous margin all arouind but following the outside shape
 

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