Project CB690 (KTM 690 engine in a CB550f frame)

Side note, I replaced my 20 year old Felo screwdrivers with a new Wera set. I absolutely love them, highly recommend.
 

Attachments

  • IMG_0758.jpg
    IMG_0758.jpg
    136.1 KB · Views: 171
  • IMG_0771.jpg
    IMG_0771.jpg
    68.6 KB · Views: 118
Clutch, alternator, waterpump, and valve covers removed, internals stripped, cleaned, and ready to be vapour blasted. I wrapped the engine up in cling film for protection.
 

Attachments

  • IMG_0778.jpg
    IMG_0778.jpg
    236.3 KB · Views: 113
  • IMG_0779.jpg
    IMG_0779.jpg
    216.1 KB · Views: 95
  • IMG_0780.jpg
    IMG_0780.jpg
    216.4 KB · Views: 93
  • IMG_0781.jpg
    IMG_0781.jpg
    228.2 KB · Views: 97
I revised the side stand switch mounting. I'll epoxy the magnet on the end of the stalk shown in the pictures, and make a final bracket to hold the sensor. This will look a lot better.
 

Attachments

  • IMG_0783.jpg
    IMG_0783.jpg
    173.7 KB · Views: 102
  • IMG_0784.jpg
    IMG_0784.jpg
    124.4 KB · Views: 102
The frame has been dropped off for blasting/powder coat! A big day indeed.

Frame and sidestand - Grit blasted, primed, powder coated (gun-metal grey)
Swingarm - vapour blasted, clear coated (Cerakote H)
Alternator, clutch, water pump, and cam covers - vapour blasted, clear coated (Cerakote H)

Lead time 3 weeks, £250 total. Well pleased with that. The guy essentially specialises in motorbikes so he really gets it, knows what to look out for and what to mask off, etc.
 

Attachments

  • IMG_0795.jpg
    IMG_0795.jpg
    3.4 MB · Views: 107
To improve the look of the speedo cluster I added milliput to the lower half. Pics below show the milliput after application. After drying I will sand it to refine the shape, and paint it matte black.
I did some sanding already but didn't take pictures, it was a messy and fussy process. Updates to follow.
 

Attachments

  • IMG_0797.jpg
    IMG_0797.jpg
    1.5 MB · Views: 106
  • IMG_0798.jpg
    IMG_0798.jpg
    1.1 MB · Views: 103
  • IMG_0799.jpg
    IMG_0799.jpg
    1.2 MB · Views: 107
  • IMG_0800.jpg
    IMG_0800.jpg
    854.2 KB · Views: 107
Small update, as I wait for the frame and wheels I started refinishing the parts that are immediately needed to make a rolling chassis. Mostly just beadblasting, wire brushing, and then clear coating or painting. This weekend I should plan on scraping engine gaskets and preparing for the newly refinished covers.
I'm really holding my breath on the frame colour choice, I hope that the gunmetal grey powder coat I chose will be dark enough for my liking. I almost called the guy and told him just to do black, but I'm holding fast. I hope it looks good.
 

Attachments

  • IMG_0999.jpg
    IMG_0999.jpg
    2.1 MB · Views: 95
Ok the frame has been powder coated. The colour is in fact a little lighter than I was hoping for, but still very nice. I had the swingarm and engine covers vapour blasted and clear coated, which in hindsight maybe worked better when I was envisioning a black frame. Now I have two different colour greys, and black wheels. Maybe I should get the rims vapour blasted too, we'll see.
I dropped off the wheels at the local Kawasaki shop, and they've had some trouble getting the Dunlop TT100GP tyres that I want. This is currently the hold up.
 

Attachments

  • IMG_1007.jpg
    IMG_1007.jpg
    1.4 MB · Views: 90
  • IMG_1006.jpg
    IMG_1006.jpg
    2 MB · Views: 93
Painted the bits. Gunmetal grey spray paint was a surprisingly good match to the powder coat frame. The other bits were just scotchbrighted and clear coated.
 

Attachments

  • IMG_1021.jpg
    IMG_1021.jpg
    3 MB · Views: 102
  • IMG_1022.jpg
    IMG_1022.jpg
    3 MB · Views: 96
Got the covers on the engine over the weekend. I'm warming to the look. I do wish I could have painted the engine, on the other hand I absolutely did not want to paint the engine, what a ball ache that would have been! I think this is a good halfway. Note the clutch cover. I removed the cover centre bit and now I can't get it back in. It must have been put in with a press and a very good fitting tool. I tried my best but I just cant get the piece in with the gasket, so it's all squirting out now. I've decided to get an aftermarket clear clutch cover kit. They bolt in place to make the seal instead of being pressed in, so it should be ok. I may replace the glass pane with aluminium because I think the clear cover is kind of cheesy. We'll see. Likely no more work on this until July.
 

Attachments

  • IMG_1082.jpg
    IMG_1082.jpg
    1,016 KB · Views: 90
  • IMG_1083.jpg
    IMG_1083.jpg
    1.6 MB · Views: 79
  • IMG_1084.jpg
    IMG_1084.jpg
    1.6 MB · Views: 82
Ok the clutch cover. I definitely don't like the black, or the logo, so I beadblasted it. Then I didn't like the star pattern, so I sanded it flat. I still don't like the transparent window, so I will replace that with 4mm thick aluminium. I COULD just trace, cut, and file the aluminium to fit the cover, and that would be fine, but I have a lathe coming next week, so I may as well have a go with it. I will probably need to make an arbor and super glue the aluminium plate to it, we'll see. Likely the next update will be the lathe install.
 

Attachments

  • IMG_1193.jpg
    IMG_1193.jpg
    1.4 MB · Views: 79
  • IMG_1192.jpg
    IMG_1192.jpg
    1.8 MB · Views: 75
  • IMG_1191.jpg
    IMG_1191.jpg
    1.2 MB · Views: 64
  • IMG_1190.jpg
    IMG_1190.jpg
    1.2 MB · Views: 63
Stopped work on the bike for a week or two while I installed a lathe.
 

Attachments

  • IMG_1200.jpg
    IMG_1200.jpg
    2.1 MB · Views: 68
Small update.
I had decided on Dunlop TT100GP tyres, and was able to get the rear tyre pretty easily, but was never able to get the front. After about a month I finally gave up and got a set of Pirelli Scorpion Trail. Now the wheels are with the shop to get fitted with the Pirelli's, and I've got the rear Dunlop on Ebay at a small loss. We'll see if I sell it.
Also, I decided against the frame colour. Just couldn't do it. Too many greys. I brought the frame, sidestand, and swingarm back to the powdercoater, he will redo them all in just a regular gloss black.
Some fair setbacks for the schedule, maybe I'll get the bike done in the fall now.
 
First project on the lathe, the clutch cover. Traced and cut out the 4mm aluminium sheet, made a faceplate for the chuck, dab of superglue, then used a live centre to hold it to the faceplate. I then used digital calipers and the DRO to sneak up on the OD.
 

Attachments

  • IMG_1495.jpg
    IMG_1495.jpg
    1.3 MB · Views: 46
  • IMG_1494.jpg
    IMG_1494.jpg
    1 MB · Views: 44
  • IMG_1493.jpg
    IMG_1493.jpg
    1.3 MB · Views: 41
  • IMG_1492.jpg
    IMG_1492.jpg
    1.2 MB · Views: 45
  • IMG_1491.jpg
    IMG_1491.jpg
    1.4 MB · Views: 44
  • IMG_1490.jpg
    IMG_1490.jpg
    2.3 MB · Views: 43
  • IMG_1489.jpg
    IMG_1489.jpg
    2 MB · Views: 46
  • IMG_1488.jpg
    IMG_1488.jpg
    2.3 MB · Views: 48
  • IMG_1487.jpg
    IMG_1487.jpg
    1.8 MB · Views: 50
Then I beadblasted the two parts and gave it a scotch-brite finish, then clear coated them. I was worried about how it would look, but to be honest I like it better than the original!
 

Attachments

  • IMG_1500.jpg
    IMG_1500.jpg
    1.4 MB · Views: 47
  • IMG_1499.jpg
    IMG_1499.jpg
    1.4 MB · Views: 50
  • IMG_1498.jpg
    IMG_1498.jpg
    1.7 MB · Views: 46
  • IMG_1497.jpg
    IMG_1497.jpg
    1.7 MB · Views: 51
  • IMG_1496.jpg
    IMG_1496.jpg
    1.3 MB · Views: 48
Changed my mind on the powdercoat. Both the frame and swingarm I got repainted black. I think they may have just gone over the gunmetal grey instead of beadblasting it, but the finish looks ok. Much happier with black, there were too many different kinds of grey on the bike, so had to go back to basics.
 

Attachments

  • IMG_1690.jpg
    IMG_1690.jpg
    2.5 MB · Views: 23
  • IMG_1691.jpg
    IMG_1691.jpg
    1.5 MB · Views: 21
Swingarm all built up. Parts all cleaned and clear coated where needed. Engine ready to go. New tyres mounted and wheels all cleaned up. I had to scotch brite all the spoke nipples, that was a pain.
 

Attachments

  • IMG_1735.jpg
    IMG_1735.jpg
    2.2 MB · Views: 22
  • IMG_1732.jpg
    IMG_1732.jpg
    2.1 MB · Views: 21
  • IMG_1731.jpg
    IMG_1731.jpg
    2.5 MB · Views: 19
  • IMG_1730.jpg
    IMG_1730.jpg
    2 MB · Views: 24
I decided actually that I DO want the centerstand. As I left it I needed to make a stop, and move the spring pivot. So I made a new spring anchor in the lathe and fabricated a bracket for it, and made an adjustable stop and tacked that to the stand.
 

Attachments

  • IMG_1776.jpg
    IMG_1776.jpg
    665.1 KB · Views: 24
  • IMG_1775.jpg
    IMG_1775.jpg
    603.4 KB · Views: 23
  • IMG_1774.jpg
    IMG_1774.jpg
    935.3 KB · Views: 22
  • IMG_1773.jpg
    IMG_1773.jpg
    1.6 MB · Views: 24
  • IMG_1772.jpg
    IMG_1772.jpg
    1.3 MB · Views: 27
  • IMG_1771.jpg
    IMG_1771.jpg
    1.2 MB · Views: 27
After tacking I fabbed a spring extension, and used a CD175 spring that I had around. It all worked very well. Next I will finish weld it all and repaint the frame where I needed to remove some powdercoat. You'll never see it. The stand will get spray painted black. Again it won't match the powdercoat, but it's close enough and no one will ever notice.
 

Attachments

  • IMG_1778.jpg
    IMG_1778.jpg
    1.7 MB · Views: 30
  • IMG_1779.jpg
    IMG_1779.jpg
    888.8 KB · Views: 30
  • IMG_1780.jpg
    IMG_1780.jpg
    1.5 MB · Views: 28
  • IMG_1781.jpg
    IMG_1781.jpg
    1.2 MB · Views: 26
Last edited:
Back
Top Bottom