Shake the Box CL360/378 - The Hedgehog - Done

[ridesolo]

Guess I'll see if I can't keep this thing moving and documented this time. I bought this '75 CL360 several years ago and used it for commuting and it's funny how pieces started falling off. First the luggage rack, then the front fender, then the mufflers, etc. I started reading and lurking here, occasionally contributing a useless comment here and there. I didin't really have a good workshop and the pesky thing called making a living interfered with really tearing into it. I finally got the workshop and, still that job thing and other stuff kept holding things up. Through it all I've continued to read, study, think, aquire parts, read more, study more, and finally work has begun.

I'd love to be able to tell you that all that reading, studying and thinking brought about a careful search and buy of just the right pieces and bits that' will all, seamlessly, fit together to make the perfect bike. Ha! My dear, late mother taught me not to tell untruths. Much of what has worked out well so far has been pure dumb luck.. OK, whatever, I'll accept it.

I can't find any of the earliest pix I had, but the members here are pretty familiar with what a '75 CL360 looks like. This is after I had owned it for a few years, many miles of commuting to work, and what will probably end up being my final exhaust configuration.

[

Then I found a CB400F tank and planned to use it.



I really liked that look but unfortunately we discovered that tank had more rot on the bottom side that we first thought and it wsn't going to be suitable. Another search resulted in this tank that isn't as long, but it'll do the trick. We also found this fiberglass seat. It'll loose the brown, padded cover for something else, but it's a good start.



So, with all that general uglyness waiting to be improved, I started working.

 

[ridesolo]

Shake the Box Kit - CL360

I wanted a work table so the bike would be a little easier to work on. I dug out some scrap lumber and came up w/ this:





I wish I could say I am a great planner, but it was by sheer chance I aquired the front and rear ends of a '02 Kawi EX500. Funny how things happen. Usually I spend lots of time reading and figuring things out but this time things worked out on their own. Turns out the EX parts are going to be just about perfect for this project.

 

[ridesolo]

Shake the Box Kit - CL360

Started tearing things down. The front parts are off and now in the hands of a new owner who will, hopefully, give them a new life.

 

[ridesolo]

Shake the Box Kit - CL360

Here I've got the engine out and the EX rear end I bought is about to become an organ donor. The CL doesn't know it's about to get a swing arm transplant.



The donor is ready to go. It's just a little wide, about 1/2" will have to be removed. If it were any more it all wouldn't work; 1/2" is about the max that can be taken off.



Here's the new swinger and wheel sort of propped in place to see how it's all going to fit up.

 

[ridesolo]

Shake the Box Kit - CL360

I met up w/ my new DTT buddy hurco550 and he took the swingarm and shaft away to work his magic. Here are a couple pix he sent me:





And in record time he had it back to me and it's about perfect. Levi, YOU da man!!!!!

 

[ridesolo]

Shake the Box Kit - CL360

A long time ago I got a chance to get the rear sets I plan to use. Strange thing, another case of getting something that is going to turn out to be about perfect. When I got them they came w/ all the necessary parts except the rear brake master. Of course the one that came w/ the EX parts isn't going to work, but I found an appropriate master/caliper/hose set on eBay. They came in today and look pretty good. I should be able to sell the EX master and the R1 caliper and hose as well as the new brake pads that were included and make my $$ back. This is about where they are going to mount up once more bits and pieces are removed from the frame.



And here is how it looks with a bit of a mock-up. I think this is going to work.

 

[ridesolo]

Shake the Box Kit - CL360

More work done today untill the cold drove me back indoors. Really don't like my seat; too big for the bike. Have thought that all along, but hoped maybe it would grow on me... nope. When I aquired it there was a piece of tape on the bottom w/ CB750 written on it... much larger scale bike. The brown vinyl was going to need to be replaced anyway so I thought maybe when it came off it would change my opinion of it. Now searching for a better choice and will find a new home for this one.

Got at the cutting and grinding to remove excess metal. Not real fond of this part of the project, but it needs to be done.



Saved the kickstand mount to re-attach further forward, the rest won't be missed.



A little grinding and clean-up done, a bit more needed...

 

[filipo]

Re: Shake the Box Kit - CL360

Nice thread. I'm in a bit of the same situation -- spent a couple of years now on moto forums, learning, reading, thinking, but not nearly enough doing. Now I'm finally taking the plunge. (As evidenced by me hitting you up for parts!)

Looks like some previous grinder work was done to your frame, especially the airbox triangle area. Was that your work?
Care to elaborate on what's come off?

I ask because the 75 CL360 I bought recently came with a ton of cut-off marks, and I want to figure out what I'm missing!

Thanks, keep up the good thread.

 

[ridesolo]

Re: Shake the Box Kit - CL360

Nice thread. I'm in a bit of the same situation -- spent a couple of years now on moto forums, learning, reading, thinking, but not nearly enough doing. Now I'm finally taking the plunge. (As evidenced by me hitting you up for parts!)

Looks like some previous grinder work was done to your frame, especially the airbox triangle area. Was that your work?
Care to elaborate on what's come off?

I ask because the 75 CL360 I bought recently came with a ton of cut-off marks, and I want to figure out what I'm missing!

Thanks, keep up the good thread.

About everything is coming off but the motor mounts. A bunch of the stuff came off over at my buddy's place and then a combination of issues combined to cause things to grind to a halt again so it sat at his place. I really have to have access to it as part of the thinking process so about NOTHING got done. I got it back over here last fall and a whole bunch of the original plans went by the wayside. I had aquired the EX500 parts and that brought major changes; juice brakes rather than mechanical, finding a much smaller, in scale cafe seat, using the Kawi wheels rather than the original spokes, mono-shock rear suspension... the purists on here probably won't like it, but that's ok.

I'm about to head out to work on it for a while. I've come up w/ a different way to mount the tank that will allow me to mount the new seat so everything will match up nice. There are a few more bits to cut n grind.... hate cutting n grinding! I'll be posting more pix this evening.

 

[mrlvlagic]

Re: Shake the Box Kit - CL360

looking good Im interested to see your project

 

[ridesolo]

Shake the Box Kit - CL360

Thank you for the nice comment. We'll see how it turns out...

Got a bit done today. The side stand mount is going to be welded back on farther forward so that the stand doesn't interfere w/ the rear set shifter.



The upper shock mounts had to go, so....



Gone gone gone...



Also gone is the original tank mount. Instead it'll be rubber mounted and secured though the large hole. The tab on the rear of the tank will be shortened so it won't interfere w/ the end of the seat when it's mounted.



And finally here's a couple of shots of the tank and new seat sitting in place. The size is much more in scale than the other one and should look good. It needs some work, but will be ok. The vinyl that came w. it itsn't in bad shape, but I think I'll use it as a pattern to have a new one made out of real leather just for fun.





Still have to cut off the tool box mounts, leaving the motor mount half in place... figures that a couple of the most simple cuts will be the most PITA... no room to get the tools in there until one of them is gone. So far I've been able to use rotary tools, but I may have to break out the recip saw w/ a hacksaw blade to get the first one off. After that more smoothing and clean-up then it'll be time to get some welding done, then off to the sandblasters.

 

[timberwolffxdl]

Re: Shake the Box Kit - CL360

What are those mufflers in the first pic of the first post?

 

[ridesolo]

Shake the Box Kit - CL360

What are those mufflers in the first pic of the first post?

Those are Emgo Shorties.

 

[Hurco550]

Re: Shake the Box Kit - CL360

Lookin GREAT my friend! I am excited to see this one come together! seat looks MUCH better!

 

[ridesolo]

Re: Shake the Box Kit - CL360

Well I know it's bee a long time, but work, hand surgery and life in general contributed to keeping things at a slow pace. Hand is working better and I've retired, so it's time to get back at this.

Last summer I got a few things done.

This pix shows the new shock mounts and the lugs for the rear set mounted.



This one shows the shock, w/o the spring, mounted in place.



Here is the left rear set (shifter side) mounted:



And here is the rear brake side:



My decent capacity heater went up in smoke back in November and the replacement isn't really up to the task, so I'm having to wait until warmer weather to get much done but at least things are back underway on the project.

Next up some sand and prime, sand and prime, sandblast a few small parts, then sand and prime some more. Hmm, maybe I'll have a roller in six years? ????

 

[Hurco550]

Re: Shake the Box Kit - CL360

Still lookin sweet! Sand and prime is always the worst IMHO.. Keep up the good work! (rear sets look great)

 

[ridesolo]

Re: Shake the Box Kit - CL360

Time in the shop at last! Finally got back at the bike and started to tear down the forks for a rebuild. Of course, with all the tools I have you'd think there'd be an 8mm T-handle there somewhere, right? Of course not; back to the hardware again. Anyway, a couple of pix:



On another issue, I'm going to be using a digital speedo so I won't be using the drive on the front wheel . What's the standard practice with these? Leave it in place? Replace it w/ a spacer?



At this point I'm still not 100% on this tank and I threw this seat pan on to just see what it would look like.



At least maybe I can start making some real progress.

 

[Hurco550]

Re: Shake the Box Kit - CL360

That fender looks far better than I pictured dude! Looking very nice my friend! I hear ya on trips to the hardware store to. Always that one tool!

 

[ridesolo]

Re: Shake the Box Kit - CL360

That fender looks far better than I pictured dude! Looking very nice my friend! I hear ya on trips to the hardware store to. Always that one tool!

Thank you sir!. I think it'll work out fine. The Mrs. really likes that color and thinks the whole bike would look good in it. I like it too, but had to explain to her that, while the whole bike is completely non-traditional, I would really have trouble putting a Honda into a Kawasaki color. I don't think she agreed w/ me but oh well.

 

[ridesolo]

Re: Shake the Box Kit - CL360

New fork seals are on the way. Disassembled the first fork stanchion today. Even with the right tool in hand it took a lot of leverage with a very long handle to get the one axle pinch bolt to pop loose. Once that was out of the way everything went fairly well for 13 year old parts that probably have never been apart. The fork oil even looked relatively good, but, though they weren't leaking, the seals are due for replacement.