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Excellent build and pics. Glad you brought it back up, it gave me a couple ideas. I like the way you did the back end and tail light mount.

Re: CB 550 Winter Cafe Project-Need a name It's longer than the original but it has clip on bars. I'll measure it and compare it to the stock cb550 front end tonight. From my first look at it I thought I may have to have less than an inch of the forks sticking up above the clip ons. I can...

Start here for information on fork compatibility: http://www.clubchopper.com/forums/metric-chopper-talk/77043-jap-bikes-fork-tube-sizes-neck-bearings-axle-diameters.html That bike looks in great shape, might be a good restoration candidate rather than chopping it up.

Re: CB 550 Winter Cafe Project-Need a name Last week I also picked up a pair of Koni shocks and ordered a big bore kit from Dynoman. Next I'll be doing engine work. Shocks need a little TLC and probably will be rebuilt. I'll have to disassemble them and see if they need anything. Right now...

Re: CB 550 Winter Cafe Project-Need a name Front wheel and axle fit right in. I have 2 original brake rotors. The speedo gearcase housing will need a little modification and the hub will need longer bolts, may just cut some rod and thread the very end to match the way the stock bolts are...

Re: CB 550 Winter Cafe Project-Tank Work The forks that were on the bike were badly rusted and pitted in the travel area of the forks. I picked up a front end from a vf-500f interceptor. It looks like the triple tree will fit, just have to swap the cone from the original. If that doesn't...

Re: CB 550 Winter Cafe Project-Tank Work Another pic of tank and seat

Re: CB 550 Winter Cafe Project-Tank Work The tank is almost done, had to smooth out a few lumpy spots that showed up after priming. Got the seat in, now it time to cut up the back and fit the seat. I may end up making more of a squared off back end rather than hooping it since the underside...

I feel your pain on the forks. When I got the boots and tabs off of mine they looked about the same and one of the legs was pitted and tearing up the seal. Anyway, I was looking for 550 or 750 forks to replace them and almost all of the 550s look like yours...useless. I ended up snagging an...

Here are a couple links to simplified wiring diagrams that I found. I haven't got that far on my project yet but I'm starting to think about it. http://cycles.evanfell.com/2010/03/simple-motorcycle-wiring-diagram-for-choppers-and-cafe-racers/...

Re: CB 550 Winter Cafe Project-Tank Work I was thinking this was going to be a 'practice tank', but with as much work as it is and it's turning out decent, I may just use this one on the bike. Does anyone pressure test their tanks after hammering them to see if any real damage was done?

Re: CB 550 Winter Cafe Project-Tank Work Here's the tank after some body putty work. I think it is about ready for a finish layer or two of finishing glaze. I also found out it is a hell of a lot easier to sand short strand glass filler if you don't let it harden over night.

Thanks for the plug. Good luck with your build, it looks good.

Re: CB550 alloy sprint Thanks for the tip ffjmoore

Funny, sad part is I read it twice to see if he mentioned what he 'filled' it with. Reading is FUNdamental. Thanks

I have a stator cover that looks as bad as yours did. What did you fill the gouges with? Thanks.

Re: CB550 alloy sprint Awesome build. Is it necessary to seal the pucks? Just wondering since I will be putting mine back together in a few weeks.

Re: CB 550 Winter Cafe Project-Tank Work Cap off, cleaned up and ready to prime.

Re: CB 550 Winter Cafe Project-Tank Work Tank from the top, I like the curves

Re: CB 550 Winter Cafe Project-Tank Work Here's my practice tank that I have been working on. I have another tank that started in better shape that I will probably modify and put on the bike. This pic the hammering is done.