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Also replaced my 20 year old Craftsman 1/4 inch set with a new Wera set, highly recommend.

Also finished the instrument pod. I finished sanding and prepping the epoxy filler and gave it some paint, also don't love it, but man I have to finish this bike. It looks fine.

Chainguard is complete. It is a cut-up KTM part, with the original mount removed and replaced with aluminium, and a relief area for the shock. Also I extended it a bit in the front to get better chain coverage right next to the sprocket. I don't love it, but it disappears in the bike and looks fine.

I had thought of that! Maybe the CB550f orange colour? Or maybe KTM orange but in the two-colour CB350 scheme?

Hey I'm really struggling to pick out a paint scheme, what do you think? You think it needs something bright to balance out the black frame and wheels and stuff? I was thinking one solid colour, but can't really choose one.

Harness is all done now, and better than it was before. Very few things to do now. Chainguard, headlight shell tidy up, fluids and a test run. Then, of course, the paint. That comes last.

I took the opportunity to replace a bunch of connectors with automotive style sealed connectors. Specifically Sumitomo HM090 and MT090. I love them.

Why doesn't the neutral light work? Let's spend 2 hours hunting it down. I checked the function of the gear position switch. I poured over the wiring diagrams. I checked the continuity from the connector to the EFI computer and the instrument display. I checked that I hadn't incorrectly...

Cheers! I did make the fender stays. I rolled 6mm steel and brazed some bosses on. More on Page 14.

Hi Doc, thank you, good tip! That's something I'd be very interested in investing in.

Fender stays, I'm going to try and nickel plate them at work, too.

Finished refinishing the exhaust. I had hit it with a scotch bright wheel, but that left marks all over it. In the end I bead-blasted it then rubbed it with scotch-bright pads. It now has a kind of silver matte finish, as if spray painted. I don't really like it, but it's better than it was...

Here is the cover, with sharpie marking the angle of the new ports. The cover is poke-yoke indexed to the body of the pump, but I wanted to rotate it for best fuel line routing, so had to cut the flange on the cover to re-index. All JB welded and waiting for cure time now. I had also originally...

The fuel pump has really inconvenient inlet and vent barb sizes, I think it's 11mm inlet and 9mm vent. I previously had used two different size fuel lines joined with a reducing barb, but did not like that at all. I decided to make new inlet and vent barbs and epoxy them into place. JB weld is...

The vent cap has been nickel plated and installed. Despite indexing the threads, when it was fully tightened I wasn't happy with the outlet position so I quickly made a 2mm thick Aluminium washer to adjust the rotation. Very, very happy with how it came out.

Cheers! It's been a 7 year labour of love, and I'm almost finished. Happy new year to you!

Mocked up the breather on the engine and indexed the threads to the outlet. Then silver soldered both bits on at the same time. Bead blasted it, more scotch bright, and wham-o, all done. Except for the final breather filter mounting and nickel plating.

I silver soldered the test parts together. Wire brushing didn't work too well, but after a quick bead blast and some scotch bright it looks great. It looks really, really good. Very happy with how that turned out. I will bring this test piece to the chemist at work and have her nickel plate it...

For real now, bored the hole in the cap. Very nice fit, very happy with that. Parts mocked up and looking almost exactly like the CAD model. I don't LOVE the breather hose in that location, but it has to go somewhere, and it does look better than the previous arrangement.

Made a test piece to try out cutting the hole in the side of the cap. I used the mill attachment on the Clarke lathe, using successively larger drill bits then a boring bar to get to final dimension. Last picture shows the test parts assembled.