Project Checkbook; Chris' Small Project

[chrisf]

OK, so I have a new project. This one is a quick, dirty café that I will try to complete in about 48 working hours total. Between 3 people, it might be possible. So here’s what it is:

1974 CB360. The PO left a faulty petcock open and he suspects fuel drained into the crankcase. He drained all fluids and replaced all gaskets/seals. The bike comes with Mikuni carbs, stock carbs, a yet-to-be-filled battery, new tires mounted, new brake shoes, an extra set of wheels, and extra frame and a box full of goodies.

Grand price: $200 US

I have yet to see it, but my father is picking it up tomorrow. The guy that maintains his Harley’s sold it to the current owner and vouched for its condition.

I’ll document the project here, rather than my website, because it will be a birthday gift for my brother (april 10th!!). My father is covering the expenses and I will sell off the unneeded bits—giving him the money. Hopefully, we’ll be out $600 total.

So here’s the plan:

1.) Get it started with the battery
2.) Clubman bars (look great and save a lot of $$ over clip-ons)
3.) TTR400 foot controls (maybe Tarozzi’s)
4.) Polish forks/upper tree and anything else that can be polished
5.) Replace fork fluid (I have tons of the stuff, so I might as well.)
6.) K&Ns
7.) Hidden batteries between framerails (like mine; after we get it started on the battery)
8.) DropBars starter blank off
9.) DropBars seat
10.) DropBars headlight mounts (hopefully)
11.) Powdercoat the frame, swing arm, anything else that needs it (this will be a huge time saver)
12.) Paint the tank/seat (This will be a huge time pit but I have to paint my seat anyway

That’s about all. I’m on a tight budget. If budget allows, I may pick up a Benelli tank and paint that. So far, I’m thinking it will be Jaguar racing green.

--Chris

 

[coolatula]

Re: Chris' new Small project

Not bad at all,actually you did real well considering you got all the new /extra stuff with i.
Put up picks of the bike and parts when you get it home.

 

[chrisf]

Re: Chris' new Small project

I'll do it. I fetch it next weekend, along with my really long term project: Restoring a MG Midget for my wife.

--Chris

 

[chrisf]

Some pic of project checkbook. I was initially pretty excited about the good deal we were getting, but now I think we just got an honest deal. As Carpie would describe it, it's a snotter. I was hoping for something in better condition.

Extra CJ360 (whatever the f ck that is) frame

If anyone is interested in any of this stuff, please let me know. The Mikuni's are currently torn down and getting a good soak. Tomorrow, I'll fill her up with oil and kick her over a few times before wiring up a battery and letting the starter do the work. After that, she's getting a good powerwash. BTW, does anyone have a good method for sealing up where the carbs go before a powerwash?

--Thanks for reading, Chris

 

[shoe48]

Hey you have a lot of work in front of you .. By the way is that an Allard in the back ground ? if so whats it got in it ? ;D

 

[chrisf]

No, it is a lotus se7en-like car that I designed (well, most of it) and built from scratch. It has a Honda CBR900RR motor in it. I wish it were an Allard; that would be cool!!

--Chris

 

[ProTeal55]

Another bike Chris ?
The bike building force is strong with you... ;D

 

[NPHLYT]

I thought about building a Seven project using a kit like these guys www.flyinmiata.com/westfield/ourcar.php, and a 1.8 liter Miata donor, but then I started doing the math and couldn't bring myself to do it. Besides, the wife wants a piano and I am looking at something old and something new (bikes).

 

[zixxerboy]

Chris,

If you're looking to chuck the tank and exhuast in the last pic I'd take them off your hands. I'm in St Marys. You going to the LOndon bike show?

 

[chrisf]

Hi:

No, I'm down in Texas. Sadly, I binned the exhaust muffler! I can post the tank if you'd like, though i imagine it will be quite pricey.

I got tons of stuff in the mail yesterday. I ordered all my bits from www.guzzino.com, and they are really cool people to work with. A nice departure from working with Vintage Cosmos. I'll post pics tonight, but basically, I now have in my grubby hands:

a Bennelli tank
Tarrozi rearsets
Tomeselli clubmans
new Tires
and damn near everything I need to complete her. I decided I'm going to make an aluminum seat. Should be fun.

Anyway, I'm in the market for a 2-1 merge collector. I'm not real concerned with the condition of the chrome. It needs to have 1.5" primary and pics are always welcome. Any help is appreciated.

--Thanks, Chris

 

[chrisf]

Last week, I broke down and rebuilt the Mikunis. These are sweet little carbs with tons of adjustments; much nicer than my stock CL350 carbs. Anyway, I bolted them up (which took some figuring because it had been a week since I broke them down) and it went together nicely. Changed the points out, checked the timing. My friend Kit told me that there wasn’t much oil that went that went through the stator—not entirely true. When I went to start her, tons of oil burst out. OK, so I pulled the spark plugs and turned her over for a while. Then, I reinstalled the new spark plugs and had a go.

Nothing.

So I shot so carb starter fluid in and she began to pop a bit. I dribbled some fuel in the fuel line and tried again. Sure enough, both cylinders woke up with a bit a starter fluid. Good enough.

Saturday, Sam came over and we broke the bike down. Much of the evening was spent getting the Benelli tank mounted, which I forgot to take pictures of. I’ll do so this evening. Then, we disassembled the whole thing. Here is a picture of me looking like a flappy douche bag (I was quite a few beers in).

Here is a big pile o parts. If you need anything from there, let me know.

To get the Tarozzi controls on the passenger peg, I decided to make a little bung out of ¾” round. It’s just tacked in at this point.

Here are the Tarozzi’s all mounted up. The things are awesome. Their action is very smooth and overall, they are well engineered. The one thing I dislike is their weight. These guys literally weigh 4 times my handmade controls.

Some more trimming. I found that I like to use 4.5” 1/8” cutoff wheels. They check through tabs like butter and leave minimal clean-up. After I cut a tab, I use a 60 grit flapper wheel. Tonight, I’ll go back over everything with a 220 grit flapper wheel, followed by a rolock on an a pneumatic sander.

The final thing I did yesterday was cut another inch off the rear. I’ll weld in cover plates for strength and appearance. I’ll also weld in a cross bar for stability like I did on my CL350.

Overall, the frame and other bits need a few more hours of work. During that time, I need to start hunting down powdercoaters. I like the guys I used for my se7en, so I’ll likely go with them again. There is also a local guy that I may get a quote from. It’s just gloss black, so damn near anyone can do it. Alumicoating the tanks, however, is a different story. There is a supplier here in Dallas and another in OCK. Hopefully, I don’t get gouged on the prices.

At lunch today, I’m off to the metal suppliers to pick up some aluminum for the seat. Stay tuned!!

--Chris

 

[coolatula]

Looking good and those controls look sweet as hell.

I hope the weather changes for the better here in a few more weeks so I can get some work done on my project(s). I've also been sick as a dog for over a week,just that time of the year with funny ass weather/temp changes. Seeing you guys getting out and working make me jealous that my unheated garage isn't fixed up yet how it needs to be in order to work out there!

 

[chrisf]

Worked a lot more over the last few evenings. I'm getting a lot closer to having the frame complete shaved like Lohan. This is where the old center stand was located.


In my heart, I know this wasn't the right think to do, but due to time constraints, I decided to weld in a sheet of 16ga steel between the frame rails. On my bike, I aircraft riveted a structural sheet of 6061-T6. It was lighter by about 1 lbs, but it was also a pain in the ass to do properly. I figure if Benji can use steel all over his bikes, perhaps this isn't so bad...that what i keep telling myself! Anyway, tack welded in.

Fully welded in. Notice how I toock my time and put down 1.5" beads, then switched to the other side. Let it all cool and go at it again. I didn't want the steel to warp up. Truth be told: this is a much stronger way to brake frame rails.

I originally wanted to weld a 3/4" 16ga tube supporting the shock mounts. But due to the position of the rear wheel on the CB360, I got cold feet. It would be a disaster if my brother hit a bump and the wheel got cozy with the cross brace--to put it lightly. Instead, I welded some more 16ga sheet across the rear pan. Weight-wise, it is similar to a 3/4" DOM tube; I doubt it's too much stronger thought. The welds, of course, will be shaved into the frame.

I then started working on mounting the Bennelli tank. This took forever to find a solution. In the end, this will work, though it's by no means perfect. In this picture, you can see the left side mount. I'll fabricate a right side mount to go with it. These will ride on small rubber disks.

Tank from above. You can see a 1/4" bolt that bolts the tank to the frame. What you cannot see is a 3/4" rubber disk that isolates the tank.

And the side view. I think it looks good.

In that last picture, you can see a foam board mock-up of the seat pan. I'm very glad I did this in foam board first because the seat would have been a few inches too short. The next step is to completely smooth the frame and reassemble everything--except the motor. I'll then build the wodden buch for the aluminum seat. Once I'm happy with that, I'll tear down the bike again and throw all the bits into the powdercoating box. Whilst that's getting powdercoated, I'll make the seat and clean up the wheels.

--ATB, Chris

 

[zixxerboy]

Chris, Does welding the plate on the bottom block the sump drain or will you cut out an acess hole?

Thanks for the detail shots

 

[locOleoN]

Fantastic work so far!!...
Its really coming along for ya!!..

 

[chrisf]

Thanks gents. The plate is actually open in the front so I can run wires down it. I should drill a drain hole in the rear just in case. Good call, though I have yet to have an issue with me CL350...

--Chris

 

[chrisf]

OK, let's try this a third fourth time. I posted a nice long description and the server decided to take a shit on it...

I have to juggle moving the se7en and midget in and out of the garage when sparks fly. so I decided to take a break from garage work and make a foamboard mock-up of the seat. Plus, playing with paper inside the house passes as "spending time with the family." I'm glad i made a paper mockup first because there needs to be some changes. Right now, it pinches down too tight in the rear. I'm going to widen that by 1.5" diameter.

Side view. Note that the actual seat will have a 1.5" side skirt that goes over the frame rails. Rubber disks will go between the seat and frame.

Rear view. Notice the pinch I'm talking about. This is going to house the 4" Ford tailight I have, basically taking up the interior of the cafe hump.

Top View:

Right, so the next step is to make a strong wooden buck. I'm considering selling this seat in both aluminum and fiberglass. The aluminum seat will be rough finished with 220 grit and the buyer will need to finish it out. The aluminum seat cost will be approximately $200-$250. The fiberglass seat will be made with s-glass/epoxy resin and will likely need a skim coat of body filler or a high built primer before paint. It will likely cost $150.

You guys have seen my work and my attention to detail; the way I design and engineer. So you basically know the type of product I could turn out. The question is: will the market bear these prices? If not, I'm not going to bother and will just make the single aluminum seat for the CB360. If these prices are reasonable, I will consider making these seats on a limited basis. So far, I know the seat will fit the CB360 and the CB350.

I look forward to your responses.

--Thanks, Chris

 

[zixxerboy]

Chris,

I notice you spec s-glass and not the more common e-glass. Just curious why that would be.

 

[chrisf]

S-glass is significantly stronger and quite a bit lighter than regular e-glass. It is more expensive, but worth it IMHO.

--Chris

 

[chrisf]

Test. I keep bringing the server down...