project zen

drewvdubber

New Member
i was told i needed to start a thread that encapsulates the work i am doing by my great friend Lans. so here we go.


linked from my car site.

Well here it is, i was suggested to start a log of the project.

1965 Honda CB77 Superhawk.

the project name comes from the inspiration of a book, "Zen and the art of motorcycle maintenance". the reasoning behind it is that this is the bike that the author Robert Pirsig rode around the north west for 17 days with his son in tow and inspired the book that he then wrote about life.

the bike has some great vintage to it.
"The motorcycle was known for its robust and precise motor and the overall high quality of fabrication and assembly. One innovation of the motorcycle's design was the motor being a stressed member of the frame, strengthening the frame and improving the handling over designs with a conventional "dropped-in" motor and cradle frame. All CB models had a forward-arcing kick starter, necessary in order to miss the right-hand footpeg, and re-locatable footpegs that could be sited well rearward (at the expense of forfeiting the pillion) thus enhancing the sporting ride position, especially when the machine was the lo-bar variant.

The 247 cc version (54.0 x 54.0 mm) gave 20 bhp @ 8,000 rpm in standard Dream trim and 24 bhp @ 9,000 rpm in Dream Super Sport trim. Top speed for the Dream Super Sport was 10 mph higher than the fastest British 250 (Royal Enfield 20 bhp single). The enlarged 305 cc version (60.0 x 54.0 mm) gave 28.5 bhp @ 9,000 rpm. The 305 Superhawk proved so agile, powerful (the 1963 CB77 "Super Sport") and well-behaved that it easily outperformed many of its contemporaries with higher displacements. Some argue that the advent of the CB77 Superhawk was the beginning of the end to the British bike domination in the field of street and casual race motorcycles. The quality and reliability were far superior."

it is essentially honda's first sport bike. the later bike was the black bomber with bigger displacement.

From my first thread about it:

well here is one major reason i wanted to get rid of the beetle project among others. i have wanted a motorcycle for soooooo long. i have literally dreamed about riding a motorcycle since i was a kid. well it was time to make the dream come true.

i have been trying to sell the beetle for some time now and was getting discouraged. i have been watching craigslist for months and started to see a ton of older vintage bikes. i have wanted a cafe racer for a long time. it doesnt have to be crazy fast but it must be crazy cool. i had a bike lined up and was excited. it was a cl450. but i still could not help myself. i had to keep looking. then all of a sudden a guys posted four honda dreams for sale. i had been emailing Lans about different bikes i was seeing like the norton that i posted. i remember mentioning the dreams to him. well he goes and looks at the add and gets the guys info. i said i wanted to go because i had never actually been next to one and was a little interested in one of them. the guy ends up being his old neighbor from a few houses down. hes a huge vintage honda guy of all things. well he also has a barn full at his fathers house. he offered to go there as it was about two miles up the road, how could we say no. so we went there and there it sat in the middle of the bikes, a 1965 cb77 305 superhawk. i instantly had to go and sit on it and was in love.

well i had one person that didnt show on tuesday that was "bringing a trailer" in case he wanted the bug. i thought ahh shit here we go again a bunch of people wanting and not showing or tire kickers. well on the way back from the barn i get a call. it was someone that i had called from an email from craigslist. he was very excited to see the bug and wanted to come over right away. how do i say no. shit he gets a call and has to go to traverse city to take care of a stranded vehicle. so i asked where he was coming from and he said lowell. well i am not far off the highway for that ride i told him. he said he would feel out the situation and maybe he could swing by. well as it turned out he could. he shows up with a car in tow(a subaru outback). we get to talking and he is a really cool guy, he has a barn 6000 sqft barn that he has 17 cars in, all projects. we talk about the car, look over all the stuff i have, what i have added, the superflo heads and we came to an offer. i said no to his offer and raised him, and he said yes. he reached in his pocket and pulled out my favorite sight, a stack of benjamins, wrapped up in a sleeve from the bank, signed with a number. i called the number in his pocket. maybe he had more i dont care. so i write a bill of sale up and we agree to meet today for him to pick it up since i was mtn biking yesterday. agreed.

so i start talks with lans about the superhawk as we were both very interested, we came to an agreement as gentlemen and low and behold i can have it. so i made an offer which of course was countered. i accepted. i had to, i wanted that bike bad. so i made arangements for him to get it running and i would be there to help and what not on thursday to get it out of the pole barn and to his house with the bike lift. he ended up picking it up last night. i called him this evening and told him i would be there in an hour, after i load up the beetle. no problem. so i get there and start talking with him. we went over a ton of stuff, he switched out some parts that we found needed some help as we went over it. honestly, this was above and beyond what i expected. we checked, compression, spark, fuel. replaced fuel line, pet cock gasket, petcock filter and on and on. we switched out the starter from a bike at the other pole barn for an issue with it. we drank beer shot the shit and i was impressed with how much this guys wanted to be able to stand behind what he is selling. if more people were like this, this planet would be much better to live on. then he even offered to deliver it for me. i was planning on borrowing my roommates blazer and his old mans trailer to get it home. we get it back here and shot the shit some more. he said if i need anything feel free to stop by anytime. if i need parts, want to find out some info, have a beer, whatever. he wants to see it after i get my hands on it and turn it into my own. I could not have been happier with the way the sale went, the bike i got or how it was all handled. i met an great person with an amazing wealth of knowledge and just a all around great person. he also has a 74 super beetle and was interested in the super flo heads i had which i was going to offer him in partial for the bike, but the other guy got everything. he told me this evening he also was thinking of the partial trade because he researched them and realized what they were and how much they were worth. he didnt care much he was actually happy for me to sell the beetle and get into what i really wanted.

anyway, i guess i know what everyone is scrolling past all this for, the pictures.

had to go with my favorite shot first





original exhaust, baffles still in. these are worth a mint

honda made a race version of this bike, all the parts fit on this one. one of the sweet options was being able to mover the lower controls back in three different postions.

i love this tach and speedo. the light under it still works.

its new home with plenty of room. this weekend begins project garage time. cleaning this bitch out and organizing.

this was basically one of their first sport bikes. it sport dual carbs and came stock with velocity stacks with high flow filters.


the dog checked it out and gave me a thumbs up.

i think i am going to start tearing it down this weekend. the headlight doesnt work and i tried the power leads with a trouble light, no go. i have power in the headlight to the switch, but not at the bulb. so i have to tear off the tank to get to the harness if you can call it that.

i also want to start on the paint. i have an idea to do the ford gray on all the tins to go with the chrome. not sure yet. i also need to tweak the rear fender a little. i want to remount the rear tail and fill the holes it uses. move the plate down near the rear axel. clubman bars, cafe seat, new cables all around as they are original. start with some new hardware etc etc etc. freshen it up a bit.

super excited and cant wait to dive in.
 
ok, so i have been working on this thing.

i got back the parts from chris for paint. if you need work, give him a shout. the parts are as smooth as glass. i have had a lot of paint work done on a lot of things in the past, this stuff looks great. still needs to cure a bit to harden up more, but no worries, its not going anywhere.

here is where it was when i started tonight. tank is back together minus the petcock. and just sitting on the frame. the side pieces come on and off easy. i had to reassemble the knobs that go on them to hold them on.








i had taken apart all the hand controls, polished the aluminum, cleaned up the contacts and reassembled. new grips. and everything works like new. there was issues with the electrical but that was narrowed down between wires disconnected when whatever previous owner rattle bombed different parts to the hand controls that had to be wiggled just right to work. it all works now except the brake switch on the foot. havent dug into it yet.


it was killing me to have had spent time on the two covers, clutch and chain/alternator and not have them on. it took hours of the die grinder to get rid of the old knicks and scratches as well as endless sanding. then hours and hours of buffing wheel work. thanks so much joe for the use of the buffing wheel. so i took apart the clutch and lightly scoured them to remove any glaze. thanks for the tip doug. first time working with a wet clutch.


then i installed the cover after scraping off the old gasket and selaing it up fresh with some honda sealant. i also matte blacked all the screws.




here are some other bits. the other side cover, a chain cover that goes with it. the starter that i refinished. the starter side covers that i polished. again screws are matte black. i even had the horn done in the matching aviator gray. the horn is not done yet, i need to get some liquid electrical tape to reseal and freshen up the electrical grommet and some new heat shrink tube.



made some new plug wires. using old school wire connectors that i am not even sure will work yet. some old school cloth covered with green tracer wire. and reusing the original coil screw caps and grommets. the old wire was a little bigger so i had to bump the size of the cable up with a quick couple of turns of electrical tape to fit.









how it sat tonight when done. pulled the seat pan off to keep its sharp edges away from the tank. i am going to be doing the seat hopefully soon as well as the front fork and frame. they are both getting addressed with matte black. the two fenders were sprayed the matching gray. the rear one i removed the rear tail light bracket from as well as license plate and had the holes welded and smoothed. those are being relocated. i have to pull the wheels off to remount them . i am waiting till i finish the frame/fork to do that.

this is my garage buddy and if i get one, sidecar buddy.


more to come soon. i love working on this and man do you get to see some results every step of the way.
 
well i dont see an edit function so i will just add some pictures here.
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garage buddy
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much more to come
 
the paint work was done by a buddy of mine that does paint on the side. the fenders were also done. the rear i removed the tail from as well as the bracket and welded smoothed before paint. i need to tear down the wheels, take the motor out, address it with blasting and paint. the fork needs refinishing. etc etc etc. the headers are getting polished yet. the rear sets brackets are getting blasted. i have to make the extended shifter linkage soon.

lots of work to come.
 
Advice being worth exactly what you pay for it.......

I'd build your tail cowl around the original shape of the seat, especially with regard to the somewhat blocky shape of that bitchin' original tank. I'd bet you could find an appropriate donor tank at a wrecker that'd be close to that. If you could locate another stock tank you could get that sweet ridge down the center and match them up.


edit for crappy typing
 
Great looking bike man - Love the color. I'm redoing a '66 Superhawk myself in another thread "Red Molly" Your a whole lot farther along on yours :'(

Your polished parts came out great - hopefully she'll run as well as she looks - Keep it up!

Byrd
 
Looks awesome!

Looking forward to the finished product.
(BTW, there is an edit button, says "Modify") ;)
 
Ease said:
Looks awesome!

Looking forward to the finished product.
(BTW, there is an edit button, says "Modify") ;)

Sweet bike. You should check out the forums over at honda305.com -- they focus on Dreams and Superhawks. There's a guy named Ed Moore (username loud mouse) who is pretty much rainman when it comes to these bikes -- he knows them inside and out with his eyes closed.

My '66 Dream:
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drewvdubber said:
well i done sourced another tank tonight. seat cowl here i come. its going to be sexy.

Can't wait to see it come along! ;D
I absolutely love the stance/rake of those bikes. They just LOOK like race bike right out of the box! 8)
 
ok so i picked up a matching tank last night to slice and dice into the seat cowl. as soon as i was done with work today, i aired up the compressor, got out the wax pencil and began drawing on the tank.
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then it was time to start grinding
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and here it is all mocked up. hopefully joe will want to help me weld this beast up tomorrow so i can start working on the cover and foam. not to mention some paint.
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tell me what you think. i think it looks tits. i have it clamped on so i i jumped on and it is perfect size for my fat ass. still needs to be fin tuned for shape.
 
LansB said:
That rocks! I was kind of wondering how the knee indentations would work out....fricken smooth!

i just have to smooth where the bracket was for the chrome side panels. i love how the lines match up. i should have it all welded up and what not when you get back from chicago.
 
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