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 Honda CX 500 first Café build

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IED

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PostSubject: Re: Honda CX 500 first Café build   Sun Sep 18, 2011 6:26 am

Well, I spent most of the day just looking at my new paint job by Dave-SP2, But today its back down to earth.



Throtle and choke cables went on.







Got them all buttoned up the relised something was wrong, to open the throtle it had to be rolled forward.

I just had to swap the cables round on the carbs and all was good.







Now I've been putting off doing the wheels for a while because it means more aluminium polishing, and I would rather push hot needels up my finger nails than sit down and polish ally. But it cant be put off any longer because I need the bike up on its wheels the mount the zorst.







I made a jig to refinish my Blade front wheel a while back, so I'll use it again to support the wheels while I rub them down and polish the rims.
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PostSubject: Re: Honda CX 500 first Café build   Mon Sep 19, 2011 2:23 pm

Ok, to get the tank on I need to button up the wiring that is just a total mess at the moment.



Its not a huge issue, its just about cutting them down then soldering them back together.



Then reinstating the insulation with a small section of shrink tube



Its a really slow process, but take one wire at a time and before you know it you'll be through it.



I still have the coils to fit and sort out a few other things, but its more or less there now.

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PostSubject: Re: Honda CX 500 first Café build   Mon Sep 19, 2011 10:29 pm

That paint job is stonking, I like the wheel jig as well, off to Broken & Quickly for me today!
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PostSubject: Re: Honda CX 500 first Café build   Tue Sep 20, 2011 2:32 pm

Well, no supprise, I never went near my wheels again tonight, instead I decided to mount my seat unit.

Some time back I welded two inverted L shape brackets to my frame to support the seat.



Tonight I mounted my tank and bolted it in position, then took a measurment from the back to the middle of the brackets of 30cm and from the middle to middle of the brackets 15cm.

I sat the seat in position then stuck masking tape ove the area I'm going to drill. I did this for two reasons. 1. Its easier to set out and mark on paper tape, and 2. When you drill on your mark the drill tip wont skid over the part and ruin it.



Once taped up I did my setting out



After I drilled out the first hole,



I made sure it stayed in place by pushing a drill bit the same size through the seat and the bracket to keep them lined up while I drilled the other side.





Next I tapped out both holes to take a 10mm bolt. If youve never done this before dont just try to wind the tap in. Go about a 1/4 turn then wind back to clear the cuttings from the tap, then go forward to where you were and take it another 1/4 turn, and so on until you get through. Its not a race and you wont get very far if you break off your tap in the hole.



I will at some point get some flat head allen bolts, but for now these will do.



When I have the seat covered the corners of the seat pad will lift up to get to the bolts.

It sits nice and straight with the tank and is nice and ridged





I'm pleased with all the lines of the seat and tank and I think it sits nice on the frame





And the other great thing about it is it got me out of doing those wheels for another night.

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PostSubject: Re: Honda CX 500 first Café build   Thu Sep 22, 2011 7:02 am

man that is looking totally awsome
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PostSubject: Re: Honda CX 500 first Café build   Wed Sep 28, 2011 2:07 pm

I've been doing my wheels for the last week or so, but tonight I thought I would take a break from them.

Tonight's focus is another one of those detail parts, "The gas cap"

I've had allsorts of sugestions from Chrome it to paint it black.

Well I'm going with tbe black, but with my own twist to it

I got together a few bits and bobs to get started



I also had a decal custom cut to 70mm wide, then applied it to the cap.



Then using a steel rule, and very sharp knife I cut a strip of masking tape to the width I needed



The off cut was also about the right size I need



Then carfully placed them over the decal.



Then went round the gas cap with pinstripe masking tape



Then trimmed everything with the sharp knife, and made sure all the edges of the tape was down to prevent any paint creeping under.

This is what I'm trying to copy



next I shot it with two coats of satin black, leaving 15 minutes between coats



I left it another 15 minutes and peeled off the masking.



Its going to need 3 coats of clear, but I think I nailed it.

Yep, thats exactly what I had in my head.

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PostSubject: Re: Honda CX 500 first Café build   Wed Sep 28, 2011 9:08 pm

looks the dogs m8 but personally i would have had it other way round so it
read right whilst sat on it but that is just my opinion still looks tasty thou
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PostSubject: Re: Honda CX 500 first Café build   Wed Sep 28, 2011 11:37 pm

I did think about that mate, but the shape of the gas cap dictated what way round it went. Chech the photo of the gas cap beside the sticker.
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PostSubject: Re: Honda CX 500 first Café build   Thu Sep 29, 2011 1:01 am

Looking very good, makes me feel guilty I've not been near my CB for about a month :-(
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PostSubject: Re: Honda CX 500 first Café build   Thu Sep 29, 2011 10:03 am

Yeah know what you mean, admire how much you have got done so fast,
I've totally lost interest in the XJ Sad just not happy with the look it just dont
look right with what I had in mind Sad so back to drawing board, still I still get
a fix with the bikes that are being built on the forum.
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PostSubject: Re: Honda CX 500 first Café build   Mon Oct 03, 2011 12:26 pm

Ok, so this week I've been working on my wheels



First I removed the disk rotors



Then gave it a bath in degreaser



That got rid of most of the dirt and crud, but they still needed a going over with a wire brush in my drill



Then I used aluminium oxide sand paper to remove the anodizing



Next I polished the edges



Then masked the wheel up for painting.



And gave them a coat of primer



Then top coat of silver and then clear coat.



I used this stuff, I used it before on my blade and it stills look good.



I waited 24 hours then removed the masking tape, masked up the tyre and clear coated the polished rims.



The petrol resisting clear coat is great, and another product I've never had trouble with.



I'll crack on with the rear wheel and should have them both ready to go in by the weekend.
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PostSubject: Re: Honda CX 500 first Café build   Tue Oct 04, 2011 11:42 am

Great Job so far! Very Happy Ill be looking back on this as I build mine. Anymore pics?
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PostSubject: Re: Honda CX 500 first Café build   Tue Oct 04, 2011 4:36 pm

CO_Racer32 wrote:
Great Job so far! Very Happy Ill be looking back on this as I build mine. Anymore pics?
16 pages of 'How-to-do-it-professionally' pictures and the man's looking for more photos!

Only joking my man, take a look back at what has to be one of the most well documented cafe racer builds. Between this and Mig's CB750 you could make a pictorial masterclass of cafe racer engineering from sh*t heap to award winners.
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PostSubject: Re: Honda CX 500 first Café build   Wed Oct 05, 2011 2:51 pm

Thanks lads, its getting there now, but pull yourselves together, put on your game faces affraid and get stuck in.


I still have a few parts to get like the headlight, tail light, front break pads and lines, but by the weekend the rear wheel can go back on and that will open up a whole lot more jobs I can get on with.

Tonight I spent some time polishing the wheel rim, then masking it up ready for paint



Its a really boring job, but stick with it and the results will speak for themselves.



Other jobs tonight was to fit a new clutch cable, as the old one was really worn on the outer sleeve and would have let the end result down.



I also brought these countersunk stainless M6 allen bolts



They wont be seen as they will be under the seat pad, but they will sit nice and level with the seat and not poke up through the pading.



And thats about where we are at the moment. A bit slow I know, but as I said earlier, things should hot up again when the rear wheel is back in at the weekend.
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PostSubject: Re: Honda CX 500 first Café build   Thu Oct 06, 2011 2:33 pm

As you can see from the rear wheel I did tonight, for a 30 year old wheel, they do come up nice.



I'll leave it until Saturday before I put it back in just to give the paint and clear coat a chance to set up a bit.



Cant wait, but nows not the time to cut corners and rush things.

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PostSubject: Re: Honda CX 500 first Café build   Thu Oct 06, 2011 6:11 pm

That really is looking very nice indeed, love the tank/seat colour. Those wheels are looking superb also.

Really great and always nice when I see an update to your thread and I can see the progress.
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IED

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PostSubject: Re: Honda CX 500 first Café build   Sat Oct 08, 2011 1:18 pm

Thanks mate.

Well as I said, I would have the back wheel in by today and that would open up a whole new ball game.

This afternoon I'm going to heat wrap my exhaust. I set it up on the bike, then drilled a couple of tiny hole to pt self fappers in to hold the position. Then I dropped out the complete unit



Once I got it in the vice I sawed off the inside clamp lugs



Then ran a file over them to take off any sharp edges



I'm going to use this stuff to seal the joints



one at a time I removed the screws and smeared the paste around the pipes then slotted them back in and smeared some around the outside.





Then I used a heat gun to dry it off



Now if you are going to try this, you'll need gloves because this stuff contains fiberglass, and you'll itch bad.



You'll also need stainless steel zip ties



And a bucket of warm soapy water to soak the wrap in so it expands, then contracts when it drys out and tightens around the tube.



soak the wrap for a couple of minutes, the soap is a wetting agent and will help it to soak a bit quicker than water alone.

Next start at the bottom of the pipe so the wrap overlaps face backwards and dont catch road grime.

Start with one full turn around the pipe and tie it off with a zip.



Then wind it on over lapping by about half, and keep it pulled as tight as you can



Work youre way to the top and tie it off with a couple of zips



Then do the other side the same way. I also did the section between the can and headers.



Once I got them back on they looked far better



And there we are, another job ticked off the to do list.

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PostSubject: Re: Honda CX 500 first Café build   Sat Oct 08, 2011 1:52 pm

very tasty
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PostSubject: Re: Honda CX 500 first Café build   Sun Oct 09, 2011 3:14 pm

Thanks matey



Evolution of a Streetfighter



I guess without what our Dads were up to in the 60's moding their bikes to look like the racers of the day with a hunger for balls out speed and handling, we may not be doing what we do today.



Begs the question what our kids are going to be doing with the bikes of the future, mad little f**kers.

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PostSubject: Re: Honda CX 500 first Café build   Mon Oct 10, 2011 12:01 am

Another excellent 'How-To' Masterclass, well done IED, your bike is looking the dogs gonads! Like the fighter too, it's far enough 'out there' without looking unrideable, keep up the good work.
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PostSubject: Re: Honda CX 500 first Café build   Mon Oct 10, 2011 8:47 am

Wow, Gives me inspiration. I love the bike.
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PostSubject: Re: Honda CX 500 first Café build   Fri Oct 14, 2011 6:53 pm

Congratulations on a fine result. I've enjoyed this thread and become very inspired by your thread. And I've learned a lot from your photos and explanations.

/Alex
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Pud

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PostSubject: Re: Honda CX 500 first Café build   Fri Oct 14, 2011 9:07 pm

mate that looks good
you have done the now--- fighter
youhave done the past ----- cafe
so go on whats next compleate the trilogy go for the future?
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PostSubject: Re: Honda CX 500 first Café build   Sat Oct 15, 2011 12:38 am

Pud wrote:
mate that looks good
you have done the now--- fighter
youhave done the past ----- cafe
so go on whats next compleate the trilogy go for the future?

Perhaps the hint is there in the word 'trilogy'?

This was my attempt:





Never again, I hated the original cruiser and I hated the trike it became even more Evil or Very Mad
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PostSubject: Re: Honda CX 500 first Café build   Sat Oct 15, 2011 10:28 am

Thanks guys but she still has a few bits left to do.

Break lines

front and rear lamp

undertray

Radiator and hoses

Then we will be done cheers
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