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 Honda CX 500 first Café build

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IED

IED

Posts : 199
Join date : 2011-06-04
Age : 57
Location : Harwich Essex

Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptySun 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.



Honda CX 500 first Café build - Page 10 IMG01178-20110918-1224



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.



Honda CX 500 first Café build - Page 10 IMG01177-20110918-1224



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.



Honda CX 500 first Café build - Page 10 IMG01179-20110918-1225



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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IED

IED

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyMon 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.

Honda CX 500 first Café build - Page 10 IMG01181-20110919-1726

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

Honda CX 500 first Café build - Page 10 IMG01183-20110919-1731

Then reinstating the insulation with a small section of shrink tube

Honda CX 500 first Café build - Page 10 IMG01184-20110919-1732

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

Honda CX 500 first Café build - Page 10 IMG01186-20110919-2039

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

Honda CX 500 first Café build - Page 10 IMG01187-20110919-2039
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pauliexjr

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyMon 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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IED

IED

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyTue 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.

Honda CX 500 first Café build - Page 10 IMG00887-20110817-1631

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.

Honda CX 500 first Café build - Page 10 S1

Once taped up I did my setting out

Honda CX 500 first Café build - Page 10 S2

After I drilled out the first hole,

Honda CX 500 first Café build - Page 10 S3

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.

Honda CX 500 first Café build - Page 10 S4

Honda CX 500 first Café build - Page 10 S5

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.

Honda CX 500 first Café build - Page 10 S6

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

Honda CX 500 first Café build - Page 10 S7

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

Honda CX 500 first Café build - Page 10 S9

Honda CX 500 first Café build - Page 10 S8

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

Honda CX 500 first Café build - Page 10 S10

Honda CX 500 first Café build - Page 10 S11

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

Honda CX 500 first Café build - Page 10 S12
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Pud

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyThu Sep 22, 2011 7:02 am

man that is looking totally awsome
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IED

IED

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyWed 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

Honda CX 500 first Café build - Page 10 IMG01215-20110928-1900

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

Honda CX 500 first Café build - Page 10 IMG01216-20110928-1901

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

Honda CX 500 first Café build - Page 10 IMG01217-20110928-1903

The off cut was also about the right size I need

Honda CX 500 first Café build - Page 10 IMG01218-20110928-1903

Then carfully placed them over the decal.

Honda CX 500 first Café build - Page 10 IMG01219-20110928-1905

Then went round the gas cap with pinstripe masking tape

Honda CX 500 first Café build - Page 10 IMG01220-20110928-1910

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

Honda CX 500 first Café build - Page 10 IMG01221-20110928-1915

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

Honda CX 500 first Café build - Page 10 IMG01224-20110928-1930

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

Honda CX 500 first Café build - Page 10 IMG01225-20110928-1950

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

Yep, thats exactly what I had in my head.

Honda CX 500 first Café build - Page 10 IMG01229-20110928-1952
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Pud

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyWed 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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IED

IED

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyWed 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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pauliexjr

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyThu 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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Pud

Pud

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyThu 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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IED

IED

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyMon Oct 03, 2011 12:26 pm

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

Honda CX 500 first Café build - Page 10 IMG00812-20110813-1305

First I removed the disk rotors

Honda CX 500 first Café build - Page 10 IMG00814-20110813-1307

Then gave it a bath in degreaser

Honda CX 500 first Café build - Page 10 IMG00815-20110813-1326

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

Honda CX 500 first Café build - Page 10 IMG00817-20110813-1506

Then I used aluminium oxide sand paper to remove the anodizing

Honda CX 500 first Café build - Page 10 IMG01208-20110925-1459

Next I polished the edges

Honda CX 500 first Café build - Page 10 IMG01237-20111002-1717

Then masked the wheel up for painting.

Honda CX 500 first Café build - Page 10 IMG01231-20111002-1554

And gave them a coat of primer

Honda CX 500 first Café build - Page 10 IMG01232-20111002-1600

Then top coat of silver and then clear coat.

Honda CX 500 first Café build - Page 10 IMG01233-20111002-1609

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

Honda CX 500 first Café build - Page 10 IMG01234-20111002-1623

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

Honda CX 500 first Café build - Page 10 IMG01239-20111003-1725

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

Honda CX 500 first Café build - Page 10 IMG01240-20111003-1727

I'll crack on with the rear wheel and should have them both ready to go in by the weekend.
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CO_Racer32

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyTue 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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pauliexjr

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyTue 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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IED

IED

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyWed 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

Honda CX 500 first Café build - Page 10 IMG01254-20111005-2110

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

Honda CX 500 first Café build - Page 10 IMG01253-20111005-2110

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.

Honda CX 500 first Café build - Page 10 IMG01252-20111005-2109

I also brought these countersunk stainless M6 allen bolts

Honda CX 500 first Café build - Page 10 IMG01250-20111005-2108

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.

Honda CX 500 first Café build - Page 10 IMG01251-20111005-2109

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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IED

IED

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyThu 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.

Honda CX 500 first Café build - Page 10 IMG01262-20111006-2058

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.

Honda CX 500 first Café build - Page 10 IMG01261-20111006-2057

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

Honda CX 500 first Café build - Page 10 IMG01260-20111006-1954
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stidds

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyThu 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

IED

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Honda CX 500 first Café build - Page 10 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptySat 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

Honda CX 500 first Café build - Page 10 IMG01273-20111008-1247-1

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

Honda CX 500 first Café build - Page 10 IMG01274-20111008-1257

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

Honda CX 500 first Café build - Page 10 IMG01275-20111008-1259

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

Honda CX 500 first Café build - Page 10 IMG01276-20111008-1301

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.

Honda CX 500 first Café build - Page 10 IMG01278-20111008-1305

Honda CX 500 first Café build - Page 10 IMG01277-20111008-1303

Then I used a heat gun to dry it off

Honda CX 500 first Café build - Page 10 IMG01279-20111008-1311

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

Honda CX 500 first Café build - Page 10 IMG01285-20111008-1320-1

You'll also need stainless steel zip ties

Honda CX 500 first Café build - Page 10 IMG01284-20111008-1319-1

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.

Honda CX 500 first Café build - Page 10 IMG01283-20111008-1319

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.

Honda CX 500 first Café build - Page 10 IMG01288-20111008-1324

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

Honda CX 500 first Café build - Page 10 IMG01289-20111008-1326

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

Honda CX 500 first Café build - Page 10 IMG01291-20111008-1342

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

Honda CX 500 first Café build - Page 10 IMG01292-20111008-1412

Once I got them back on they looked far better

Honda CX 500 first Café build - Page 10 IMG01295-20111008-1429

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

Honda CX 500 first Café build - Page 10 IMG01296-20111008-1430
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Pud

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptySat Oct 08, 2011 1:52 pm

very tasty
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IED

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptySun Oct 09, 2011 3:14 pm

Thanks matey



Evolution of a Streetfighter

Honda CX 500 first Café build - Page 10 IMG01318-20111009-1331

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.

Honda CX 500 first Café build - Page 10 IMG01310-20111009-1322

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

Honda CX 500 first Café build - Page 10 IMG01313-20111009-1324
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyMon 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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CO_Racer32

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyMon Oct 10, 2011 8:47 am

Wow, Gives me inspiration. I love the bike.
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alexoest



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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptyFri 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   Honda CX 500 first Café build - Page 10 EmptyFri 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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pauliexjr

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptySat 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:

Honda CX 500 first Café build - Page 10 Trike012

Honda CX 500 first Café build - Page 10 Trike011

Never again, I hated the original cruiser and I hated the trike it became even more Evil or Very Mad
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IED

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 10 EmptySat 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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