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 Honda CX 500 first Café build

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IED

IED

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Age : 57
Location : Harwich Essex

Honda CX 500 first Café build - Page 2 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyMon Jun 20, 2011 11:27 am

The filler has gone off enough to scrape and sand back to the markers and get the rough shape

Honda CX 500 first Café build - Page 2 Img00335

I'm gonna let it dry for another day then give it a 2nd fill

Honda CX 500 first Café build - Page 2 Img00336

While I had the heat shield off I gave it a crafty refurb

Honda CX 500 first Café build - Page 2 Img00337

And pop riveted it back together

Honda CX 500 first Café build - Page 2 Img00338

Another box ticked.
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IED

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyTue Jun 21, 2011 1:32 pm

Got in tonight and gave the pod a quick sand

Honda CX 500 first Café build - Page 2 Img00339

Then gave it a coat of PVA to seal it

Honda CX 500 first Café build - Page 2 Img00340

While I was waiting for thzt to dry I decided to lower the rear seat mount

Honda CX 500 first Café build - Page 2 Img00341

after grinding it off I chopped off about 2cm from both sides.

Honda CX 500 first Café build - Page 2 Img00342

I have got a few bits and bobs to weld so I'll do them all at the same time.

Honda CX 500 first Café build - Page 2 Img00343

I went back to the pod and stuck on anothe coat of filler, and tomorrow it will get a sanding with 120 grit.

Honda CX 500 first Café build - Page 2 Img00344

Then turned to the radiator and gave that a cleas up. I think I'm gonna get it recored as its a bit forked.

Honda CX 500 first Café build - Page 2 Img00345
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyThu Jun 23, 2011 2:59 pm

The pod is just about ready for a final fill then a sand with 220 grit then I'll make the base

Honda CX 500 first Café build - Page 2 Img00346

The engin was really cruddy so I removed the fan and gave it a clean

Honda CX 500 first Café build - Page 2 Img00347

The fan wont be going back on as I'm gonna do an electric fan conversion.
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyThu Jun 23, 2011 5:58 pm

Looking good Bud, keep up with the commentary and piccies :-)
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyFri Jun 24, 2011 1:18 pm

OK, on to the base

I placed a section of 12.5mm ply on to the frame and marked a center line on it, then from the front marked back to the pod 330mm and sat the pod onto it.

Honda CX 500 first Café build - Page 2 Img00348

I marked round the pod and marked up the front of the seat

Honda CX 500 first Café build - Page 2 Img00349

The it was a quick wiz round with a hand saw and jig saw for the curvy bits.

Honda CX 500 first Café build - Page 2 Img00350

I need to do something with that gap under the seat above the frame

Honda CX 500 first Café build - Page 2 Img00351

I cut some blanks and ran a plane over the edges to bevel them as I want the sides to taper out

Honda CX 500 first Café build - Page 2 Img00352

Its important to get both sides the same so take care doing this

Honda CX 500 first Café build - Page 2 Img00353

Well then, I'm not a 100% on the shape of the sides but I can always chop em.

Honda CX 500 first Café build - Page 2 Img00354

Starting to look a bit more cafe now.
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptySat Jun 25, 2011 4:28 am

I got stuck in to shaping the front of the seat edges today after removing the fixing screws. The glue is really strong and I'm less likely to damage my blade by removing them.

Honda CX 500 first Café build - Page 2 Img00355

Its not that easy to see, but I sanded the base about 1mm smaller than the pod so I can fill it and get the two to blend

Honda CX 500 first Café build - Page 2 Img00410

Its a bit easier to see how the infills taper out from the front of the bike.

Honda CX 500 first Café build - Page 2 Img00411

Ow!!! I forgot about this. A real stumbling block was removing the fan as I didnt have the right tool for the job. Basicly its an M14x1.5 bolt, but the tool costs £7.95.

I had a bit of a mooch around on ebay and found a Mercedes car wheel stud is also an M14x1.5 but only cost £1.75.

Honda CX 500 first Café build - Page 2 Img00412
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptySat Jun 25, 2011 6:38 am

Bit more filling and it starts to come together.

Honda CX 500 first Café build - Page 2 Img00413

Honda CX 500 first Café build - Page 2 Img00414

Honda CX 500 first Café build - Page 2 Img00415
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptySat Jun 25, 2011 12:55 pm

I cleaned the engine Thursday evening with Gunk then washed it off with soapy water

Honda CX 500 first Café build - Page 2 Engine10

This afternoon I had a bit of time to kill while I waited for filler to go off, so I went over the engine with a dremil to brighten it up a bit.

Honda CX 500 first Café build - Page 2 Engine11

Rocker covers are going to be powdercoated black along with the clutch cover, oil filter cover and the tops of the carbs.
I'm gonna do a bit more to the engine to brighten it up but I think I might take the heads off, re-seat the valves and polish the inlet ports.
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptySun Jun 26, 2011 2:13 am

Well thats it then, final sand is done and its ready for 3 or 4 coats of pva then lots of waxing

Honda CX 500 first Café build - Page 2 Final_10
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptySun Jun 26, 2011 7:08 am

While the seat is sitting in wax I decided to make a start on rebuilding the heads, so after removing the carbs (4 x 9mm bolts) I popped of the rocker covers.

Honda CX 500 first Café build - Page 2 Img00416

The plan is to polish the inlet ports, reseat all the valves and new head gaskets.
For a 30 year old motor I was really pleased to find the barrels were in first class order

Honda CX 500 first Café build - Page 2 Img00418

Apart from a bit of gloop the tops of the pistons look great too.

Honda CX 500 first Café build - Page 2 Img00419

The face of the heads need a good clean so thats my next job

Honda CX 500 first Café build - Page 2 Img00420

Just a very light going over with some fine sandpaper is all thats needed, just to remove any old gasket and crud. be carefull not to damage the surface of the head.

Honda CX 500 first Café build - Page 2 Img00421

I find it a good idea to keep everything organised so you know what went where and how it goes back together.

Honda CX 500 first Café build - Page 2 Img00422

These are great little engins to learn on because there aint much to them.
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Honda CX 500 first Café build - Page 2 Empty
PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptySun Jun 26, 2011 9:57 am

This bit always bores the pants off me

Honda CX 500 first Café build - Page 2 Img00423

Wax on........... Wax off.......... Wax on.......... Rolling Eyes
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Pud

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptySun Jun 26, 2011 9:26 pm

looking good really impressed with seat unit out of interest are you going to change cam chain and tensioner as they are a real bastard to do as the whole back casing has to come off.
cheers
Steve
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pauliexjr

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptySun Jun 26, 2011 11:38 pm

You're really hammering on with this one, impressed my friend, very impressed. BTW Like the 'fighter in the background, funny how some of us can't leave things alone, fighters, chops, bobs, trikes, cafes, it must be an inherrent urge to be different!
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptySun Jun 26, 2011 11:46 pm

Pud wrote:
looking good really impressed with seat unit out of interest are you going to change cam chain and tensioner as they are a real bastard to do as the whole back casing has to come off.
cheers
Steve

Hi mate, I see you are only about 10 minutes down the road from me, I'm in Harwich.
I hadnt thought about the cam chain mate but now youve flagged it up its somthing to consider.
Thanks for your interest in my project and your positive input.
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptySun Jun 26, 2011 11:50 pm

pauliexjr wrote:
You're really hammering on with this one, impressed my friend, very impressed. BTW Like the 'fighter in the background, funny how some of us can't leave things alone, fighters, chops, bobs, trikes, cafes, it must be an inherrent urge to be different!

Thanks for those kind words mate.
I built the fighter about 3 years ago, and nothing has captured my imagination untill I saw a CX500 that some other guy had done. Instantly I knew it had to be my next project, I thought, I gotta have me one of them bad boys. cheers
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Pud

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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyMon Jun 27, 2011 9:05 am

Hi M8
Yeah saw you weren't that far away I'm in the process of doing an XJ600 Diversion cafe racer like you nothing has captured my imagination like this style i am loosely basing my bike on the hyde harrier will put a few pics up when I get time also if you do do the cam chain I have a machined extractor for the rotor if you need it.
Steve
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyMon Jun 27, 2011 3:44 pm

Valves are coming out tonight, the inlet valves dont look to bad but the exhaust valves have a build up of carbon. Not the sexy stuff you bolt to your bike, this is the cruddy stuff inside your zorst

Honda CX 500 first Café build - Page 2 Img00410

So youre gonna need some valve spring compressors

Honda CX 500 first Café build - Page 2 Img00411

One of those screw drivers with the magnet is a good idea to get the colets out as they are a bit fiddly.

Honda CX 500 first Café build - Page 2 Img00412

As you take them out keep them in order so they go back in the same guides

Honda CX 500 first Café build - Page 2 Img00413

be carefull when you remove the exhaust valves, as sometimes they can get a bit of carbon up the stems and be a bit of a bugger to get out. Dont force them through the guids as you could damage them, just get a small bit of very fine sand paper and remove any deposits and they should drop out.

Honda CX 500 first Café build - Page 2 Img00414

All this black stuff has to com off. You can use a wire wheel but keep away from the valve seat

Honda CX 500 first Café build - Page 2 Img00415

Under the black stuff there is white stuff, that has to come off too

Honda CX 500 first Café build - Page 2 Img00416

You should end up with nice clean valves that will perform as they should once they are ground in.

Honda CX 500 first Café build - Page 2 Img00418
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyMon Jun 27, 2011 4:22 pm

The inlet ports were not to bad, but if you run your fonger inside them you can feel the rough texture from when they were sand cast at the factory. Im not building a race bike so I didnt go over the top, but I gave them a good clean up with the Dremil and the polished them.

Honda CX 500 first Café build - Page 2 Img00421

Run your finger in there now and they are really smooth

Honda CX 500 first Café build - Page 2 Img00422

Exhaust ports got a decoke too

Honda CX 500 first Café build - Page 2 Img00423

Next I started grinding in the valves, a piss boring job as each one takes about 30 to 40 minutes.
Radio on! brain off!

Honda CX 500 first Café build - Page 2 Img00425

this is how they look when ground in, as you can see the one on the right has a nice flat grey band around the valve and the seat

Honda CX 500 first Café build - Page 2 Img00426

In all I have 7 more to do, but I wont bore you all with that.

Oh and remember to keep the valves, springs and collets in the same sets as you removed the and mark them up so you know where they go back.

Honda CX 500 first Café build - Page 2 Img00427
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyTue Jun 28, 2011 3:51 pm

Ok, so tonight I got in from work and finished off grinding in the other three valves

Honda CX 500 first Café build - Page 2 Img00428

That only took about 2 hours so I decided to revisit the ports and go the extra mile, so I went back in the inlet and exhaust ports and cleaned the up a bit more.

Next I fitted new oil seals for the valve stems, they are a patten part but fit really good

Honda CX 500 first Café build - Page 2 Img00429

valves back in, and the jobs done. Well half done, theres the other head to do yet

Honda CX 500 first Café build - Page 2 Img00430

Kind of a before and after shot here

Honda CX 500 first Café build - Page 2 Img00431

Over all it took me just over 6 hours to refurbish one of the heads so I have about the same to look forward to with the other one. I think I'm gonna have a break from them for a few days and go back to working on my seat unit, then once I've made the seat mould I'll go back and do the other head.
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyThu Jun 30, 2011 4:01 pm

While I was doing the 2nd head to break up the bordom I took a look over the other parts of the valve system. I niticed the tappet adjusting screws on all the exhaust rockers were either chipped or pitted. the intake side all looked in a1 condition. I dont know why it only affected one side, but they were all replaced with new.

Honda CX 500 first Café build - Page 2 Img00432

20 quid for 4 tiny little screws, Sheesh!!!

Honda CX 500 first Café build - Page 2 Img00433

All ground in and back together

Honda CX 500 first Café build - Page 2 Img00434

I'll put them back on at the weekend after I learn how to use my torque wrench, lol. yup Ive had it for a few years now but never used it. Well, how hard can it be.

Honda CX 500 first Café build - Page 2 Img00435

Never been more pleased to see something done.
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyThu Jun 30, 2011 9:13 pm

look forward to next installment refreshing to see some one doing things properly and not just rushing it to get the image and loosing heart when it breaks down Very Happy
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyThu Jun 30, 2011 11:46 pm

Thanks mate.

Between valves I've been waxing and polishing the seat unit, and on saturday I'll be making a mould from it to cast my seat pod from.

I'm looking forward to that Very Happy
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyFri Jul 01, 2011 1:26 pm

Not a huge amount to report tonight.

The waxing is done, and left between coats to dry over night.
This is so it builds up layers of wax that will help the mould seperate from the original plug.

Honda CX 500 first Café build - Page 2 Img00436

One last step before I can start laying on glass and that is to give it two coats of pva.
All pva is, is carpenters white wood glue. It forms a skin over the part and also aids seperation

Honda CX 500 first Café build - Page 2 Img00437

Its a milky white now but when it dries should go clear and shiney.

Next I'm gonna be laying on fiberglass to make my seat mould, then paying my mate Porky a visit to borrow his mig welder and do a few frame mods.
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptyFri Jul 01, 2011 2:35 pm

This is my torque wrench, I've had it for a few years but never used it or understood how to read it

But now................

Honda CX 500 first Café build - Page 2 Torque10

I'm really please because I found out how to read a torque wrench, and it turns out its really easy Very Happy



Enjoy!!!
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PostSubject: Re: Honda CX 500 first Café build   Honda CX 500 first Café build - Page 2 EmptySat Jul 02, 2011 4:46 am

Right then,

Fiberglass. The thing about fiberglassing is preperation. Make sure you have everything to hand, then either cut up or tear your matting to the sizees you need. Remember big bits wont go round corners as easy as little bits and if you rip the edges they will overlap much better too

Honda CX 500 first Café build - Page 2 Img00438

The guid on the can says 2cm of hardner to 100ml of resin. the can holds 500ml so 5cm of hardner for one of my paper cups should be about right as they hold around 250ml

Honda CX 500 first Café build - Page 2 Img00439

I like to get a coat of resin on then add the matting and apply another coat of resin to wet it right in

Honda CX 500 first Café build - Page 2 Img00440

The first layer is really important as that will be the outside face of the finish pod so take care to get it right. A few minor imperfections are no biggy as they can be got out with a little body filler

Honda CX 500 first Café build - Page 2 Img00441

After that its just about getting the layers on. I'm gonna do a 3 layer seat so the mould needs to be 5 or six layers as it needs to be really ridiged.

Now it can sit and cure for about 48 hours then i'll remove the plug.

Honda CX 500 first Café build - Page 2 Img00442
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