Honda CX 500 first Café build

looking good, the firm I use for my GRP supplies is westsystems follow link they do every thing you need

http://www.wessex-resins.com/westsystem/index.html

Steve

Well I got up this morning and decided to pop the mould off the plug



I cleaned it up and trimmmed the edges with a hacksaw blade in my jigsaw



There are a few small air bubbles on the inside, but I'll sort those out with a little body filler



First time I've attempted a seat, and so far its all gone to plan

that is so impressive mate cant wait to see finished article did come off plug easy

Plug came off ok mate, but the pva was a bit of a git to remove. When I went back and looked at the bottle it said "Waterproof" Doh!!!

The sexy side of the CX'y500





Am I winning you over yet, lol

wow not seen those before you don't need to win me over built a CX500 special about 10 years ago sound mean on open pipes will put a photo up later.
Steve

Get it on matey, cant wait to see it

Kneedoon on a CX!!!!

Nice photo that. Anymore like it???

Col.

Time to get the heads back on.

I applied silicon to bothe sides of the head gasket and droped the heads back on.
Next I greased both ends of the push rods and put them on to the followers.
The rockers went on next and the four head bolts went in.



The head bolts need to be tightened in the correct order to prevent the head warping.
there is a torque setting for the head bolts of 36 ft lb



I was advised by my mate to start at 15 ft lb's and tighten to the sequence shown
working up 5 ft lb at a time untill I reached the maximum shown in the Haynes manual



There we are then, back on.



I'm pleased that I learned how to use my torque wrench, and think its going to
be a real asset on this build

My mate Rob was the second pair of hands tha held the engine for me while I
tightened everything up and gave me some sound advice.

I think I'm gonna start pulling the carbs apart next so I'll be hunting for
a carb rebuild gasket set next. While I do that I'll get to welding the frame mods.

Tonight I thought I might add a bit of bling to the project, so I gave these bad boys a look



I started with 240 wet and dry then went finer until I got to polish



I'll do the other one when I get in tomorrow.

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hibernator wrote:

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Oops , sorry, that didn't work!

Done a bit more to the mold today, I started with 240 wet and dry then went to
400, 600, and finished up with 1200 then T cut to get it as shiney inside as I could
Now ten coats of wax.



While I was looking through my Hains, I saw that the cooling system was all
push-fit with O rings. I have some on order but thought I would have it all apart
while I'm waiting.



I'm glad I did, because it was proper rotten and I believe it would have leaked
if I had just put it back.



Everythings cleaned up now and I'll set about polishing the end bends tomorrow
morning. When I put it back together I'll repaint the tubes and I think I will also use
a bit of silicon to back up the rubber O rings.



I also polished the other rocker cover today and gave the engine another going over.
I plan to paint the motor so I want it as clean as I can get it.

Looking good m8 bit more adventurous than the CX I built for my mate (see photos in rice burner sec)
Steve

You're going to paint that??!! There are people out here who would die for a finish like that!

Following this with great interest.
Hope it ends up close to being as nice as this.
Please don't paint the engine though.
It never looks quite right, no matter how well it's been done.
I think we'd all prefer to see a bit of age related patina that a bright silver spray on finish, which I think could ruin it.

devonrider wrote:

Following this with great interest.
Hope it ends up close to being as nice as this.

Ooooh, me likey lots!

just love CX's they can look good they sound good and there affordable love to know who makes that tank on the red one

That is sweet mate, but I was thinking of going black on the motor, not silver

On the clutch cover at the front of the motor there is the Honda logo



On each side of the motor there are two Honda badges with small screw fixings.

A bit of a logo overload I think. I rekon if you know a bit about bikes then you know what a CX500 looks like and who made it, so I decided to dump the small Honda badges on the side of the motor,



and got my mate's mate to make me a couple of these bad boys on his water jet. He just text me this photo of them, and I think they will look tasty on a black motor.

I'll get my hands on them tomorrow at work. []

On the front of the motor is the oil pressure sensor and there Is a wire that although cliped at one point, is a bit messy as it goes where it wants



It has a braided protective sleeve, that can work in my vavor.
I removed the copper wire fron 230v 2.5 twin and earth house socket wire and slipped it inside the sleeve to enable me to put positive bends into it and guide the wire where I WANT IT to go.



I clipped it to the engine and the thermostat mount and made off the ends



Now it all sits where I want it. I might be a silly little thing, but all these little things add up

your right it is the little things, people might not notice but you know its there and it just bugs you. Been in the workshop for the past two hours trying to get my seat line right and I'm still not happy might take some photos on and put on the group and see what feedback I get. Also love the "cafe 500" badges.
Steve

Cheers mate.

Have you thought about doing the seat pan out of card then use it as a template matey?

thought about making my own seat but want to use a TZ500 seat unit I have but just cant get it right.
Steve

Photos matey