Honda CG125

Hi All
Said hello in the 'introduce yourself ' section recently.
At the tender age of 63 I have just started my first cafe racer project !
Used to work on cars and bikes when I was young but not done anything for 30 years !
Decided on a CG125 as its a nice simple bike but the build will get me 'up to speed' on all the techniques of a bike restoration and conversion at a small scale - the next project will be a lot more ambitious.
The CG125 was original, complete, started and ran when I bought it - It's a Honda CG125BR 1988 (Brazilian model E/F )
I intend to do everything myself on the build. I already have spraying equipment, bought myself a small mig welder and I even have a vinyl cutter connected to my computer so decals will be no problem.
As of last weekend the bike is fully stripped down (which went really well for a 25 year old bike !) All major components were found to be sound with only surface rust here and there.
I took a rotary wire brush to the frame and it is now bright shiny steel ready for a final prep before painting.
Here are a few 'progress photos'

https://2img.net/h/i1345.photobucket.com/albums/p678/m_halls/honda/DSCF1561_zps0f97f2c3.jpg?t=1384863130
https://2img.net/h/i1345.photobucket.com/albums/p678/m_halls/honda/DSCF1602_zps47a9e1b3.jpg?t=1384863154
https://2img.net/h/i1345.photobucket.com/albums/p678/m_halls/honda/DSCF1636_zps0460b603.jpg?t=1384863166
https://2img.net/h/i1345.photobucket.com/albums/p678/m_halls/honda/DSCF1652_zps3482bc3d.jpg?t=1384863176
https://2img.net/h/i1345.photobucket.com/albums/p678/m_halls/colours_zpsee9c7831.jpg?t=1384864024

I will try to post a few pictures as the project progresses - Aiming for on the road next spring.

Be intrested in any comments.

Mike

Must be doing something wrong ! The pictures are only showing as a link to photobucket not the actual pictures ! ??

Think I have the photo thing sorted.

Hi Mike, welcome, small is beautiful bud and if your bike turns out anything like your CGI it will be impressive, now you know how to do it keep posting the pictures so we can see how it's coming!

I'm going through that tedious but necessary stage of 'preparing' all the various components, want a high quality finish so , as we all know, its all down to the preparation !

On another topic -
I'm thinking about how to make the seat. I have never done any sheet metal work / metal forming and I hate using fibreglass so I had an idea !
I bought a second hand petrol tank (same as on the bike) and I intend to chop it down and use the rear section as the 'hump' on my seat. As the shape and curves will match the back of the tank I hope it will look nice and integrated.

Wonder if anyone has tried this and, if so, how it turned out.

Cheers

Mike

Not seen the tank and matching seat tail done before, but I can see how it would work very nicely. Keep us in the loop on that.

I'm starting my own new project over Xmas, I don't get much time in the man cave due to working away a lot, but I have two weeks off with only one day of enforced gluttony so hopefully I can make a start.

I have an old Cagiva TR250 frame which my father gave to my son as a complete bike about 15 years ago. It's actually registered as a Harley Davidson (they owned Cagiva at the time). The engine is long gone, but I've picked up a Honda 250 Superdream engine and box for 30 quid and I have a fair few other bits and bobs lurking so I'm going to try and build a cafe from that. I'll post some pictures up when I've tidied said man cave and assessed just how big a job I'm letting myself in for!   

Hi Paul (I assume it's Paul from your user name)
I did a rough 'mock-up' today of the tank and the 'tank hump / seat thing'
I think it will work really well. basically I will use the whole tank as the seat frame with most of the top cut away apart from the hump at the back, and then make an upholstered seat to fit. The whole assembly will be removeable for access to the battery and odds and ends in the hump. Going to do the seat in yellow / black vinyl to match my colour scheme and probably bend all the needles on my wife's sewing machine in the process !! hell ! no pain - no gain.
Hoping to get loads done over Xmas. My sone is home for Xmas and said he will help, he graduated from a masters degree in mechanical engineering at Sheffield University 2 years ago, sh*t hot at finite element analisys and fluid mechanics in computer simulations , between me and you, doesnt know one end of a spanner from the other !! so that should be fun.
Recons he can butt weld 1mm steel with my MIG welder without blowing it full of holes ! this I have to see, there is a £10 bet riding on it so that's my Xmas beer money sorted.
Your Xmas project sounds interesting, I'm not yet at the stage where I would consider mixing and matching frames and engines. But in the future .....?
How many 'Cafe's' have you done ?
I'll post some progress photos of my tank butchering (sorry I meant modification)

Cheers

Mike

Hi Mike, yes, it's Paul, Paulie because a very good friend from the US used to call me that (in a broad Bronx accent) and XJR because I've had 3.

Cafe racers? I've built 5, two Triumphs, first one in 1976/7 from an ex-police 'Saint' long before the Internet, and one in 2004 which you will find here https://caferacer.forumotion.com/t81-my-76-oif-bonneville a CB175 in the early '80's, a Suzuki 550GT Ram-Air in 1992 and a CB750 2 years back which I had to sell before completing because I lost my job.

I just love the look and feel of cafe racers and I think this one will be 'interesting', mind you, thinking of a name for a Harley/Honda hybrid is going to be a b*gger, Harlonda? Haronda? Harleyda? They all sound like someone clearing their throat at a posh dinner!

Hi Paul
How about a  HONDASON  (Son from the Davidson bit !)

Even done you a tank badge LOL.

Cheers

Mike

Cheers Mike, I like that!

Naming convention says it's normally engine first and frame second, hence Triton, TriBSA etc. so you're spot on there. A friend of mine actually built a bike with a Norton Dommie engine into a T'bird frame, he was somewhat upset when it was pointed out to him that would technically be a 'Norumph'!   

So does that mean if you stick a James engine in a Greeves frame it's technically a 'JimmyGreeves' ? !!

Very good. Now get on with that bike and don't forget to post lots of piccies!   

I have cut down the tank to make my seat pan, bit of fabrication to extend it in length - looking really good.
I'll post some pics soon.
I'm also on with the upholstered part of the seat. Came across this youtube tutorial, this is the sort of construction I propose to use. The seat base and foam should be reasonably straightforward - The sewing up of the seat cover will probably be more challenging, I'm better at woodwork than sewing, we shall see !

https://www.youtube.com/watch?v=fhy6UsiXh3Q

Mike, I'm liking the idea of replicating the tank lines with the seat, look forward to some pictures as it might be an idea I will unashamedly plagerise!

Hi Paul
I was going to wait till the seat was a bit more advanced to do photos. However I have done some of 'work in progress' that should give you an idea of how its going.
With some careful packing I should be able to get the line of the underside of the seat to follow the line of the u/s of the tank nicely.
There are 3 existing lugs on the back of the tank which will be used for fixing turn indicators and the rear light / number plate bracket !
Don't laugh at the welds, it's only tacked at the moment.
Let me know what you think of the concept.

Cheers

Mike

I think that works in a big way, now....... where do I find another Cagiva tank?   

Hi Paul got mine on E-bay for £27 from a breaker quite close to where I live. Free next day delivery using his own transport. It was even complete with the petrol cap, fuel tap/fuel line and even had a cupful of petrol left in !!!
It was better than my original so I cut the original one up to make the seat.
I think the concept would work even if you don't match the bikes tank. The back end of most tanks would make a half way decent seat hump, with minimal fabrication.
I'm going to trim the raw steel edges with yellow nylon tube, split down the length and fixed with clear silicone (see pic)
I've got the fabric to upholster the seat in black / yellow.
I'm also going to install a 12v socket next to the ignition (mounted on the lug below the tank) This will be (apart from a useful 12V supply) a good way of trickle charging the battery without taking the seat off.

Cheers

Mike

This thread is going to go quiet for a few weeks.
I have prepared most of the stuff for painting but, as my 'workshop' is an unheated and uninsulated shed at the bottom of the garden ! , it's far too cold to attempt any spraying. I can get the temperature up using blower heaters but I want to start with an ambient temperature better than 5 or 6 degrees !
Think I'll make my next project spring / summer rather than autumn / winter !

watch this space - end of March, begining of April when things will progress again.

cheers all

Had to have a big lay-off over the summer as I had too many things to do.
I'm now back working on my little Honda CG125

Started the re-assembly and it shouldn't be too long till its finished.

Couple of progress photos attached.

Cheers

Mike

that's looking pretty cool mikey, you got the lines just right (apart from the orientation of the bars )

Hi Russ
Thanks for the comment.
Using a CG125 tank and cutting it down to make the seat pan / hump has worked out really well and I'm also pleased with the lines.
I'm on with the seat upholstery in 2 tone yellow / black so that should look good. Found a good tutorial on youtube for making the cover - see here

https://www.youtube.com/watch?v=8nVyPiPvR2g

I have access to an industrial sewing machine so I'm hoping it should go together OK.

The bars are just a temporary fit so I can move it around easily. I'll sort the final position later.

Cheers

Mike

Mike that looks fantastic, great inspiration as I am going to start a build myself with the cg125

Hi Kris
I think you will enjoy working on the CG125
Couple of tips !
Get yourself a Haynes manual for the bike - invaluable for stripping down and rebuilding
Take LOADS of photos during the strip down, it's a great help when you are putting it back together.
Get yourself some plastic 'freezer bags', the type you can write on, bag up and label bits as you strip it down - especially bolts and fixings.
Carefully examine components and replace anything worn or tatty - bits are only cheap and it's an ideal time to do it.
Shop around for parts - ebay is a good source for second hand parts, there are also quite a number of places that stock new parts (my bike is 1988 and I've had no problem sourcing parts)
just google what you need !
There are plenty of places on the net where you can get info to help as you go along - youtube is great for 'how to' tutorials.
The wiring diagram in the manual is in black and white and hard to follow so I found one in colour on the net - much easier, see below.
Most important is to enjoy it - hard work at times and some of the stuff like rubbing down and preparing for paint is boring but just remember what you are going to end up when its finished !!
Start a build thread on here and post loads of pictures - we are a nosey lot !
Good luck and I look forward to seeing you progress.

Cheers

Mike

Thanks for the message mate

I'm actually an engineer for a wiring harness firm so wirings the only bit I think I'll be able to manage comfortably, all the rest of the advice is brilliant and I've got it written down in my little black book ready for when I've sources a bike to modify! (There's a couple on eBay I'm keeping my eyes on)
Cheers

Kris

Ha You will find the wiring on the CG125 a doddle !! Not an 'onboard computer' in sight. It's a 12volt system. Some of the very early ones had a 6volt system so probably best to steer clear of these. I think all the CG125's made in Brazil have the 12V. You can tell these as they are designated Honda CG125(BR)

Cheers

Mike