[sugarkryptonite]

Test fitted the rear pegs so I could sit on the bike and see how they feel. Felt good so finally started to take the bike apart for final disassembly for final welding of everything.

My dad also fabbed up a nice tool for removing the lock nut on the sway bar. Worked real good.

 

[shinyribs]

"My Dad has better tools than your dad".

Yes. Yes, he does.

 

[makenzie71]

haha I make my spanner sockets with an angle grinder.

 

[Mongoose]

Still debating on the rear shock for now.

As for the wheels, I might go with spokes next year if I can find the right hub for the rear (I think Shadow or Nighthawk). Because this is a driveshaft driven bike, wheel choices are extremely (if any at all) limited.

you have a mill and a lathe...

convert the output to chain.. run any arm ya want then.

 

[makenzie71]

The way the driven gear bolts to the wheel, and given access to a lathe and a mill, it would not be impossible to make an adapter that would mount whatever wheel he wanted.

I had sand cast a piece that would fit into the cush slots of an R6 wheel that I could bolt the pinion gear for my CX500 to. The only thing that held me up was I could not physically fit the R6 wheel into the CX500's swingarm. Had I had access to a lathe and a mill I would not have been deterred.

 

[sugarkryptonite]

you have a mill and a lathe...

convert the output to chain.. run any arm ya want then.

Hah...yeah. There's nothing small about doing that sort of modification, though, and I'm not willing to go that deep just to switch to a chain.

Also, from what I hear, engines on a lot of shaft driven bikes turn the opposite way from chain driven bikes, so that's another hurdle.

 

[makenzie71]

Not in general, but the V45 and V65 outputs go the wrong way to convert to chain. That part isn't worth even the time to contemplate.

However, adapting in a different wheel really isn't all that prohibitive...you have the required tools. Biggest hurdle you'll have is width...I don't think you'll be able to get away with wider than a 5" wheel in the V65 arm. I know that a 170mm tire is tops for the arm.

 

[sugarkryptonite]

Not in general, but the V45 and V65 outputs go the wrong way to convert to chain. That part isn't worth even the time to contemplate.

However, adapting in a different wheel really isn't all that prohibitive...you have the required tools. Biggest hurdle you'll have is width...I don't think you'll be able to get away with wider than a 5" wheel in the V65 arm. I know that a 170mm tire is tops for the arm.

Yeah. I think I've heard of one person fitting in a 170, but even a 160 is a stretch without modifying part of the arm.

I guess if the driven gear can be mounted to another wheel, while still keeping the wheel centered in the bike, it wouldn't be so bad.

 

[sugarkryptonite]

Quite a bit of progress the past week. First we got started on building the battery box to fit the new battery I got. A smaller Motobatt instead of the Shorai I had planned on going with.

My dad made a short video showing the process:

https://www.youtube.com/watch?v=or19b62n9I8

Made some custom mounts on the foot peg extender for the rear brake master cylinder.

Placed the frame back on the engine to check for clearances with the kick stand, and also finding a spot to mount the new ignition switch.

And finally today I set up the portable sandblaster and went to town blasting the frame and swingarm.

I ordered 2 pounds of gloss black powder coat, along with some buffing tools and bars which should be here any day. Hopefully can get the final mounts done for everything on the frame and have it powder coated near the weekend!

 

[sugarkryptonite]

Update from this past week.

Got the final drive painted:

Rear brake reservoir and starter solenoid mounted:

More work on the frame:

Tabs welded on for the new ignition switch and choke:

Tabs welded on for exhaust hangers when the time comes:

And the things that have taken up most of the time...
Made a rear cover and seat pan:

And finally mocking up some ideas for the side panels:

Hoping to get the frame powder coated later on this week when the weather warms up more (oven won't start if it's too cold outside).

 

[sugarkryptonite]

Some more work on the side covers today...took a few tries to get the proper procedure and bends to them. In the end they look pretty good IMO. With the way this tank is with the indentations for the old seat, there's not much that can be done to hide it without doing something drastic and way more complicated. Standing 5ft from the bike it's not really noticeable anyway.

 

[sugarkryptonite]

Well a pretty big update, been working on this all evening with my dad. Finally got the frame + swingarm powder coated. Pretty proud of this one. Doing the frame was a real job, and it got banged up a couple times getting it into the oven (justtttt fit). We had to touch it up a few times while it was placed in the oven (before the heat), and pray that the touch ups got to the front of the frame where we couldn't see.

In the end it came out great. Pics speak for themselves.

 

[Gazmo65]

That looks like a really nice job, well done there, pretty tight squeeze in that cabinet

 

[F'dup]

nothing like fresh out of the oven frame parts lol, nice work man!

 

[sugarkryptonite]

That looks like a really nice job, well done there, pretty tight squeeze in that cabinet

Thanks man! Yeah it was really tight. The door barely closed without touching.

nothing like fresh out of the oven frame parts lol, nice work man!

Just like mamma used to bake

 

[scottyp]

this build just gets better and better...

 

[sugarkryptonite]

Got the valve adjustment done, fixed my starter clutch f-up, and got the engine back together today.

Did some polishing yesterday and today on two engine covers, got them pretty good. I initially wanted to polish the valve covers but they were so far gone I had to sandblast them then just decided screw it and painted them.

Just need to get some hobby type paint to put in the recessed emblems (Honda). Anyone got any tips for doing that? Guess I should have waited until I got some to do it when the covers are on the bench so it flows out easier, but time is running out until spring comes and so much more to do I didn't want to wait.

Next step is sandblasting and powder coating the engine mounts so I can put the engine back in this week.

 

[sugarkryptonite]

Update from last night, stayed up until 3am working on this ****ing exhaust! Got the wrap on and painted, then fought with it for hours trying to get it to fit and line up properly. I think this exhaust was bent when the bike had an accident, so one of the pipes going to the front cylinders was bent slightly, what a pain in the ass to get on.

Then the holes for the support bolt in the rear didn't line up (like an inch off for some reason), so after drilling, bla bla bla, I ended up getting a nice bolt in there with a nut and washer. Going from memory, I don't even think there was a bolt in there to begin with, think the whole exhaust was just hanging from the studs.

 

[sugarkryptonite]

Powder coated some more parts, changed seal on the driveshaft damper unit, basically ready to put the engine back in the frame now. Might work on that today. Hoping to get the wheels back on and the bike rolling by the weekend.

Quick video my dad made of building the side covers:

https://youtu.be/NDfiNmgzbEs

 

[sugarkryptonite]

Marriage complete.