9th sept 2012 - exhaust and fuel tank

All the wiring was now in place and everything working as it should. the new exhausts could be put on, an original set of silencers were proving very hard to find. i contacted a few places and this was the only response i got.............

So i decided to buy an aftermarket set which are similar in shape/style to the originals and cost me about £150. They went on relatively easily and look pretty good.

 The fuel tank was one of the first jobs i did on the whole bike so i was happy i could finally put it back on and see what it looked like. the inside of the tank was rusted and had to be chemically washed, de-rusted and then re-sealed. 

The bike as it stands is almost complete and il soon be able to start it up again.

24th July 2012 - Rear mudgaurd, wiring and seat

Next job was to recover the seat, a cover was brought from america and a fair amount of time spent to fit it properly. Pictures show the before and after. very happy with the results.

 

 

I struggled to find an original tailight and bracket, did find one for £90 but obviously wasnt paying that. instead i brought a very similar one which was off a honda XL125 and had to chop it up abit to make it sit at the right angle when mounted on the newly sprayed rear mudgaurd.

 

during the fitting of the seat and the rear mudgaurd the wiring loom was checked, repaired in some places and re-taped. it was then all carefully put back into place and connected up.

I decided i would put some indicators on the bike to make it abit safer as it is my first bike, a universal indicator kit originally from a royal enfield was brought, the front indicators are intended to sit on the headlight but i didnt like the look of it so decided to make some brackets from some steel plate and mounted them lower down on the forks.

25th June 2012 - Engine and wheels

Alot of time was spent cleaning and polishing the engine block, it was carefully put back in along with the newly powdercoated centre and side stands. The clutch side cover was polished by my grandad and put back on with new screws.

wheel rims finally arrived after 2 months and alot of hassle. The hubs and spokes were cleaned up and the wheels rebuilt with new tyres.

The rear wheel was put in first and the bike could now be put on its centre stand to stabilise it.

The front wheel along with the newly painted front mudgaurd could now go back on.

29th May 2012 - Handlebars, headlight, rear shocks

a few updates,

After my grandad resprayed and refurbished the headlight i installed the gauges back in and wasnt happy with the condition of them. I decided to replace the old faded dials by removing the old ones and replacing them with a vinyl sticker.

once back in place i decided to continue with the handlebars by fitting the new clutch, throttle and front brake cables. new original handlebar grips were also added. i do have the mirrors but will be adding them at a later date to save them being damaged.

 

the next job was to start building the back end ready for when the wheels arrive. the shock absorbers refurbished by my grandad where put back on with the newly powder coated swingarm.

13th may 2012 - Front shocks, handlebars, engine

The handlebars were put back together this weekend.

The ignition, horn and headlight switches were refurbished, re-soldered in places and polished on the outside. the throttle mechanism was sticking so the bore was ground and sanded to remove the burrs and dents so it now operates smoothly. Both the brake and clutch lever assemblies have been polished aswell. handlebar grips and mirrrors will be added when they arrive.

The newly painted and refurbished headlight has been added.

Over the past few weeks i have started cleaning the engine. once all the fins etc had been cleaned i began work on the head. the casting marks were removed by grinding (as can be seen in the top half of the photo below) and the hole area was sanded and polished.

10th may 2012- 1966 honda cb77 superhawk

1966 Honda cb77 superhawk, following pictures show the bike as brought from dk motorcycles Feb 2012.


 

Once home a new battery was brought and all the electrics tested.




with the tank and seat removed the carbs and fuel filter were cleaned and the bike started up, its believed the bike has been standing for a few years but the engine seems strong with no nasty noises or smoke. Now the bike was known to work complete disassembly began......






 

most of the parts were in reasonably good condition and only needed a good clean and polish. However the fuel tank required a complete repair due to major rust on the inside. a fuel tank repair kit was used to chemically remove all the rust and completely reseal the inside. http://www.frost.co.uk/automotive-tanks-products/por15-motorcycle-fuel-tank-repair-kit.html

whilst the frame was out at the powder coaters various bits where cleaned and sprayed. the forks were resprayed and polished, rebuilt with new seals etc. A set of standard original exhaust silencers were brought which will need rechroming. All the bodywork has now been resprayed. Ive chosen to return the bike to completely standard, black and silver are its original colours as can be seen in the picture at start of the blog.



This photo shows what i had when the frame,swingarm and stand returned from the powdercoaters. all the bodywork including the tank, mudgaurds, chaingaurd and air filter covers were placed out of the way until they are needed.

The fork rings were too heavily pitted to sand/polish out, they were skimmed on a lathe to remove the corrosion, this photo shows the before and after. they were then sanded and polished.