Honda-SOHC

SOHC.co.uk Forums => Project Board => Topic started by: UK Pete on August 21, 2019, 03:05:20 PM

Title: Re: 30 years of storage later, the project begins.
Post by: UK Pete on August 21, 2019, 03:05:20 PM
Omg, I would look for another set rather than tackle that


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Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on August 22, 2019, 09:40:33 AM
Omg, I would look for another set rather than tackle that


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Casting look good inside though Pete ..no nasty water damage and part that main jets fit into look good I reckon. I have seen three sets of 500 carbs that looked pristine on the outside but old fuel and water ingress have rendered the bodies to be almost scrap.
Title: Re: 30 years of storage later, the project begins.
Post by: Trigger on August 22, 2019, 10:54:55 PM
That is the worst bar I have ever seen Ken.

Looks like everyone is doing carbs at the moment. I have just finished a one set have another set to build and just stripped a 500 set. Yours should look like these soon  ;)

[attachimg=1]

Title: Re: 30 years of storage later, the project begins.
Post by: Trigger on August 22, 2019, 10:59:27 PM
[attachimg=1]
Title: Re: 30 years of storage later, the project begins.
Post by: Trigger on August 23, 2019, 10:43:13 AM
The fuel T's are on the black mate just below the tops  ;)

When you got the new plate, did it come with the alloy arms x 2 ?  The set I have just taken apart had one of the top arms broke and am looking for another.
Title: Re: 30 years of storage later, the project begins.
Post by: Trigger on August 23, 2019, 10:39:17 PM
I have 3 x 1&2 and 1 x 3&4 ken


[attachimg=1]
Title: Re: 30 years of storage later, the project begins.
Post by: Bryanj on June 08, 2020, 07:51:41 PM
Better plull my damn finger out on mine!!
Title: Re: 30 years of storage later, the project begins.
Post by: taysidedragon on June 09, 2020, 01:01:45 AM
Considering the state the carbs were in, they've come out pretty good! 👍
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on June 09, 2020, 04:47:05 PM
When I investigated recently I found that the zinc plating on 400/4 steel  carb parts was originally gold passivated finish. Anyone know if this was the case on early CB500/4's?
Title: Re: 30 years of storage later, the project begins.
Post by: Trigger on June 09, 2020, 07:35:53 PM
When I investigated recently I found that the zinc plating on 400/4 steel  carb parts was originally gold passivated finish. Anyone know if this was the case on early CB500/4's?

Yep, but not all the parts were yellow  ;)
Title: Re: 30 years of storage later, the project begins.
Post by: Laverda Dave on January 16, 2021, 06:28:08 PM
I think I'm going to be sending the frame of the Z400J to the powder coater via a courier, I need to see how much it's going to cost first though. If I don't I'm going to be sitting looking at four walls again until we are allowed out! The idea of this rebuild is to give me something to do whilst playtime is suspended!
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on January 16, 2021, 07:53:41 PM
Did you get any further with the hard chroming idea on the pinned type rocker spindles Ken?  Or did you find a set of NOS ones in the end?
Title: Re: 30 years of storage later, the project begins.
Post by: Trigger on July 07, 2021, 06:27:39 AM
The top collar is 18231-333-000 fitted to the CB400 and CB550F1/F2.
The bottom collar is 18231-323-000 fitted to the CB500 Four  ;)
Title: Re: 30 years of storage later, the project begins.
Post by: Laverda Dave on July 07, 2021, 12:58:17 PM
Nice work Ken. 6 hours to clean and polish each clamp is dedication! Hopefully the hard work will pay off and may your clamps never rust again😊.
Nice to see the thread back up and running, isn't retirement great👍
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on July 07, 2021, 01:09:10 PM
Nice work Ken. 6 hours to clean and polish each clamp is dedication! Hopefully the hard work will pay off and may your clamps never rust again😊.
Nice to see the thread back up and running, isn't retirement great👍

I would have been tempted to just leave them in a tub of Evaporust for a few days - lightly brushing with a paint brush every 12 hours or so.
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on September 23, 2021, 10:08:13 AM
Good on you Ken for trying something different .... hard chroming the 500/550 rocker shafts. To me this is what forums like this should feature a lot more. I tried finding NOS pinned type or even standard rocker shafts and talk about rocking horse poo. OK a few places advertised them NOS  in Europe etc.,  at a high price but all of the ones I tried to buy were no longer in stock.  It will be interesting to see how the hard chromed pinned version works out in terms of wear resistance. I don't think Honda themselves solved the problem because the lack of rotation resulted in localised wear fairly rapidly. 
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on September 23, 2021, 02:25:50 PM
Impressive restoration work being done on this project - just over 2 years from the start of the project - admirable patience & attention to detail.
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on September 23, 2021, 02:50:22 PM
Your bike, your build,  your choices, your money - the only person to please with the end product is you so I agree with your philosophy 100%.

"To be yourself in a world that is constantly trying to make you something else is the greatest accomplishment".
"We are our choices"
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on September 23, 2021, 07:56:34 PM
How far off are you with your project Ash, I was thinking if you have a later style camcover

I  am OK thanks Ken .. The only later cam cover I had was the one I sold to you.  I managed to get a decent non-pinned shaft early cover with decent shafts  for my 500K0.
Title: Re: 30 years of storage later, the project begins.
Post by: Seamus on September 24, 2021, 08:46:09 AM
Very interesting project. Patience is an understatement. I love the attention to detail, but that is where it all pays off in the end. Looking forward to seeing more progress and the final article.
Keep the story going.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on October 03, 2021, 11:29:32 AM
Loving this thread, Hard chroming deffo on the list of possibilities for the 550 coming to the bench in the next 8 weeks.
This forum is great 8)
Title: Re: 30 years of storage later, the project begins.
Post by: SteveD CB500K0 on October 03, 2021, 06:52:31 PM
Given the typical demographic on this forum, you shouldn’t mention Aero chocolate without expecting an immediate tangential discussion (ITD in forum-speak)

Yum.


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Title: Re: 30 years of storage later, the project begins.
Post by: Bryanj on October 03, 2021, 06:59:20 PM
Only f its mint or orange
Title: Re: 30 years of storage later, the project begins.
Post by: SteveD CB500K0 on October 03, 2021, 07:05:24 PM
See what I mean?


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Title: Re: 30 years of storage later, the project begins.
Post by: smoothoperator on October 03, 2021, 08:04:56 PM
Went for a ride around Lincolnshire last week, queued 5 minutes for petrol, put in £10 worth at £1.50/litre of E5, bought a peppermint Aero for a pit stop. Forgot how rubbish they are. At least it melted a bit in my jacket pocket, unlike on any rides for the next 6 months.
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on October 05, 2021, 08:46:01 AM
I am too much of a gentleman to repeat the story about Marianne Faithfull and her favourite chocolate bar.
Title: Re: 30 years of storage later, the project begins.
Post by: andy120t on October 05, 2021, 07:14:08 PM
I liked the 400 Aero back in the day. I'm not sure what flavour blue and white was but it didn't have chocolate cams...
Title: Re: 30 years of storage later, the project begins.
Post by: heli_madken on October 09, 2021, 11:14:24 PM
Wow that is some transformation, a lot of patience and hard work to get them that good. It is immensely satisfying inst it to take something so badly corroded to what looks like a new part
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on October 14, 2021, 06:16:05 PM
Impressive work Oddjob - I admire your persistence - if I only had a quarter of your application my bike would be less of a Dogs dinner when it's done - I work on a sort of pre-diminishing returns basis.lol
Title: Re: 30 years of storage later, the project begins.
Post by: philward on October 15, 2021, 11:00:17 PM
Really great job Ken - see you are making use of your newly found retirement time!
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on October 27, 2021, 11:06:14 PM
THay look fantastic Ken, I too think thats kinda cool looking. Well done mate
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on October 28, 2021, 09:36:06 AM
As has been said the restored polished items look fantastic - well done Ken - that is either fantastic attention to detail or you need to see a trick cyclist about early onset OCD. ;D ;D ;D
Title: Re: 30 years of storage later, the project begins.
Post by: taysidedragon on October 28, 2021, 03:03:25 PM
I keep joking I have OCD but in fact I don't, I just like perfection and will strive endlessly to try and achieve it, I do however always leave one part deliberately wrong, like the Japanese symbol, if I ever get perfection then there is nothing to strive for. I'm not 100% happy with the slider TBH, I thought it would be brighter but maybe it just needs more polishing. We'll see. Got some stainless studs for the spindle, stainless bolts for the oil drain and stainless fork caps along with the hard chromed fork stanchions, new dust covers as well, should look ok once assembled.

Very bling!
Title: Re: 30 years of storage later, the project begins.
Post by: philward on January 02, 2022, 10:39:08 PM
 found a new method by accident which gets alloy looking like a mirror, some parts I could shave in they are that clear. Back in the shed tonight, probably another all nighter.
[/quote]

Prey tell Ken?
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 03, 2022, 12:51:05 AM
Dont tell him Pike! :D
Title: Re: 30 years of storage later, the project begins.
Post by: philward on January 03, 2022, 09:03:36 AM
Thanks for spending the time to share that with us Ken. I've not got anything for polishing at the moment but will save that info for the future when I have

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Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 03, 2022, 10:20:53 AM
Well thats me ordering some felt wheels for mine then,that looks great Ken
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 03, 2022, 09:46:03 PM
I'mnot sure what you mean by pigtails Ken. Not herad that one before,what do you mean?
Title: Re: 30 years of storage later, the project begins.
Post by: Nurse Julie on January 03, 2022, 09:54:13 PM
I'mnot sure what you mean by pigtails Ken. Not herad that one before,what do you mean?
I'm not sure what pigtails are but this is the type of attachment we use on the polisher for holding the mops etc.

[attachimg=1]
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 03, 2022, 09:59:01 PM
aaaaaaaahhhhhhhhhhhhhh!



Nice one Julie,I didnt know they were called that,what a weird name to call it!  I didnt even know they had a name.  It's always, "Put them on't bench wheel"" not, "Go wind that onto those pigtails" not heard that reference before.


Cheers Julie x
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 03, 2022, 10:36:06 PM
All sorted, I had forgotten about Bolgers, my Dad used them years ago when he did a lot of wood turning.  Great contact refreshed, thanks all. Now £50 lighter! Its similar to going to the tackle shop; you spend £90 andcomeout with a kilo of wormsand a smallbrown paper bag! ;D


Sorted though, happy bunny!
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 03, 2022, 11:06:07 PM
Now that sounds like a stroke of genius Ken, I'd be really interested to hear your findings on that as that would be a very worth while mod tbh. Ive metal rodsa nd wires in both wrists from a  previous offsome years ago so anything to ease the wrists is spot on for me. Its why I got rid of the 853, I couldnt ride it forlong without pins and needles inmy handsand white finger, which sucked a fat one!

I've nothing set up on Mejima and never had so have no experience of the throttle strength,  have they an issue with 'over officious' carb springs  giving you a dead hand?

A spring that would allow that would be great if they do. The 400 is quite a hand ful too and  The Long Haired General has passed comment on it being a bit strong, similar to the clutch being a bit of a pull. I've ordered a selection of cranked clutch levers to see if I can sort it or I may even swap some springs over with some milder ones I have from a Ducati basket I've got lying about. She's only tiny and finds it a bit of a grab, bless her soit needs a bit of a fiddle to get it right for her.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 03, 2022, 11:07:30 PM
Extra crap typing tonight, decorating done but laptop full of dust and the space bar isnt playing ball! Apologies! >:( ;D
Title: Re: 30 years of storage later, the project begins.
Post by: heli_madken on January 04, 2022, 03:33:17 PM
.... and to aid it I've been in touch with a Chinese spring manufacturer to see if I can get a carb return spring the same dimensions and look as the original but with a much lighter poundage....

Ken, Have you  tried Lee Spring in Wokingham - https://www.leespring.co.uk/?gclid=Cj0KCQiA_c-OBhDFARIsAIFg3ezG4XRpFhEs8SFAWo55rx5dR6HhRYhQia3M99vMiq749VmU05j-_30aAn__EALw_wcB (https://www.leespring.co.uk/?gclid=Cj0KCQiA_c-OBhDFARIsAIFg3ezG4XRpFhEs8SFAWo55rx5dR6HhRYhQia3M99vMiq749VmU05j-_30aAn__EALw_wcB) They have millions of springs and can make to order. You can enter the dimensions of the current spring and choose the weighting you want, perhaps several for experimentation. Might be worth a try as it will be quicker than working with China
Title: Re: 30 years of storage later, the project begins.
Post by: SteveD CB500K0 on January 04, 2022, 04:21:18 PM
That’s 10 minutes walk from my house.

If you need a personal visit I’d be happy to help.

Steve


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Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 04, 2022, 06:57:23 PM
Talking of springs Ken, I had a reply from FLEXOSPRING in Bristol and they need a drawing to even think about making anything, and the old one as a pattern but not one without the other so Unless I can manufacture a drawing of a 1978 CB550f rear brake pedal spring that they can bob into their machine via a stick or PDF format showing angles of dangle, coil diameter, all the 'dims'etc,  its back to the drawing board and or the gas bottle in the shed. I'll try these chaps mentioned above next and see what they have to say. Good contact though,
cheers heli_madken
Title: Re: 30 years of storage later, the project begins.
Post by: Seabeowner on January 04, 2022, 07:08:47 PM
I presume Honda used the strong spring and the closing cable as belt and braces against the throttle staying open under unforeseen conditions. But then had a screw that provided extra friction under the throttle pipe. Confused thinking? When the carbs are closed the spring still needs quite a bit of stretching to fit so they are very firmly closed.
But I just fitted a small strong keyring between the spring and the top fitting and still had to stretch into place. Been on one bike for nearly 20 years, I just occasionally check the throttle closes ok when I let go and check at a few bar positions.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 04, 2022, 07:55:16 PM
The main problem now is the cables, I think that's as far as the original cables can be used as they is little to no play left in them. If I could somehow get the cable clamp closer to the carbs I may be able to get enough play for mod number 2. It could also be that mod number 2 works better than mod 1 and if you can only use the one then use the more more efficient. However mod 1 is simple and anyone can do it, it's fairly cheap to do as well. Mod 2 isn't so simple and requires a lot of work, so mod 1 may prove a lot more popular if indeed it is seen as worth the effort.


Surely wouldnt it be easier to have some cables made up once uyou know the required legnth Len, Failing that make your own, I think the kit I bought was only £15 or something daft. You didnt actually say what the mod was as that sounds the most satisfactory way of sorting it. If youre keeping it quiet until testing, no worries but interested in what ever it might be; I was thinking about poly welding some small plastic cutouts to the throttle tube so that I could vary the distance from closed to open but it got a bit complicated so thought about something else for a bit and then fprgot. Besides I'mmilesaway from there yet bu t at the stage of fitting thenew carb spring I ordered from DSS some weeks ago. Do you remember the picture of it bent up like an S from the PO? ;D

As for spring strength Roo, try this. Get the spring off your 550 in your hands whilst the carbs are apart. Try pulling both ends apart, it's surprising hard for such a small spring, ok you've got leverage with the throttle pipe but it's heavy enough for a softer spring to be really attractive. Even in my youth I got sore wrists after a few hours, so much so that fitting the Honda throttle grip retention setup was done on my 550 switch gear, the 750 and 500 got it as standard but after them they stopped fitting it, it's a god send on motorways as you just tighten it up until the throttle stays open and reduces the wrist ache considerably, in an emergency you can still close the throttle due to the pull/push cable arrangement. It can be fitted to both the 550 and 400 switches and is a fairly easy mod.

 Ive read about thesebefore so i might revisit those blogs and have a look, thanks.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 04, 2022, 08:05:39 PM
Roo, check the cable routing on the 400, make sure it follows the PDI instructions perfectly, remove the cable and hang it up if possible, slowly drop silicon oil (and only silicon oil not normal oil) down the cable until it comes out of the other end. Check the cable first for rubbing spots, sometimes the inner cable can grate against the braided metal sheaving as it's get's worn inward.  Grease the lever pivot pin, grease the actuating lever point on the clutch case as well. Everything must move with little to no effort, the 500 four is renowned for having a heavy clutch but mine was so light I could pull it with one finger, it's all about how it's setup. Test the cable when fitted but not attached to see if it feels like it's snagging or binding anywhere.
Thnaks for all that mate, I'll cast an eye but on the rebuild I've fitted NOS where I could but had to get pattern bits when I couldnt:-

New cables,
spring on the bottom in the cover plate,
 new clutch and springs and plates,
 new sleeve on crank case,
new lever and clamp.
 I think its ok if a little on the firmer side but with Rae being so dinky, finds it a bit of a claw full so anything just to make it a bit easier will help immensly. I have since found the holy grail of the chrome ring that sits on the crank case breather cover the other day in the wrong drawer which I though was well lost so that might make a bit of difference once fitted. Apart from that is as the book describes on the fit. I checked all the cable lengths against all the old ones and the only differing one I had was the speedo as it was miles too long but apart from that all were spot on to fit as required.

I'll have another go before she comes off the ramp but worked great on her maiden voyage up the lane on the sly the other day ;D

Carb work required I feel, oh, and the silencer fitting 8)
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 04, 2022, 08:16:38 PM
fair comment, yup,I'll go with that.
Title: Re: 30 years of storage later, the project begins.
Post by: philward on January 05, 2022, 07:03:43 PM
Great job Ken - I'd have fell asleep on the job at that time of night though (or should I say morning!)

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Title: Re: 30 years of storage later, the project begins.
Post by: Lobo on January 06, 2022, 08:23:50 AM
Hey Ken, I plan to do a fair bit of polishing in the coming months and am asking whether a 350W / 3000rpm bench grinder unit fits the bill. (specifically the 3000RPM bit - ie is it enough?)
My grinder is a Bosch jobby with 150mm wheels, and due the local Bunnings selling a 150mm polishing wheel range I thought I’d stick with this versus your 200mm wheels. Thoughts there?

Cheers,
Simon
Title: Re: 30 years of storage later, the project begins.
Post by: Seabeowner on January 06, 2022, 09:14:33 AM
When the carbs are closed the spring still needs quite a bit of stretching to fit so they are very firmly closed.
But I just fitted a small strong keyring between the spring and the top fitting and still had to stretch into place. Been on one bike for nearly 20 years, I just occasionally check the throttle closes ok when I let go and check at a few bar positions.

 I don't find it hard at all to fit the spring on the carbs BTW, spring puller works great.
The ring is not there to help put the spring in position. It is there so that the spring is not so stretched when in the closed position Therefore it will also not be so stretched when in the open positions = less effort to open.

On the subject of the throttle travel there is probably enough play in the cables of the 500 to increase the diameter of the throttle slightly. But there is not much clearance between the throttle and and parts of the lower clamp. But you could shave a mm or so off internally so it would not show and get 4mm on throttle dia. 14% less travel.
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on January 06, 2022, 09:18:40 AM
All things being equal (and technically the correct way to make the components) the disc size is related to the spindle speed as it's the linear surface rate that's critical. 

Logic follows that they made the spindle rpm for linear cut speed of 150mm stones, and continued with same to size the mops. Increased diameter would usually require a motor with higher torque output to maintain speed under load too.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 07, 2022, 05:24:33 PM
I’m this far into mine Ken and could bob the spring on after me tea and throw a ruler at it. I’m just at the test fit stage with some more to do and all my polishing gubbins came today from Scotland so need   to whip them apart again to get the bar off to polish so happy to pop the spring on if it would help?(https://uploads.tapatalk-cdn.com/20220107/6ab8e09009715065ae28170754e9ef12.jpg)


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Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 07, 2022, 05:26:23 PM
(https://uploads.tapatalk-cdn.com/20220107/bd322c0aae57453968ed2e95c920bd44.jpg)


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Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 07, 2022, 10:15:51 PM
Length of the spring, (brand new from DSS) once on the carbs and under tension is 72.43mm on my set Ken. That’s the actual coil of spring. If you need from top of hook to bottom of hook, let me know. They’re coming apart tmrw to go on the polisher so won’t be able to measure for you buddy.(https://uploads.tapatalk-cdn.com/20220107/4570ce3ca975d423b82fb7f992e71c81.jpg)


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Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 08, 2022, 12:17:13 AM
Ok, so……at rest, hook to hook is 100mm

When the position of the spring is fully extended at max throttle, hook to hook is 113.5mm

This might be +or- a mm only because it’s quite tricky to orientate, hold and measure but out of 5 measures the average came to the above number
Any other dims let me know bud.


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Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 08, 2022, 12:25:10 AM
Hook to hook please Roo and same again fully extended, so full throttle.

Oh and the screws used by Honda to secure the carb top onto the body are too short, they quote 16mm but if you look inside the bottom of the screw hole you'll see there is LOADS of thread left unused, I fitted 20mm stainless JIS screws with a flat and spring washer and even then there was a few threads left untouched. It's no wonder these screw holes get stripped out.

Strange as the bolts used to hold the carb lifter brackets onto the bar are miles too long. What happens then is the bottom of the bolt starts to rust and if you need to remove it then the thread gets stripped out or damaged as it passes through. Same thing on the front of the rocker cover next to the tappet covers.
I was looking at those threads on Wednesday and ended up ordering 2 x 20mm JIS screws  in an attempt to sort that very issue

Hopefully the zinc plating will help things to last a bit longer and not rust with any luck. A good point well noticed though


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Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 11, 2022, 10:24:09 AM
Got a reply back from the manufacturer, he's recalculated the spring rate and at full throttle the pull is 7.94lbs, even at rest is 5.92lbs. Like holding a bag of spuds for a long while, no wonder it hurts after a bit.

I've asked for a price for 20 at 50% spring rate and 20 at 75% spring rate, we'll see what the figures are like when they come back to me.
Well done Ken, good skills mate, see what turns up.

Brake plate looks ace, don’t be so critical, it looks fantastic


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Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on January 11, 2022, 01:02:13 PM
Ken that's a brilliant result on the brake hub - I do not know where you get your energy from you put me to shame!

What's your Moto - Have buffing wheel will polish?
Title: Re: 30 years of storage later, the project begins.
Post by: Seabeowner on January 12, 2022, 08:57:58 AM
When the carbs are closed the spring still needs quite a bit of stretching to fit so they are very firmly closed.
But I just fitted a small strong keyring between the spring and the top fitting and still had to stretch into place. Been on one bike for nearly 20 years, I just occasionally check the throttle closes ok when I let go and check at a few bar positions.

 I don't find it hard at all to fit the spring on the carbs BTW, spring puller works great.
The ring is not there to help put the spring in position. It is there so that the spring is not so stretched when in the closed position Therefore it will also not be so stretched when in the open positions = less effort to open.

On the subject of the throttle travel there is probably enough play in the cables of the 500 to increase the diameter of the throttle slightly. But there is not much clearance between the throttle and and parts of the lower clamp. But you could shave a mm or so off internally so it would not show and get 4mm on throttle dia. 14% less travel.

I'm not sure whether in fact the ring is helping at all, I'm thinking the effort required to stretch it remains the same anyway. Maybe I'm wrong, only way to know is to test it.
The spring is already stretched quite a bit even in the closed position. The ring gives less stretch when closed and therefore less stretch when open. Hookes's law applies over this limited type of stretching.  Stretch length directly proportional to weight required.
But the extra force required to open the throttle from one position to another position will not alter as that is determined by the spring rate so I'll add that a different spring rate will probably give a better result.
Title: Re: 30 years of storage later, the project begins.
Post by: heli_madken on January 12, 2022, 05:51:11 PM
Ken, Tried to email you, If you are taking your previous employer to a tribunal be very careful about mentioning them in an open forum.

Sorry to hear about your health issues it sounds horrendous, all the more wonder at what you can achieve with all that polishing, it is actually quite tiring to do. 
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on January 12, 2022, 10:02:12 PM
Jees Ken that a rough deal - my worry is how long these things take to reach a court. Clearly you need closure like we needed after our house fire. I ended up writing a letter that I never posted to the neighbour who was hosting the bonfire party where a guest fired the rocket that caused the fire (£190k claim).Due to the Data Protection Act the Police would not disclose the details of the person that caused us so much misery to Wendy & I or to my insurers. It sounds daft but I was able to move on after I wrote the letter I never sent to anyone  except to our insurers legal team. Wendy was treated for PTSD some 7 months later whilst we were living in temporary accommodation. Not sure what your coping strategy is but hope it all works out for you.
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on January 13, 2022, 06:12:58 AM
The only funny part about this is when me and my daughter went to the first meeting. I introduced her as my daughter and they were as condescending as hell to her, she didn't say anything all meeting. At the end of the meeting they said hang on while we give you a copy of the notes, so whilst we were waiting for them to xerox them we had a little chat. And what do you do my dear they said, Oh I'm a partner in a large law firm in Manchester and I specialise in Industrial Diseases she said. Well the looks on their faces was worth a fortune, I still smile about it now. After that the next 3 meetings they were walking on egg shells around her. But by then the damage had already been done.

Oh and the Chinese manufacturer has quoted $200 for 20 springs. Not sure about that.

That first meeting sounds priceless - it's often the case that when you struggle with one aspect of your life like health issues something else happens to kick you in the teeth when you least need it. Hope it all works out for you Ken I really do. As they said in The Life of Brian song  - always look on the bright side of life.Cheers Ted
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 13, 2022, 07:02:33 PM
The only funny part about this is when me and my daughter went to the first meeting. I introduced her as my daughter and they were as condescending as hell to her, she didn't say anything all meeting. At the end of the meeting they said hang on while we give you a copy of the notes, so whilst we were waiting for them to xerox them we had a little chat. And what do you do my dear they said, Oh I'm a partner in a large law firm in Manchester and I specialise in Industrial Diseases she said. Well the looks on their faces was worth a fortune, I still smile about it now. After that the next 3 meetings they were walking on egg shells around her. But by then the damage had already been done.

Oh and the Chinese manufacturer has quoted $200 for 20 springs. Not sure about that.


Blinder Ken, that made me laugh when I read it. ;D ;D
Title: Re: 30 years of storage later, the project begins.
Post by: philward on January 16, 2022, 08:59:59 PM
Had a set of those on my CB1100RB before I restored it to original
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on January 26, 2022, 01:25:55 PM
"If it works as planned would it be better to detail it here on this thread or do a complete new thread etc."

Probably worth a new thread if you want dedicated discussion of it.
Title: Re: 30 years of storage later, the project begins.
Post by: SteveD CB500K0 on January 26, 2022, 02:51:45 PM
For future searches, a separate thread would be preferable. Also use a more specific title.

If not bothered, I can copy the relevant posts into a new thread.

I had one of those quick action throttles in the 70s too. It pushed the grip about 1/2” down the bars as it fitted between the grip and the switchgear.


Sent from my iPhone using Tapatalk
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on January 26, 2022, 08:50:32 PM
For rear springs, how about these in gold https://www.hosnti.com/product/grade-5-ti-springs-for-motorcycle-shocks/ no further coating and should be effectively "stainless" in any conditions.
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on January 26, 2022, 10:45:52 PM
You may be lucky, there's quite a demand out there for different sizes along with manufacturing for various scale original kit.

Big market is MTB downhill bikes with monoshock rear suspension, pretty close in size to motorcycle rear (could get a size if you need) along with usual lb rate from 250~650 so plenty of wire guage is in general use.

Title: Re: 30 years of storage later, the project begins.
Post by: Sesman on January 27, 2022, 07:42:31 AM
Second the paramos. It’s the only paint stripper stuff I’ve found that behaves as advertised.
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on January 27, 2022, 08:05:33 AM
Second the paramos. It’s the only paint stripper stuff I’ve found that behaves as advertised.

Yes it's great and at autojumbles it tends to be typically £25 a tin there. The 1st time I bought it, I quizzed the woman selling it, asking if it works OK, as she was recommending it over some cheaper unbranded stuff she was also selling. This was the reply .... 'I can tell you for sure that it works fine for removing paint,  love... my daughter cadged a tin off me and threw it over the roof and bonnet of her ex-husbands car'  ;D ;D

I have also used some stuff at £7/1 litre tin branded 'Final Systems' CS20 and that work well (gel type). OK if you don't want to buy a big tin.

I think any paint stripper that contains methylene chloride and formic acid (y'know the stuff in ant bites, that's why it stings like hell if you get a splash on your skin  :-[ ;D),  it will work pretty well.

All of the paramose I have bought from autojumbles is the runny type but evidently you can get it in gel form too
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on January 27, 2022, 02:10:05 PM
Oddjob "Not bothered about discussion TBH K2, it's a mod for me, if others like it then they are free to copy it, if they don't then that's ok, it's a free world. I am surprised though that no one has thought to tackle this issue, I mean back in the 70s I remember buying a quick action throttle for the 500, it was a sort of small gearbox that fitted between the grip and the switch and the cables went into that instead of the switch, it was bulky, unsightly and if I'm honest not that great but it did reduce the twist needed for full throttle so in that respect it was worth it."

Fair enough.

If you're interested in practical input though;- worked a bit on those some considerable years ago for travel and lightness of operation. A friend on 750 F2 amalgamated (from scrap yard) a 750 switch block by machining off the throttle chamber,  then the opposite from a CB900 with the twin cables exiting in much more gentle arc to weld then finish a hybrid switch/throttle assembly. It may have used a larger diameter pull for the cables which made it quicker. The reduced friction from cable route seemed to give lighter response to allow faster travel without increase in twist grip weighting. Standard carb end was used though I recall.

The springs Honda use appear (yes an assumption) to be most in demand at low slide position when engine over run causes the slides to be most affected by vacuum and risk of not being closed. They look to have set the spring rate to counter this and ensure,  for example, as you roll off the throttle from fast straight into a corner that they could be confident it wouldn't get stuck there.

Coil springs I understand as linear in rate. Which means that if you have to pull it at 2lb to travel 10mm then the next 10mm would require another 2lb. So spring linear response,  but throttle grip accumilative to give that heavy feeling.
They may, with geometry (you'd have to check it) get the initial weight as they want it but with further travel cause the mobile end of the spring to move in an arc above the fixed end, and so deliver an accumulation initially but by not lengthening the spring further it would stay at that. Observation of existing would show that.

If the above isn't true and it keeps accumulating throughout travel, then it's problematic to reduce the overall spring rate as it will most likely affect competent closure of slides but not necessarily improve much.

What it could really do with (it won't fit in though) is a much longer spring application, that's just to let you use the initial rate through the whole pull as the spring moves a very small proportion of it's total accumulation with the carbs at full travel. That would give low end rate to close slides but not get any heavier in practical reality.

Someone (we were apprenticed in engineering) made smaller diameter "butterfly" for the main carb rod where the cables attach, in effect turning an new wheel and then milling off the surplus,  but I don't know what happened to that.
Title: Re: 30 years of storage later, the project begins.
Post by: taysidedragon on January 27, 2022, 06:00:53 PM
If the closing cable got stiff or restricted in action a stronger spring might help to overcome the resistance.  Maybe that's why Honda fitted such a strong spring.
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on January 27, 2022, 06:23:02 PM
I see it the other way in contingency terms. A tension spring has a (albeit remote) risk of snapping in comparison to for example an old single type carburettor slide with a simple coil installed down in the slide bore. The return cable is there to cover that eventuality.

The return is of course pushed back by the twist grip, but should always effectively have slack in it as they are non adjustable (certainly on 750) from Honda design.

If you've ever ridden a 750 with the little nylon sleeve down inside that first tight corner on the pull cable as it leaves the twist grip, then fully closing the throttle at higher revs gives a significant vacuum on the slides,  such that it's hard to start the opening smoothly against that suck. As the revs come down you can feel it gets easier with vacuum diminishing. This area of use seems to demand most from the spring in automatic closing.

The earlier suggestion to use a "key ring"  ? Will actually work as it simply puts less initial accumulated load on the spring before you even start to pull it open.

A functional test could be to remove the spring (not in riding use) and rig up a lightly tensioned bungy cord to the mech, this should demonstrate a long spring with low percentage movement (very low accumulation of tension over the range of use) to see what it feels like.
Title: Re: 30 years of storage later, the project begins.
Post by: taysidedragon on January 29, 2022, 01:40:21 AM
Interesting experiment.  By reducing the butterfly leverage does that increase the force required to open the throttle,  or does the larger throttle pipe radius cancel that out?
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on January 29, 2022, 04:59:01 PM
Interesting to work around these things and assess different geometry.

I've been working a fair bit on MTB bike suspension which has a lot of leverage ratio changes built in, but with adjustment to set up on some of them. Sit there looking at them thinking, right this travels that way, that moves there,  so that must rise ?......right start again.  Some of the swingarm run seperate from frame on two individual levers and so effectively float.  Look like they'll collapse if set down on the floor, but incorporate anti squat during pedalling, running to soft mid range travel,  then ramping up toward the end to take a big compression from jump landings. Coil springs using a rising rate with air springs needing a reducing rate linkage as they naturally accumulate higher spring lb as they are compressed.

A thought about throttle travel;- you could bring the nipple location much closer into the spindle, but leave the cable channel out at it's original radius.  This would give you initially soft throttle just off idle but gain speed through progression the further you open it.  In effect a progressive rate but with overall shorter travel.
You'd have to do the same for return cable too in avoiding potential conflict.
Title: Re: 30 years of storage later, the project begins.
Post by: Lobo on April 02, 2022, 10:16:12 PM
Very neat Ken.

Strangely I had a Voltmeter (0-20V declared range) that came in 4 colours jury rigged into my 400F, whilst I was trying to ‘understand’ the Voltage Regulator vs RPMs.

The highest voltage I saw was 14.2V, and yet the bloody thing blew in a very short time. Cheeky I know, but can I suggest you wind the voltage up to specified near max for a few minutes on the bench to check it didn’t come from the same Chinese shop…. before committing to buttoning the Speedo back up.

Title: Re: 30 years of storage later, the project begins.
Post by: Oddjob on April 02, 2022, 10:31:53 PM
420
Title: Re: 30 years of storage later, the project begins.
Post by: Trigger on April 02, 2022, 11:01:24 PM
I can not see the point in a volt reading, if a SOHC is set up right you should never have any problems with the electrical changing system on a standard set up.
Title: Re: 30 years of storage later, the project begins.
Post by: Oddjob on April 03, 2022, 03:22:42 AM
421
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on April 03, 2022, 10:58:20 AM
There was a lot to be said for the old style Charge/Discharge analogue gauges. I have a vague memory of trying to ride home before the battery gave out switching off the lights on well lit roads. Just can't remember what bike it was did old Triumph Twenty Ones have a white faced gauge in the headlamp bowl?
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on April 03, 2022, 12:29:53 PM
Nice shuttle mod, with the volt gauge. Watch all the Millyard videos too, remember seeing his mod on the Kawasaki, wish I had a fraction of that guys engineering skill.
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on April 03, 2022, 04:34:25 PM
Very neat Ken.

Strangely I had a Voltmeter (0-20V declared range) that came in 4 colours jury rigged into my 400F, whilst I was trying to ‘understand’ the Voltage Regulator vs RPMs.

The highest voltage I saw was 14.2V, and yet the bloody thing blew in a very short time. Cheeky I know, but can I suggest you wind the voltage up to specified near max for a few minutes on the bench to check it didn’t come from the same Chinese shop…. before committing to buttoning the Speedo back up.
An 18v zener diode across the feed voltage with a suitable series resistor will protect it... Ken I can send you the bits if you wish.
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on April 03, 2022, 06:22:47 PM
The meter has 3 wires Ash, ones earth, ones feed and ones the voltage sensor. Which is best to protect it, I think feed but I'll defer to your judgement.

Can you send me details of the module Ken and then I can advise better.
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on April 03, 2022, 08:53:48 PM
I'll send you one Ash, might be better.

OK ..Sounds good ...  I will add mods for you and send back
Title: Re: 30 years of storage later, the project begins.
Post by: Trigger on April 04, 2022, 12:01:36 AM
Parts fail, it’s a safeguard against that. Also an early warning indicator of when they start to fail. If it prevents even one incident of a roadside breakdown then it’s done it’s job. Plus I think it looks cool.

I’ve never been and never will be one of those who think that original must be best, my bikes are built to suit me and that includes changing anything that I consider to be wrong from the start, the single fuse on the 500 being a prime example, how anyone can think that’s a good idea is beyond me, if it blows the bike stops, if you can’t find the fault your either walking home or getting a mate out with a van etc. After having one blow in a dark country road in Devon one night whilst on my honeymoon and trying to fix that in the pitch black I vowed never to go through that again.

This bike will have a combined reg/rec, mosfet type, they are more reliable and better at controlling the output than the mechanical regulator Honda fitted. Plus the charging system is being updated to provide more power. The volt meter provides a way of monitoring the new system, to be honest I got the idea from Alan Millyard after seeing him fit one on his 6 cylinder Z1 Kawasaki, I liked the look of it in the video so decided to copy it for myself.

As for never seeing any problems on a standard system, how many 500 fuse wires have you seen melted, fuse holders almost falling apart due to burning. It’s not being set up right that’s the problem, it’s coping with parts well past their intended life expectancy, connectors going blue etc. Wires just breaking where they are crimped to the spade connectors, if just one of those happens whilst on a ride and you don’t notice, you risk an electrical fire at worst or a breakdown at best, seeing the voltage start to drop could warn you that there’s a problem, giving you time to head for home before it gets worse.

I have come to the conclusion that the standard electrics good and have never had a problem with them even when they are more than 30 years old. Out of the six SOHC's we have on the road, 3 of them run with a single standard fuse box 
( non of mine show any signs of melting) and in the thousands of miles we have put on those bikes Julie has only been let down once with a flat tyre less than a mile from home.

I did go down the LED path with my silver 550 ( lets build a bike for a grand ) and found that the stop and tail lights were not as bright as an original bulb. All the led bulbs blow within 100 miles and the number plate lights just melted. Ash kindly made me a box of tricks so, i could run the number plate LED lights. All the rest apart from the cob led head light bulb have been put back to standard bulbs. For some reason that cob led bulb still works today and that is the most important light on a bike. On that bike my conclusion was, that if you mess about with the original electrics then, they become unreliable and will let you down  ;) 
Title: Re: 30 years of storage later, the project begins.
Post by: Bryanj on April 04, 2022, 05:28:59 AM
Just to throw my twopenorth in here, the 3 fuse box i have seen melt several times, i think its because you have to "clip" the fuse in and out whilst the single fuse has a complete round fitting so it slides in and out which i believe cleans it so reducing resistance.
Simply for convenience of supply i fit a blade fuse holder if using original loom but keep the original if nos loom.
I had many odd electrical problems when in the trade, mostly caused by owner error and the only bad regulator i had was on one of my own where the contacts would "stick" on half charge but start working again at the next pothole, similarly the only stator fail was on another one of mine where there was a broken wire where it had been dropped on the floor, soldered it back together, insulated it and caried on for years.
I believe these bikes were well over speced and have lasted well, hopefully to carry on for much longer
Title: Re: 30 years of storage later, the project begins.
Post by: Trigger on April 04, 2022, 06:39:52 AM
Same here bryan, i have never seen an old 3 honda fuse box without any damage. Even ones that still have the cover on them.
I must of bought 100 single honda type fuse holders 5 years ago and have only sold 5 in that time via ebay and the forum so, owners never seem to have too much trouble with them   :'(
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on April 19, 2022, 07:30:57 AM
You can strip chrome (reverse plating) with a stainless steel cathode and caustic soda solution and make the part to be stripped the anode. Be careful with the electrolyte afterwards .. if the original part was plated with the nasty hexavalent chrome (which it probably was in the 1960's & '70s), then the stripping solution will contain it afterwards (i.e it will be tinged yellow). The Gateros stuff is probably just a strong alkaline solution. Nickel definitely has a slightly yellowy tinge to it. Worth asking Gateros if their stripper has additives to convert the chromium deposited in in the solution to something less toxic.

Nickel is  more difficult to strip .. I got some stuff from Youplate but not tried it yet although with all of those strippers, using reverse current rather than just dipping  is the quickest method and will probably be kinder to the base metal.

The way I check for all removal of nickel is to give the item  a quick dip in acid copper solution.. .. this solution will give you a thin copper plate, which removes really easily (doesn't adhere) as you can't directly plate acid copper onto steel, without a nickel strike plate first (they used to use cyanide copper directly onto steel in the 'good old days'  ;D. Any areas with nickel still present will show up easily, then you just buff off the copper. The acid copper is simply a mix of copper sulphate and weak sulphuric acid... Garetos sell it I think or it's available on eBay. That copper method is used by old school engineering guys for marking out steel .. i.e. a thin removable copper layer .. a bit like the blue stuff commonly used now.

Can't say a lot about the power unit ... as I said in a previous post both myself and Caswell Europe (was owned by Motoclassic in Hamphire) tested that same supply and deemed it very poorly built and basically not fit for purpose. We had the same problems as you and I stripped one down and the build quality was awful. If you connect a cheapo mulitimeter in series with the positive lead on 10A range you can monitor the current properly. I didn't trust the digital meters on that cheapo unit. Just calculate the current required .. typically 0.1A/square inch of surface area for most plating, possibly higher for stripping but Gateros will confirm that.
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on April 19, 2022, 09:35:51 AM
As Ash has identified some very toxic waste that needs proper disposal certainly not into the sewer.
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on April 19, 2022, 10:33:39 AM
As Ash has identified some very toxic waste that needs proper disposal certainly not into the sewer.

True and most chromers ...even the guy in Hull ...happy to just strip parts for you .... just tell them you are going to paint or powder coat them. Not a lot of money and they actually strip in the chrome bath in reverse plate mode. Turnaround usually a week at most. Personally, unless it's a valuable part you don't want to trust with somebody else, I would leave stripping to the pros.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on April 19, 2022, 11:59:59 AM
I stripped the chain guard and the headlight ears down to the metal with Caustic drain cleaner. Wet them up , pop in  jug and gently pour on top and stand back, plenty of fizzing and bits coming off before being consumeed by the solution. They rapidly turn orange afterwards so I'm prettu sure they are down to the metal and ready to be cleaned up and worked  on.

I used the stuff from the builders merchants that you have to sign a disclaimer for.....(in case you accidentally drink it and decide to sue ;D).
Its a behoind the counter job and is pretty evil stuff, you open the bottle and it bloody chuckles at you :o

Its nasty stuff and has sulphuric acid in it so works in about 20 mins. I did the exhaust clamps too and theyre really spotless now. Just thought I'd mention it as it works so well and all for a tenner 8)
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on April 19, 2022, 01:39:32 PM
I stripped the chain guard and the headlight ears down to the metal with Caustic drain cleaner. Wet them up , pop in  jug and gently pour on top and stand back, plenty of fizzing and bits coming off before being consumeed by the solution. They rapidly turn orange afterwards so I'm prettu sure they are down to the metal and ready to be cleaned up and worked  on.

I used the stuff from the builders merchants that you have to sign a disclaimer for.....(in case you accidentally drink it and decide to sue ;D).
Its a behoind the counter job and is pretty evil stuff, you open the bottle and it bloody chuckles at you :o

Its nasty stuff and has sulphuric acid in it so works in about 20 mins. I did the exhaust clamps too and theyre really spotless now. Just thought I'd mention it as it works so well and all for a tenner 8)

If it's the stuff I am thinking of, then  it's almost neat concentrated sulphuric acid plus some other additive. There is a place in Hull makes a version of  it called 'One-Shot' . drain cleaner ...  .really nasty stuff  ... not sure how they are able to sell it really .. but as you say you have to sign for it. Bloke behind counter said .."Do you know who John George  Haigh was" So I replied "Yea he was the acid bath murdered from Crawley" and the bloke replied 'Well this stuff is three times as strong as the stuff he used ... Sign here!

Not sure how gentle that is to the base metal particularly if the part is badly pitted to start with but if it works for you fine.

Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on April 19, 2022, 09:24:46 PM
As I suggested earlier Ken if you can connect a digital multimeter on 10Amps range in series with the positive lead and you can achieve the desired current by twiddling the knobs then go with that.

I use an industrial laboratory  type bench supply with adjustable accurate current limit  but they tend to be a bit expensive something like this.

https://www.ebay.co.uk/itm/275054250693?hash=item400a82cac5:g:elAAAOSwss1hrgJ2

 Only 4A which would be  fine for me but depends on the sizes of items you are plating. There are a lot of cheapo ones out there but you basically get what you pay for. Also ideal for testing electrical components on the bike. I treat something like this as being an item that you will always nearly get all of your money back if it becomes surplus to requirements .. a cheapo Chinese one will only really be fit for the bin.
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on April 22, 2022, 11:36:00 PM
Looking good then Ken .... Yes agree on the copper left behind ..Prestige can't remove the copper as it needs a cyanide solution I gather, which is too nasty for them to handle. I think they just buff it  all off. When I took some parts to Allenchrome they just buffed the copper and nickel and chrome plated over it if it wasn't pitted. Is that R&S you are going to in Manchester for chroming?
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on May 12, 2022, 03:12:49 PM
Ooooh, they look very nice Ken  :)
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on May 12, 2022, 03:15:23 PM
Very, very, very nice  ;D ;D ;D

Just looked again.
Title: Re: 30 years of storage later, the project begins.
Post by: Oddjob on May 12, 2022, 08:08:07 PM
433
Title: Re: 30 years of storage later, the project begins.
Post by: Laverda Dave on May 12, 2022, 08:45:57 PM
You can see the quality in those Ken. Shame to hide them inside the engine!
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on May 13, 2022, 12:11:08 AM
They look fantastic Ken, really top notch mate 8)
Title: Re: 30 years of storage later, the project begins.
Post by: Bryanj on May 13, 2022, 01:03:15 AM
Might be bloody expensive but at least available!
Title: Re: 30 years of storage later, the project begins.
Post by: philward on September 10, 2022, 10:05:17 PM
Looks like you have had it chromed Ken - top job again

Sent from my moto g(50) using Tapatalk

Title: Re: 30 years of storage later, the project begins.
Post by: Lobo on September 10, 2022, 11:32:20 PM
Good lord Ken, I’m in awe of that finish; just don’t know how you do that. My polishing is ok, but plateau’s well short of your chrome-like finish… amazing.
Title: Re: 30 years of storage later, the project begins.
Post by: SPR on September 11, 2022, 07:43:26 AM
That looks superb ! All three of my casings need work but suspect I'll not get them to that standard !!

Simon
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on September 11, 2022, 07:48:14 AM
Great work again there Ken. My problem is if it’s not shiny in 10 mins, I’m bored with it! 🤣
Title: Re: 30 years of storage later, the project begins.
Post by: Sesman on September 11, 2022, 07:59:12 AM
Those parts look really nice. Out of interest, how would you achieve a satin finish? I was thinking of trying a satin finish and lacquer.
Title: Re: 30 years of storage later, the project begins.
Post by: Rozabikes Tim on September 11, 2022, 08:29:32 AM
Great work again there Ken. My problem is if it’s not shiny in 10 mins, I’m bored with it! 🤣

I recon Ken was a parade guardsman with shiny boots. Final finish on these alloy bits is spit and polish I would imagine. Super stuff.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on September 11, 2022, 12:32:00 PM
Thankfully , I think Ken is off the 'DO IT RIGHT' crew and he has a bit of time. He is teh Forum's cheif polisher now though, the official 'Bling Master'

Stunners as ever Ken, too much of a filthy job for me, bloody hate it but my hatred of polishing has been muted on here before. Hats off not just for the technique but the staying power, did I tell you I hate polishing? ;D


The bits I've done in the past through necessity have come out well but not after sanding for hours. I use ABRANET sheets that you can get on ebay in assorted sizez, it wears much better than wet n dry and works out a bit cheaper. I got the tip from watching Alan Millyard do his bits in the shed, utter genius.   But, like Ken says, all about the pre work, sanding ally is a horrible job but if you've the time and the will, results like Ken's can be achieved to a fantastic finish as Ken shows on here. Well done mate, they look the cats swingers mate.

Title: Re: 30 years of storage later, the project begins.
Post by: Rozabikes Tim on September 11, 2022, 12:55:50 PM

Well done mate, they look the cats swingers mate.

That's a new one. Are cats parts seen as better value than run of the mill canine tackle ? (maybe a stronger bag?)
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on September 11, 2022, 01:21:07 PM
Usually a better class of bollock thabn the canine items mentioned.... ;D


This chap does a mix bag of vrious grits Ken, at leastthen you dont need to buy loads and y0u get to see if its good fpr what you want for only a tenner. I've found this the most cost effective but appreciate that you have a load of stuff to do so get some and count it as an experiment.

Slept in before joining up, love it..................Probably not the right mind set there for the Navy, eh? ;D


https://www.ebay.co.uk/itm/322284949822
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on September 11, 2022, 01:44:18 PM
 ;D ;D My thoughts exactly mate,  ;D ;D ;D
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on September 11, 2022, 03:07:57 PM
Great work again there Ken. My problem is if it’s not shiny in 10 mins, I’m bored with it! 🤣

I recon Ken was a parade guardsman with shiny boots. Final finish on these alloy bits is spit and polish I would imagine. Super stuff.

Ah "Bulling" boots with Parade Gloss shoe polish by KI-Wi that was part of the old police initial training - spending hours with a dab of cotton wool with spit to lubticate the polish - tiny circles was the key.
Title: Re: 30 years of storage later, the project begins.
Post by: Lobo on September 12, 2022, 01:25:42 PM
Once the piece is polished, is it protected by residual soap, or is it better to wash the soap off with turps, clean it and then apply (eg) an Autosol / metal polish type product?
Title: Re: 30 years of storage later, the project begins.
Post by: Lobo on September 12, 2022, 09:36:04 PM
Well, that answers my strange goings-on Ken. Occasionally I’ve had some very impressive polishing (relatively!), and been dead chuffed. I’ve then ‘turped’ them, and Autosol’d them… only to be disappointed, and left figuring it was never that good anyways… all in my head etc.
Kinda regretting now that I’ve done the above on everything I’ve polished. 🙁
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 27, 2023, 10:32:53 PM
That looks a great do Ken, nice one. It took me three goes to get mine looking good. Your's have come up a treat how terribly satisfying
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on January 28, 2023, 07:16:52 AM
Great attention to detail Ken..How easy was it to remove the orange letters intact? Some later model  CB250/350K badges have that same colour emblems. I have some water clear resin that I might try tinting orange with candy paint concentrate (I also have yellowy gold) to mix to adjust the colour. With that you could re-cast the letters or perhaps you could mix up some 2-pack clear coat lacquer un-thinned and tint that orange and try that.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 28, 2023, 11:04:33 AM
I'll bob you a selection of brushes in the post Ken, I've hundreds so I wont miss them. It'll be some time this week as Ive summut for Phil in York too to post.
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on January 28, 2023, 09:42:28 PM
Nice job on the emblems Ken! Good to know that these can be removed.
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on January 28, 2023, 10:06:33 PM
Just noticed Ken you are in year four of your project - looking forwards to plenty of pics when the assembly really gets going.
🏍️🏍️🏍️
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on January 28, 2023, 11:59:46 PM
The F on the 500s badge is a doddle to remove, it doesn’t look it but it’s not a perfect fit, there’s usually a gap somewhere, usually on the bottom edge. Get a Stanley knife blade and just force it in and lever gently up, the glue used looks like double sided tape tbh, as soon as the bottom edge lifts slide the blade in further to minimalise the risk of it snapping. I’d imagine other badges from that era used the same method.

I have quite a few of the orange Fs, kept them from broken badges, Menno sent me a few some years ago.

I have some orange acrylic sheet to make some new inserts, the surface isn’t flat it’s domed, so cut the acrylic to the correct shapes file into shape and then quickly subject it to a blow torch flame, this melts the upper surface and gives it that glassy look that it has as standard, back with gold leaf and it should look authentic.

You are correct Ken I looked at one of the NOS ones you sold me a couple of years back and the orange 'F'  is an insert not cast in. I wonder if you could make a silicone mould of one and cast some inserts,  using the orange dyed resin I described though.
Title: Re: 30 years of storage later, the project begins.
Post by: andy120t on January 31, 2023, 06:57:59 AM
A quick search gave me this link for 3-D printing badges. For a 550, but how easy would it be to create the files for the 500? It might then need a separate piece for the ‘F’ insert, or paint the surface with orange/gold flake.

https://www.thingiverse.com/thing:4868497
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 31, 2023, 07:12:32 PM
having never hd any experience of 3D printoing, is that just a program that you vou can download and then presumably get spomepone to print?
I've hot even looked at side panel badges yet and it kind slipped my mind that I haven't got any at all. Are they 'hen's teeth'as I  better get looking I suppose? ::)
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 31, 2023, 07:34:44 PM
Just had a look and it appears that they are decals, but you lot already knew that ;D

Well I don't like those so might have to do something a little different and quite like those you've been doing up on the thread Ken, are they off a K something then? They look great and as the bike's going to be a type of orange, those would be a  great alyternative.  Not keen on decals and quite like badges and these would suit the tank badges Ive done for her. Would that be considered  a 'frowned upon' move?
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on January 31, 2023, 08:08:52 PM
Just had a look and it appears that they are decals, but you lot already knew that ;D

Well I don't like those so might have to do something a little different and quite like those you've been doing up on the thread Ken, are they off a K something then? They look great and as the bike's going to be a type of orange, those would be a  great alyternative.  Not keen on decals and quite like badges and these would suit the tank badges Ive done for her. Would that be considered  a 'frowned upon' move?

Allankelly on here may be able to offer you more insight roo. I believe he's producing in this sort of area for RD yamaha owners.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on January 31, 2023, 08:32:28 PM
good shout, I'd forgotten that.  :)
Title: Re: 30 years of storage later, the project begins.
Post by: Bryanj on February 01, 2023, 12:52:03 AM
The us 550 K0/K1/K2 had badges like the 500 that said 550, maybe ebay.com?
Title: Re: 30 years of storage later, the project begins.
Post by: Sesman on February 03, 2023, 02:36:08 PM
Very nice results Ken, thanks for sharing.
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on February 03, 2023, 03:45:19 PM
Very nice results from reasonably priced coaters there Ken. But sounds like you’ve done most of the time consuming work. Regarding the handlebar switch casing, had it been repaired on the rear mounting screw threads. (Noticed perforations)
Title: Re: 30 years of storage later, the project begins.
Post by: Seabeowner on February 03, 2023, 07:21:33 PM
Thanks for posting this. You're doing the experimentation for all of us. Finish on the switches is good and alternative to just aerosol spraying to improve the fading anodising.
Phil
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on February 03, 2023, 07:37:24 PM
You did most of the work mate but they all look absolutely bob on. I'm just waiting to get paidand finish the rear mudguard and I'm sending the pipes and the guard up for the same. The chap is dead friendly too, especially as I'm a Yorkshireman and we cant be arsed with anybody ;D

Super stuff mate and a top price bud ;)

Has it increased the size of the spindles by much if at all, alyhough a gnat's chuff is appliedm it must have some size increase overall?

The zaust clamps are epic, I had mine chromed as I couldnt face rubbing them down to how you have although yours look far nicer and as you say shouldnt deteriorate as fast hopefully. I'd be really chuffed with that lot. Even the master cylinder is supurb, might take mine off and have it done, even though I've painted it as I love the finish youve got on that, its ace. ;) :D
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on February 03, 2023, 07:39:26 PM
Forgot to say, that badge for the 13 looks amazing, go on, how much did that rush yer? Something like that for Mejima would be superb. Bob up some shots of the rims,bet theyre spot on too aren't they?
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on February 24, 2023, 11:23:50 AM
All looks really good Ken.

Are the Brembo a straight swap onto existing mount or do they need different brackets?
Title: Re: 30 years of storage later, the project begins.
Post by: taysidedragon on February 24, 2023, 11:38:15 AM
I do love a bit of brake porn in the morning!  🙂
Title: Re: 30 years of storage later, the project begins.
Post by: taysidedragon on February 24, 2023, 12:12:45 PM
Need new pad pins for the Brembos, £65 for 4 pins, bugger that.

Ouch! Must be gold plated.
Title: Re: 30 years of storage later, the project begins.
Post by: Oddjob on February 24, 2023, 01:09:34 PM
455
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on February 24, 2023, 03:32:36 PM
Those wheels look fantastic Ken and the stoppers are fab. Had those on the 748R and they're bloody effective. I think I had Carbon Lorraine pads in mine and like you say, little dust and they're hand stand inducing once deployed in anger!

I did a steel line swap on the VFR, including the clutch, there's 14 braided lines on it! similar to what you found, bloody lines everywhere, it's some monster plumbing!!

New lines, pads and EBC discs however, work brilliantly and probably the best set up I've had on her!
Title: Re: 30 years of storage later, the project begins.
Post by: Sesman on March 06, 2023, 03:56:58 PM
Very nice Ken. I’d say that’s a success. Put them with the shells for me.😁👍
Title: Re: 30 years of storage later, the project begins.
Post by: Sesman on March 06, 2023, 04:26:38 PM
I was hoping to visit Nick, but I’ll have to take a risk, choose a colour finish and post.

If James can sort me out with a seat pan I’ll have them powder coat it as you suggest.
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on March 06, 2023, 08:25:19 PM
These brackets have turned out great Ken. Lot of work gone on there.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on March 06, 2023, 10:44:11 PM
Better than brand new. Good work mate ;) :)
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on March 07, 2023, 01:38:11 AM
have you used the fine wire wool and autosol method Ken? Gis a look when youve done em...
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on March 07, 2023, 09:06:11 PM
These look great Ken, that coating is the dogs, they just look like SS springs.
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on March 08, 2023, 07:20:57 AM
Ken, your posts here has made me look at these rusty bashed up old parts in a different light. Probably chucked stuff out I shouldn’t. But glad to say every days a learning day.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on March 08, 2023, 03:00:16 PM
I'm having a go at the petrol cap on mine at the min Ken. Being steel it has bloomed a lot but its coming on really well. My question is though, albeit it will be flat, smooth and probably polished to death, (Sensai ;) :D), What would stop it going rusty again now that the surface is all done because it will only be bare steel really? Would petrol  resistant laquer be the way to go or that canuba wax gubbins you mentioned ages ago and I still havent bought yet?

Obvs, my cap sits under the fuel flap so is covered but I dont want to open the tank at the petrol station and see a crap petrol cap. AND I'm determined to use it! 8)
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on March 08, 2023, 03:18:36 PM
Ken, it’s commendable work! My petrol cap had been painted along with the tank, nice coordination? No hyena probably just couldn’t be arsed to cover it up. Thankfully like they should have done, they didn’t roughen the surface before painting. Just stripped the paint and the chrome wasn’t in bad nick.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on March 08, 2023, 04:28:39 PM
It was just between the pipes, I cant get in with one of those sadly, did think that..

If I zinc plate it dont you think it'll look a bit naff? I was hoping to open the flap, (leave it Phil), and be dazzled by shiney! I'll put a piccy up on my thread a bit later on and you see what I mean.......
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on March 08, 2023, 06:06:15 PM
I shall investigate..............cheers bud, hadn't thought of nickel.
Title: Re: 30 years of storage later, the project begins.
Post by: taysidedragon on March 10, 2023, 08:28:52 PM
Reply from Philpotts today.

To hard chrome the 2 damper rods is £110 per rod, how the hell is that justified. I bought 2 NOS rods from Italy the other year, after the dreaded B word, for £70 a pair. I was going to have the old ones redone and sell them on but how could you do that if they already stand you at £220 not including the cost of postage back and to Luton.

I guess they don't want to do it. ☹
Title: Re: 30 years of storage later, the project begins.
Post by: mickwinf on March 24, 2023, 05:19:20 PM
They look really good Ken.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on March 24, 2023, 05:48:56 PM
They look great, love the green detail


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Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on March 27, 2023, 11:03:24 AM
Jesus Ken! Sun hits that and it’s instant black out,🤣 I can honestly say I have never seen a carb body shine like that. Would love to see a bank of shiny ones. Great work! “King of Bling” strikes again!🤣
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on March 27, 2023, 12:51:23 PM
Me n Phil have 550’s

Just saying……


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Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on March 27, 2023, 12:58:12 PM
That carb body is well Bling Bruv Yo-Yo.  8) 8) 8)
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on March 27, 2023, 01:18:12 PM
I blame Wendy for all sorts of stuff I can't find both in the house & garage - to be fair I think its an older  bloke thing we just forget where we put things we blame the usual suspects  can't possibly be our male memory can it? lol
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on March 27, 2023, 01:26:24 PM
No Ted, it’s definitely them!

Go on then Ken, if I have to I’ll do the fourth one, you just get the other three sorted then for us

Offer accepted


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Title: Re: 30 years of storage later, the project begins.
Post by: Bryanj on March 27, 2023, 02:17:01 PM
NO, we are perfectly sane and have put them somewhere safe, its just that this place is interdimensional(like sock holes) and different every time!
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on March 27, 2023, 02:36:58 PM
I put some bits in an extra safe place then can't find them when needed. >:( >:( >:(

I suspect safe is sometimes just stupid. :-[ :-[ :-[

At this point I mentally blame she who must be obeyed. ;D ;D ;D
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on March 27, 2023, 02:39:36 PM
Of course, it's the law! ;D ;D
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on March 30, 2023, 09:19:49 AM
Nice looking seat base - what are you doing about the foam section have you sourced a replacement - they do seem to deteriorate quite badly?
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on March 30, 2023, 10:10:27 AM
That looks well Ken, Honda only do it so you get an opportunity to catch them out and then moan about it ;)
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on March 30, 2023, 10:57:53 AM
Seat base is looking brill Ken. I don’t think Honda was fully committed to anti corrosion! Or correct bolt length.
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on April 20, 2023, 11:48:59 AM
That's a fair bit of work you have done there. I empathise with spending time looking for parts. My solution took time I spent a couple of days doing an inventory of all my plastic baskets that contain my various 500 parts. I lettered the baskets with a pen starting with A currently my highest is L. Where bulky parts are elsewhere I record what's in the Garage Loft, my bedroom wardrobe (clocks) my office floor etc.
A brief description of the contents of a box is then listed on a spreadsheet. New parts are currently stored in a cardboard box with contents listed. I rarely print off a boxes contents I have a PC in my garage office so easy enough to update or check what's where. My baskets are stored on shelves so even if I put one back on the wrong shelf the lettering is still there.

I also have a work log where I record what I have done and flag up in red things that need torquing up with desired settings. As this is a hobby I have the time to be meticulous with written records & photos. Like most filing systems once it's in place really easy to maintain.
So Ken I guess it's a personal  choice in the end - just think of all the saved time you could spend doing one more buff up instead of looking for parts. My search for a brake return spring that I never actually had was the catalyst for my orgainisational phase.👍👍👍
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on April 20, 2023, 04:21:48 PM
I write a list,buy it, it then goes in the new bits box fopr teh 550.
Anything thats shagged gets slung in the scrap or the 'might make something with that lot and the welder in the future, maybe'  pile, yer know something to sit and go rusty in the garden or something.

Simple system, seems to work ok but like you Ken, I have to go through the newparts box if Iwant to find anything which is a bit tiresome but we like simple and do it quite well. 8)
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on April 20, 2023, 06:09:23 PM
Nice to hear she’s starting to come together Ken. Very satisfying when it comes together.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on April 21, 2023, 12:09:41 PM
Result! Nice one

All plating in the post, recorded del bud, going to your lasses work


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Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on May 23, 2023, 08:48:57 PM
So where will you fit the headstock nipple Ken or are you fitting two = that will be a lot of grease in there to reach top & bottom?
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on May 23, 2023, 09:09:12 PM
That’s interesting Ken regarding your ill fitting or unsupported seat. I’ll certainly be checking mine to see if it’s supported.
Title: Re: 30 years of storage later, the project begins.
Post by: gary123 on June 08, 2023, 06:28:39 PM
Ive got a couple of the 550 ones, at least I think they are going by your pics. You can have em for nowt but cant get to PO till next week.
Still got your address, Ill let you know when they are posted.
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on June 08, 2023, 06:43:04 PM
Nice work there as usual Ken! I have a set that came off my 550, that has spurred me on to do something with them. Maybe a winter job?
Title: Re: 30 years of storage later, the project begins.
Post by: Laverda Dave on June 08, 2023, 11:26:48 PM
You must have the patience of a saint Ken to grind and polish every clamp but without doubt they are a think of beauty. Having the 409 clamps re-plated in chrome, yes they rust the first time the bike is taken out in the rain or washed!
Title: Re: 30 years of storage later, the project begins.
Post by: Matt_Harrington on June 09, 2023, 09:20:18 AM
Ken, that is a labour of love. Last time I had some chromed for an old Triumph, the polisher almost polished the fins away, so I may try and emulate you next time.
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on June 09, 2023, 10:25:51 AM
So I take it the recommendation is to have them ceramic coated rather than chromed?
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on June 09, 2023, 01:32:45 PM
Thanks Ken! That’s a very comprehensive reply to my question. I have a cheap version of the Dremel, Lidl’s best. Won’t be a massive loss should I burn it out.
Title: Re: 30 years of storage later, the project begins.
Post by: gary123 on June 13, 2023, 01:57:45 PM
Ive got a couple of the 550 ones, at least I think they are going by your pics. You can have em for nowt but cant get to PO till next week.
Still got your address, Ill let you know when they are posted.


Posted
Title: Re: 30 years of storage later, the project begins.
Post by: gary123 on June 14, 2023, 11:13:49 AM
You've certainly got more patience than me.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverda Dave on June 15, 2023, 09:42:34 AM
You are a true perfectionist Ken. Not wishing to put any pressure on you but when do you think the bike will hit the road?
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on June 15, 2023, 05:59:59 PM
Ken! Thanks for the heads up on the rotary tool! I will be interested to see how you get on with the Draper!
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on June 21, 2023, 10:34:33 PM
Nice job Ken! Better than new. We’re they coloured originally?
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on June 22, 2023, 12:03:17 AM
That’s a sound little tweak on making it easier to see


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Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on June 22, 2023, 09:02:56 AM
Love the colours Ken I use white or yellow paint as it shows up well with a strobe - never tried green I would worry it might be too dark.
Never tried two tone either - neat.
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on June 25, 2023, 03:26:57 PM
Ok Ken, that sounds like I’ll avoid that one. That’s a pity when it showed promise with having extra power.
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on June 25, 2023, 03:48:47 PM
What about something like this for initial and heavier application https://www.ebay.co.uk/itm/115837107903 may need collet adapter to use different size tools.

110v @ 710w

There's Makita made too with 240v supply available.
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on June 25, 2023, 03:50:14 PM
No gratuity or sponsorship was paid directly or indirectly  for mentioning Dremel - other inferior brands are available.
Title: Re: 30 years of storage later, the project begins.
Post by: gamma on July 05, 2023, 06:56:56 PM
Just read your project Ken for the first time. Like the attention to detail, I am of a similar disposition, that’s why it all takes sooo long😃
Interestingly I had a set of those beautiful Stradas on a CB750 F1 that got stolen in Germany in 1980. It also had Raask rear sets and other good bits like finned covers.
I also like all the parts to look clean and polished, and spent god knows how many hours achieving this. I probably could have done it all quicker if I had you used a bench grinder with polishing wheels
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on January 30, 2024, 05:40:29 PM
Good to hear of your progress too Ken. I think the bar is high as far as your standards are with your project but cant fault you for that. Admire your attention to detail
Title: Re: 30 years of storage later, the project begins.
Post by: davidcumbria on January 31, 2024, 06:47:29 AM
Looking forward to seeing the rebuild progress Ken. As I  finish mine I wish I had spent more time like you preparing the engine and frame before painting and powder coating. Fresh paint shows up the defects more.
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on January 31, 2024, 08:33:58 AM
Interesting write up Ken my 400 has some odd areas like the rear axle spindle that I should have had zinc plated or similar. To keep costs sensible (failed on that) I just used a cold black pasivation process - now it has sprouted some surface rust.

Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on January 31, 2024, 01:28:11 PM
Ken, we can all learn from you that’s for sure, I remember seeing your springs and they were impressive just looked like polished stainless. I too have the brake rod and brake torque arm chrome plated, and does look good. I’ll keep an eye on it as far as corrosion goes. Although I’m not running in the wet or winter. Also had the brake pedal pivot shaft chromed too. Definately want to see you bike when it’s done Ken even if means a run to Cheshire.😂
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on January 31, 2024, 07:55:20 PM
Think it must be spreading the polishing bug, I have a spare set of exhaust clamps and made a start on them. I told myself if I can achieve a satisfactory job on one I’ll do the rest. Here’s a picture after two hours, although spent a bit of time swapping different attachments to find what works the best.
The originals are very rough.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverda Dave on February 01, 2024, 03:33:54 PM
Looking good Ken, I like your idea of a 'light sanding', I call that a polish 🙂.
Are you going to spray the frame with wd40 or suchlike to protect it in its raw state and whilst you attend to the welds. I know powder coat doesn't like any kind of corrosion or are you planing on fixing the welds and then giving it another light dusting with the blast gun?
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on February 01, 2024, 03:42:27 PM
Is that a 550 chain guard as my 500 one is  plastic ?
Be good if its a straight fit but I guess it's not.

Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on February 01, 2024, 06:14:07 PM
"Onto the powder/ceramic coaters, dropped the frame off so they can grit blast it, then they'll return it to me and I'll drop it off at the welders on my way back, again filling in all the brackets and lugs etc that Honda again didn't seam weld, stuff like the lower front engine mounts, water gets under and rots the frame underneath the lug and you can't see it. When the welders finished I'll bring it home and inspect it to see how the metal has held up, dress all the welds and get rid of all Honda weld splatter, I want the frame to feel like glass so the powder coating comes out as well as it can"

The gaps are left as stress mitigation in part of the design and testing, normal to not connect bracing completely to avoid failure.

The swing arm ones (in exaggerated illustration) if you push one arm up the other down, then those gaps will move like a fish mouth as the bracing takes the stress. The top and bottom welds running along the arms themselves are in shear stress, with the brace itself in compressive and tensile loading diagonally across the flat surface.

Welding the "open" ends on the arm constrains it such that it can crack rather than "breath", the crack can then travel into the main arm tube via the weld, just where you dont need it.

Welding is often delineated in structure to avoid stress cracking to follow along the weld route in causing ultimate failure of the main component.
Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on February 01, 2024, 10:25:55 PM
Generally the joints are designed into it from concept, r&d then durability testing to ensure they perform adequately.

Specialist frames likewise, but you'd not ordinarily change one to the other without good cause or background information.

A lot of special hand-built frames historically have been brazed joints that doesn't melt the steel during that process. These don't then have the same pathway through the principal structure t give failure of base material if that bronze material should crack.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverdaroo on February 02, 2024, 12:42:18 AM
I did just that with my frame as you know Ken, only from your recommendations mind. Wax oil in everything, holes in the bottom rails and all the gaps welded up before powder coating. Looks much better now and hopefully won’t rot as bad as standard.


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Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on February 02, 2024, 09:35:11 AM
I'll get off Ken's thread with it  :)

But don't think there's appreciation for structures and the impact it can make, or is seen conventionally. The swingarm bracing as it goes down along the arm is supposed to be a "soft" finish and why most bracing like this is shaped similarly. Welding that opening together in fixing it to the main tube changes that characteristic, first to remove flex and putting a circumferential weld halfway round the tube, making a failure pathway in that material section. Its now got a raised stresss point halfway along the arm, and with compromised structure potential as it was never designed to be welded there.

We could all see the problem of replacing a fuse with a stout woodscrew for example, feeling that's obviously going to risk a potential problem, but it would work all the time the circuit wasn't under too much stress. Modification like the brace compromise do exactly this though.

It doesn't matter to me what people do individually to their own frame, but I don't think it should be viewed as a reasonable path in modifications.

If anyone wants to feel swingarm flex, then hitting a dip in the road at speed while in a corner (amplified with a passenger) and the bike wallows, the line is altered and you can feel the steering move, that's swingarm flex, present in many of these old bikes with one arm moving up and the other down as the wheel cocks sideways from the load coming in to it.  That squirrely feeling  ;D
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on March 04, 2024, 08:35:08 AM
Irrespective of what Moorey says my current  500 project would be all the poorer if you deleted your posts on my build I would respectfully ask you to leave them as they are please Ken.

Title: Re: 30 years of storage later, the project begins.
Post by: K2-K6 on March 04, 2024, 08:57:12 AM
Almost true Nige, when I get to 1000 I start again at 1, around 4000 of 9020 are now gone, everything from 2014 to May 2021 is now gone for good. Moorey stated my posts were causing members to leave the site so I'm remedying that.

Whether it has impact, I for one value your contribution Ken along with opinion and the presentation of work personally completed.

Between us we can have opposing views but still discuss and offer why those may be desirable or give clarification to the topic in question, essentially a part of having interesting conversations on a forum like this.

I'm OK with holding a different view of something, with sometimes the debate offering important insight to another forum member in possible explanation of why something has happened on their bike. You'll never know what these conversations will turn up.

Whatever you decide in personal position, I wish you well with your riding and projects.

Nigel.
Title: Re: 30 years of storage later, the project begins.
Post by: Rozabikes Tim on March 04, 2024, 09:01:06 AM
Almost true Nige, when I get to 1000 I start again at 1, around 4000 of 9020 are now gone, everything from 2014 to May 2021 is now gone for good. Moorey stated my posts were causing members to leave the site so I'm remedying that.

Whether it has impact, I for one value your contribution Ken along with opinion and the presentation of work personally completed.

Between us we can have opposing views but still discuss and offer why those may be desirable or give clarification to the topic in question, essentially a part of having interesting conversations on a forum like this.

I'm OK with holding a different view of something, with sometimes the debate offering important insight to another forum member in possible explanation of why something has happened on their bike. You'll never know what these conversations will turn up.

Whatever you decide in personal position, I wish you well with your riding and projects.

Nigel.

Plus one on this and Teds post.

Title: Re: 30 years of storage later, the project begins.
Post by: Laverda Dave on March 04, 2024, 09:49:20 AM
The last time I checked this was a free country with free speech (although that has now been eroded by the woke/tin hat brigade). The problem with the written word as opposed to the spoken word is the individuals interpretation of the written word. It can be very easy to be offended by the written word in the context of a debate.  We have to remember this site is about responses to threads. I don't sit down and very carefully consider my wording when posting a response in order not to cause offence and I have never set out to cause any offence either. I just type a response as I think it, if my response is helpful that's good, the reader can interpret my response in any way they wish.
At the end of the day we are all grown ups and are here to help each other, that's why I joined the forum and I'm 100% grateful to ALL the individuals on here for their help and advice.
So, make that a plus 2 with Nigel and Ted's thoughts.
Title: Re: 30 years of storage later, the project begins.
Post by: McCabe-Thiele (Ted) on March 04, 2024, 10:08:11 AM
True Dave plus an Emoji is not a substitute for normal body language.
When Wendy says "I would love to go to Stafford Show with you" her voice intonation delivers the opposite message. I go with her brother every year with her blessing (relief) instead.
Title: Re: 30 years of storage later, the project begins.
Post by: Johnny4428 on March 04, 2024, 10:35:40 AM
I agree with the above comments and just to add Ken was one of the first to offer help to me when I joined this forum, I too will be forever grateful for all the help over the years from Ken and many others. I also found out very quickly that there are straight talkers on this forum and there are times yes we maybe don’t agree but we move on. (at least that’s what I do) It would be a great shame if we felt we had to tread on egg shells around an issue just in case we thought someone might be offended.
Title: Re: 30 years of storage later, the project begins.
Post by: SteveD CB500K0 on March 04, 2024, 11:04:14 AM
I'm sorry Ken but you are confusing this with a democracy.

You are effectively filling our forum with thousands of non-sensical posts. My server has reported tons of spam recently.

It's you.

So sorry but you are done.
Title: Re: 30 years of storage later, the project begins.
Post by: AshimotoK0 on March 04, 2024, 11:20:52 AM
All very sad. I always appreciate yours or any other bike related posts on this forum so you and your old posts will be sadly missed Ken. I fully appreciate Steve's predicament too as he kindly keeps all of this up and running without ruling with a rod of iron like many other forums. A lot of the forums have either gone to the wall or hardly visited now due to the FB groups but this one seems to thrive. Long may it continue.
Title: Re: 30 years of storage later, the project begins.
Post by: Laverda Dave on March 04, 2024, 12:03:09 PM
All very sad. I always appreciate yours or any other bike related posts on this forum so you and your old posts will be sadly missed Ken. I fully appreciate Steve's predicament too as he kindly keeps all of this up and running without ruling with a rod of iron like many other forums. A lot of the forums have either gone to the wall or hardly visited now due to the FB groups but this one seems to thrive. Long may it continue.

+1 on those thoughts Ash. This is the best motorcycle forum on the planet, end of. I would put the content on this forum far above my favourite Classic Bike Guide and Classic Bike magazines and that is simply down to the members of the forum and all the help they give  :)
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