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Honda CB750K5 Restoration by Royhall

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Johnny4428:
That is getting to the exciting part now Roy! Nice work on the headlight.😜

royhall:
I was going to get the exhaust system unpacked and fitted, but looking at the bike it would be better to do some of the smaller parts first as the access would be much easier. So firstly I built up the footrests and rear brake mechanism. The footrests required more work than I realised. The main struts were powder coated when the frame was done, all the zinc parts were cleaned and replated, and new rubbers were fitted. They went together quite easily with just the powder coating requiring drilling out for the pins. Right side first went on at the same time as the re-chromed back brake lever, all fitted with new bolts and nuts and a new switch spring.

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The left side went on and after centralising the engine stud the bolts tightened up.

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Next up was the refurbished oil tank. This has been taped up and carefully blasted to remove the old paint then re-painted using two pack gloss black. After painting it was carefully cleaned and checked for any blasting residue. I must have flushed it out at least 6 times. A good look with my borescope revealed that it was totally clean. I was a bit worried about the painter blasting it (I didn't know he was going to do it) due to leftovers getting into the oil. I didn't need to worry as he used rubber bungs on the holes and masked everything else then turned the pressure right down on the blaster. I fitted the second hand hoses that I got from DK as the ones with the bike were frayed and in a right mess. I fitted new aluminium washers and o-rings and tightened everything up. Of course the tank went on with new mounting rubbers and bolts (all these little bits add up to more than you realise).

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I thought next I would have a go at the bit I was dreading, painting the Honda logo on the rear of the seat. I was right to be dreading it as it went very wrong. I got a stencil off PIki which was firmly stuck in place after careful measuring. I then masked off the rest of the seat to prevent overspray. After ensuring all the edges were down I sprayed a first coat of clear to seal the ridges in the cover, followed by three light coats of silver Rustoleum PVC spray. I let it dry for a couple of hours then unmasked it to find this horror.

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I then spent a fun two hours trying to gently clean it up with a new scalpel blade, dragging it like a razor. This only worked to a degree but did improve things quite a bit. Next I ordered some black Rustoleum off Amazon for next day. With this I carefully touched in the nasty bits around the edges, It's not perfect but still good enough to use.

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You can see the black around the logo as it's a bit more reflective than the PVC cover (it looks worse due to camera flash, nothing like that in reality) so I polished the sides of the seat with wax furniture polish and now the shiny bits are blended better. After this fiasco the exhausts will be a welcome easy job.

Oddjob:
What most people forget Roy is to grease the footrest pins, they then rust and start to oval out the holes. A little bit of foresight can save an awful lot of heartache years down the line.

Same with stuff like the brake pedal pivot pin, they get so excited about starting to put it together they seem to forget to do stuff.

Is the points cover a temporary affair as it seems quite dented, I know the price of these has gone through the roof so I wouldn't be surprised if you've fitted the old one until it's finished to save potential damage etc.

Coming on though Roy, starting to look the part.

royhall:
Don't worry Ken everything is very well greased. Yes the cover is still the dodgy £3 thing I got off eBay to sit the engine on whilst the frame was lowered over it. Wont be doing stunts like that with a £180 points cover, the real one will be fitted shortly. I now actually have two nearly perfect covers so if anyone is needing one it's yours (at a price of course).

Oddjob:
Yeah, I'd have done the same thing Roy, not worth risking the new cover.

BTW, mate of mine was trawling round Macclesfield superbike centre the other day and told me that an identical CB1300 to mine was for sale, must still be your old one.

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