SOHC.co.uk Forums > CB500/550

CB550 First Build - Hondvarna?

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cinqmars2:
I also had a look at the tank which came off the crash bike, dented from every angle, some were fixable but others are completely creased and will need to be filled. I tried the 'hot-then-cold' method to no avail, that explains the singed tank in the last picture, but found success in hot gluing a piece of wood to the dent and yanking it out. Remarkable how flush that side is now!

 

cinqmars2:
I'm beginning to get very concerned about the way I treated the frame and have decided to cut out some metal and replace with straight tubing, or perhaps even the whole of that triangle.

There's a thread on Do The Ton which features a bike that had no rear end, they just fabbed in a new a*se and it looks immaculate! I'm hoping to be able to do the same.

Does anyone have any advice or any concerns about doing this? I'd most likely build a jig to hold it all in place and keep it as  true as I can when it comes to it.

I have attached the bike from DTT and also some scribbles about how to go about cutting my frame, advice please! I'm thinking gussets may help spread the stress around too. Floundering...

matthewmosse:
In reality a lot of these bikes will be running frames with more metal missing from rust than you have taken with the grinder. My 500 was really bad and was doing a lot of miles often at some speed and had a sidecar attached that adds to the loading on the rear subframe. I tested the thickness of the thinned metal by running a gas welding torch run over it - if it went red fast it was thin. I repaired by sleeveing in a smaller diameter repair pipe with a repair section of the same diameter as the removed metal so the butt welded repair was supported internally. The internal re enforcement was tapered off a few inches past the joint to avoid stress raisers. Plug weds were also used. I actually ended up re fabricating much of the rear end metalwork and was quite glad of my blacksmith skills as a fair bit of sheet metal bashing was needed to keep an invisible repair. For your project a simpler approach can be used. How is your welding? if it ain't spot on then a simple bit of gusset as you show might help but I'd leave as is.

cinqmars2:
Thanks Matthew, that puts my mind at ease to some degree, I'll still fill the seams and chuck on some gussets just to be sure, want it to be stiff!

kifer:
I wouldn't worry to much we all make mistakes the best way to learn I tend to use a linnesher to tidy things up cheap and not as aggressive as grinding discs Keep going you will sort it in the end and no problems in over doing it with gussets

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