SOHC.co.uk Forums > CB500/550

Finally after too many years I'm working on my 500/4

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matthewmosse:
Well the latest update, started attacking the flaking paint, and found the rear left of the frame where the mudguard brace part is, has rusted through, not a lot left of the inner face of the gusseting that holds the shock absober top mount, so it looks  like I have a days of welding and fabrication ahead and the engine will probably be comming out and the sidecar may also come off. Luckily I can weld and have already done the other side about 8 years ago. I also will repeat my easy find rust detection method on the rest of the at risk frame areas - I play an acetalene torch over the frame, if it heats easily, it must be badly rusted. I am a bit peeved to be welding the frame again but such is life. The welding I did last time seems to be holding up ok.

matthewmosse:
Well looking like a fair bit of work, frame now bare and sat on the workbench. Needs new headstock bearings, after using a slag hammer for arc welding and a 3lb ball pein hammer I have found the frame tube has severe (but looking quite localised hopefully) rust, right through the frame tube where the pillion footrest hangar sits and at the top, will get photos before cutting the rust out, going to be a major bit of surgery, basically the rear end has seen too many winters.

matthewmosse:
Rust is localised to 2 areas in the main frame, but the steel pressings are shot -

matthewmosse:
more of the frame, going to need a bit of thought before welding this up, given that it carries a sidecar and 2 of the 5 mounting points are rusted to tin can thickness. Amasingly after taking these I cut the rot out and the rest of the frame tubing is still shiny factory fresh steel inside, within mm of gaping rust holes.

matthewmosse:
Now welded up the frame tube having cut all the thinned steel out, footpeg hanger mostly fabricated, had to stop before it was done as it was time to cook dinner, also I managed to chop my thumb quite badly with the angle grinder when dressing the edges of the new footpeg hangar to get the taper right, think if I need to make any more replica footpeh hangars then I'll make a set of steel formers up, that said this one only took an hour so far and is looking like a close enough replica. Last time I think it took nearer 8 hours tin bashing the differnce being I now have a swage block to get the curves so am able to use 2mm thick steel and really bash it to get the shaping close to how Honda made it probably using big presses. Think gas welding will be best to get the ridge right round the middle. Top shock mount still to re make.  Hopefully another few hours will see the frame ready for wire brushing and re paint, more likely it will take a day , but in dribs and drabs of an hour or two as and when childcare, work and daylight allow. Workshop lights have fused out.

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