Thumper Club Forum
Technical => Project Progress => Topic started by: iansoady on November 03, 2022, 02:59:23 PM
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Just to recap - I initially wanted a CB400SS grey import. But wiser counsel, mostly from this forum prevailed and I am now in possession of a beautiful XBR500. I'm not going to go overboard with this but intend to fit a CX500 tank which seems to be the easiest fit / best looking, and mod a spare XBR seat by getting rid of the raised front end and possbly other things. I foresee side panels may prove interesting.
To remind my faithful public what it looks like:
(http://www.iansoady.org.uk/XBR500/images/St%20asaph%2001.jpg)
(http://www.iansoady.org.uk/XBR500/images/St%20asaph%2002.jpg)
Under the bonnet - all in excellent condition.
(http://www.iansoady.org.uk/XBR500/images/frame%20etc.jpg)
VF400 bars arrived and look as if they will fit; arranged to buy another seat. All I want now is a tank......
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That is absolutely lovely. Can't wait to see how it progresses.
Ian
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Don't hold your breath Ian.....
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Well Ian, I've followed this thread and the associated ones and as a former owner of about 5 XBRs and about the same number of CB250s it's proved most interesting.
As I think I may have said before I do find the RS a bit underpowered and lacking in much torque and they can be snatchy at low revs. The only way to ride them is to use the revs and not pull too high a gear especially around town-others may disagree.
I've now SORNED 2 of my other bikes - my 750 Monster has never been fully reliable and its developed a misfire or two so that is being looked into as well as a slipping clutch so the RS is my main bike at the moment.
The best feature of the RS is as again I've said before it its light weight which the Monster also benefits from even though its a750 but there's not much to it with the trellis frame and it's not unlike a super thumper to ride.
The point of this diatribe is just to say in comparison to the RS, the XBR is much torquier and not too much more heavy.
I know you don't like the styling-hence your intentions to modify and I do understand that. They are a bit of an acquired taste-but I can remember while not exactly drooling over one in Bob Joyner's showroom when they came out in 1985 when my sole bike was an early 400/4, I couldn't afford a new XBR due to mortgage etc and it wasn't until about the early noughties IIRC that I got my first one.
So anyway I hope you find the XBR more suitable to your needs than the RS.
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Many thanks Martin. It's partly because of help from you & others here that I've ended up with the XBR - although having said that the same could have been said for the CB250!
I have to say that in the metal the bike isn't actually as ugly as I'd thought. In any case I will not be making any irreversible changes - I know this will limit what I'm able to do but want to be able to revert to standard if my conversion foes pear-shaped.....
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Yes understood Ian.
I meant to say the bike does look very nice indeed.
The build quality of 80's Honda wasn't always the best.
If it was mine I would want to preserve the condition but I know that can be a pain but this can be done as long as you're careful where and when you go in the poorer weather months avoiding wet country lanes which never seem to dry out and gritted roads.
I think it was Michael (Moto 63) IIRC but could be wrong ( senior brain moments) who recommended heated clothing. I finally got a waistcoat (only £50 new off Fleabay) and have been out this afternoon on my RS and it's so much warmer I couldn't believe it. I fitted heated grips on my last XBR but couldn't get along with them!
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Looking forward seeing this project progress :)
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VF400 bars arrived and look as if they will fit; arranged to buy another seat. All I want now is a tank......
You've certainly hit the ground running - should be finished by Tuesday next? ;D
Best of British to you, Ian.
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You might think that - I couldn't possibly comment.
Like most of my projects I expect it will progress in fits and starts. And it's nowehere near as complex as many here. But should keep me busy during the winter months. Ride on greasy leaf-strewn lanes? Not any more......
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I've drained the oil and am awaiting filter etc from David Silver. Also checked the tappets which were fine. But I think I've found the source of the noise (apart from the silencer). The exhaust gaskets were squashed flat and the whole lot plastered with gun gum or similar. Bodge number 1 discovered...
(http://www.iansoady.org.uk/XBR500/images/exhaust1.jpg)
The silencer as I expected is empty but this is in the exhaust going into it:
(http://www.iansoady.org.uk/XBR500/images/exhaust2.jpg)
I don't know whether it's fixed as part of the exhaust or not.
These are the VF400 bars which have a couple of inches rise and pull back a similar amount as the XBR ones are in front of the stanchions:
(http://www.iansoady.org.uk/XBR500/images/VF400%20bars.jpg)
A quick coat of Tetrosyl wheel silver should have them looking tidy but it'll be a while before I need to look at them. Still on the hunt for a CX tank.
I suspect my plan of swapping gear lever / brake sides will be very tricky as there don't seem to be any convenient gaps to install crossover shafts. I do have a cunning plan for potentially lowering the footrests however if it proves necessary.
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Aha. I think I've discovered the reason for the bodge - the exhaust collars p/n 18233MK4000 seem to be unobtainable. Does anybody here happen to have a set lying about? Alternatively, if you have one that you don't want to part with I could make them if I had the dimensions.
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Aye Ian,
Predator Motosport are producing reproduction sets in stainless steel, at a price! :o But cheap in terms of man hours faffing about! Link to Predator site below.
Honda-XBR500-repoduction-exhaust-clamp-in-s-steel-each (https://predatormotorsport.co.uk/honda-xbr500-repoduction-exhaust-clamp-in-s-steel-each/)
Good health, Bill
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Morning Ian... I’m pretty sure predator still do the down pipes and silencer for the XBR in S/S too.
I had one on one of the XBR’s I bought a while back, sounded good. Loud enough to be a ‘real” motorbike but not offensively loud, road legal.
Cheers, Michael
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Looks like you've found a very nice example Ian, good luck with it!
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Thanks both. Now I've cleaned the gunge off I can see that the pipes I have - which are stainless and in good conition - have a ring welded to them and a captive clamp (ie its ID is less than the OD of said ring). Hence I think it's designed to not use the split clamps / collets I've been looking for. Careful measurement seems to bear this out but will check. It will be nice to use what I've got. There were a couple of the copper seals in there but squashed beyond retrieval.
That predator site is very interesting and if I was to replace everything would be a good port of call. They do lots of other useful stuff as well.
CX500 tanks seem rare. I'm enquiring about this one: https://www.ebay.co.uk/itm/185629257177 which looks reasonable. The filler cap area looks to have been molested but I'd probably want to change that anyway.
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The cx tank looks in reasonable condition, give it a coat of tank sealent to be extra sure before you use it, (mine had a few pinholes and alls been fine for 8+ years) Those are a good set of downpipes, the copper seals are pretty much a one use item so will always need replacing.
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I'm a bit wary of tank liners having heard some horror stories. The Francis Barnett I rebuilt a year or so back had some awful resin like stuff inside - but floating about loose. It was the devil's own job to get it out as some lumps were too big to come through the filler hole & I had to use a hacksaw blade to cut them inside. Horrible.
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That's the old stuff. POR15 system is an easy 3 part, modern system - degrease, etch and seal. I've used it and all is well on the CB200 tank which was really rusty.
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Hopefully will be getting that tank this week so will check it out carefully.
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Cracking on...
Bits arrived from David Silver so fitted oil filter and plug - I ended up turning down an old 3/8 drive one si it fitted in the narrow gap. Filled up with 10W/40 semi-synthetic.
Checked the VF400 bars to be sure they'll fit - they'll be about 45mm higher and 40mm further back. I think the cables will reach except maybe the choke so I may have to make a new one. Gave the bars a couple of coats of wheel paint which gives a nice silver colour.
Also started to attack the broken clip on the side panel. Flattened off the face and drilled 3/8". I'm now making a delrin part to mimic the existing one.
Bars as they were:
(http://www.iansoady.org.uk/XBR500/images/VF400%20bars.jpg)
Painted:
(http://www.iansoady.org.uk/XBR500/images/painted%20bars%201.jpg)
and:
(http://www.iansoady.org.uk/XBR500/images/painted%20bars%202.jpg)
Clip position drilled 3/8":
(http://www.iansoady.org.uk/XBR500/images/clip%201.jpg)
and what I'm trying to replicate:
(http://www.iansoady.org.uk/XBR500/images/clip%202.jpg)
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Sounds as though you have got lots to occupy you in the coming months before the better riding weather hopefully returns.
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I knew I was going to enjoy this thread - good quality workmanship and photos to match 8)
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Turned up a replacement clip from a bit of delrin I had lying about and glued it in using superglue. Will it work? Don't know but worth trying. I may have made it slightly undersize as it was tricky to measure. Measure once make 3 times.....
(http://www.iansoady.org.uk/XBR500/images/clip%203.jpg)
(http://www.iansoady.org.uk/XBR500/images/clip%204.jpg)
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And here are the repainted VX400 bars installed. Everything fitted very nicely except the choke cable which I will have to remake 3 or 4 inches longer. It's an awkward thing though. The bars look as though they were made for the job.
(http://www.iansoady.org.uk/XBR500/images/bars%20installed%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/bars%20installed%202.jpg)
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Result Ian... fingers crossed the nylon lug holds out with the super glue🤞. Certainly looks good 👍
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Seat arrived from a nice chap on the FB pages - just what I needed. I think I will mod the base myself but get someone more expert than I to modify the foam and make a new cover. I need to get rid of the kick up at the front and get it reshaped to remove the step and get something like a straight line along the top. I got a replacement seat to fit in with my idea of making reversion to standard a simple job.
But I can't move forward till the tank arrives, which I've agreed to buy but need to organise carriage. Nobody here in Eastbourne I don't suppose?
(http://www.iansoady.org.uk/XBR500/images/seat%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/seat%202.jpg)
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Are you going for the same classic seat as the German bike Rossco500 posted up?
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My initial feeling is to keep the tailpiece as that simplifies mounting (and also avoids making any structural changes). But the idea is to remove the step, chop the front off to (almost) meet the tank and have a cover made. That should achieve a nice clean line.
Eventually have agreed on the tank and will need that before I go further. But I did pop down the classic bike shop just down the road and bought some Lucas pattern indicators and a Goldie pattern silencer.
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Aye Ian,
Predator Motosport are producing reproduction sets in stainless steel, at a price! :o But cheap in terms of man hours faffing about! Link to Predator site below.
Honda-XBR500-repoduction-exhaust-clamp-in-s-steel-each (https://predatormotorsport.co.uk/honda-xbr500-repoduction-exhaust-clamp-in-s-steel-each/)
Good health, Bill
I've got some on mine and can recommend them ( Yes they are pricey!!)
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those bars look great ian nice work your doing on this xbr ..tommy
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Thanks Tommy, hope it doesn't all go terribly wrong.....
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I wish I'd have known about all this when I had my XBR500 as the bars were one of the main reasons I sold it. The ones you've fitted do indeed look like they were factory fitted and that's a lovely paint job by the way.
Having a project to do is just the best feeling in the world. If it all gets too much there's always the option of a quick squirt round on that lovely Norton to clear your head I suppose.
Isn't life great when simple pleasures are enough!
Ian
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Result Ian... fingers crossed the nylon lug holds out with the super glue🤞. Certainly looks good 👍
The problem with superglue is it doesn't like shearing forces. There is a new glue out that you put on like a superglue but then 'set' with a UV light which then sets very permenantly.
https://diy.bostik.com/en-UK/products/repair-assembly/fix-flash (https://diy.bostik.com/en-UK/products/repair-assembly/fix-flash)
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I wish I'd have known about all this when I had my XBR500 as the bars were one of the main reasons I sold it. The ones you've fitted do indeed look like they were factory fitted and that's a lovely paint job by the way.
Ian
You can also use CBX550 bars ( though they're probably getting scarce now).
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Ian - I am able to retain the original choke cable when using the CBX550 bars. As I recall the cable is relocated outside the fork tube rather than between them. You do need to tweak it a bit to ensure it doesn't stretch on full lock. This however is when using the original tank. Might be different with a CX tank. One other thing is there is a bit of weight in the original bars (the combination of the end weights and the weight within the bar if that makes sense) to soak up some of the vibes. I suppose some notice the vibes more than others though.
Regards
Tony
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The VF400 bars seem fairly available - there were a few to choose from on ebay but for some reason most seemed to be left side only. They also seem to be just as heavy - I think they're steel while the originals are alloy but haven't checked it out - will look for these weights. Vibration? Surely less than the Norton with that balancer shaft.
I've got the materials from Venhill to make the new cable as I wanted to keep the same routing - although the old cable is a thing of wonder and complexity I can simplify it. Oddly there's no real adjustment on it so I may put a mid point adjuster just in case.
If the superglue fails it's not the end of the world as I can always reglue - maybe with epoxy - although that clever UV stuff looks handy.
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Moving swiftly on, although none of this is moving the actual project forward - just sorting out details while I wait for the CX tank which is on its way....
Made a new choke cable. I really struggled getting the plunger installed so decided to remake it and do what I should have done in the first place - include an inline adjuster. It seems weird to me that there's no adjustment facility for the standard cable. Note in this photo one ferrule isn't properly seated...
(http://www.iansoady.org.uk/XBR500/images/choke%20cable.jpg)
This is the pattern Goldie silencer. I started the bike up this morning and it's quite loud but nowhere near the one that came with the bike. Quite a nice deep sound. There are mutes available for the end if I decide I need to quiet it down a bit. If fitted onto the 45mm exhaust very nicely.
(http://www.iansoady.org.uk/XBR500/images/silencer.jpg)
Pattern Lucas indicators - not original but I hated the tiny LED things the bike came with. Indicators and silencer came from the Classic Bike Shop a couple of miles away from me in Redditch https://www.classicbikeshop.co.uk/. They seem excellent quality and the indicators are better made than original Lucas ones. It's very much like I remember going to Vale Onslows in the 1970s but without the queues and surly counter staff.
(http://www.iansoady.org.uk/XBR500/images/indicator.jpg)
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That is coming along nicely by the look of things. Should be a nice mixture of old school and 80s chic.
Keep it up.
Ian
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Is that chic or cheek?
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Is that chic or cheek?
I had a lot of one and none of the other in the 80s, but I will leave it up to you to guess which was which!
Other Ian
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Looking good Ian. The standard indicators are terrible so most people bin them. They are mounted on rubber / plastic stems and after this many years they go floppy!
The ones you have fitted suit the bike very well.
Ah that takes me back -Vale Onslows. Spot on about the queues and surly counter staff. My 1974 Suzuki GT185 was supplied by them from new. I swapped it for my RE Continental GT 535 with a friend in June.
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Looking very good :)
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And there's more....
A previous owner has seen fit to cut the rear brake pedal stop off so I had to make a replacement:
(http://www.iansoady.org.uk/XBR500/images/brake%20stop.jpg)
The last MoT had an advisory for a slight run out on the back wheel so I decided to check it out. A few judicious taps with a lump hammers and old chair leg reduced the runout to between 1 & 2mm which I hope is enough. I'm reluctant to hit it too hard....
(http://www.iansoady.org.uk/XBR500/images/wheel.jpg)
Oh, and what's that I hear at the front door? It's a yodel parcel delivery. It must be my CX500 tank! Be still my beating heart. At last I'll be able to get on with the object of the exercise.
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Progressing at a pace........
Those rear brake stops can break off if the bike is dropped on the right hand side. Don't ask me how I know!
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I suspect that may be where the kink in the back wheel came from. Anyway, back wheel back on - with the usual struggle, even needing my wife to help. "Hit that with the soft hammer, No not that that!"
Just done a very rough dry build with the tank, which is actually in excellent condition. It's still a bit porky looking but miles better to my eye than the XBR one. Following Matt's advice to move the front bobbins up & forward the back mounting is virtually spot on. And the seat will only need the horn at the front removing! The only issue I can see at the moment is the petrol tap wants to be in the same place as the side panel. Maybe I can get it moved?
Pics of the dry assembly:
(http://www.iansoady.org.uk/XBR500/images/cx%20tank%205.jpg)
(http://www.iansoady.org.uk/XBR500/images/cx%20tank%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/cx%20tank%202.jpg)
(http://www.iansoady.org.uk/XBR500/images/cx%20tank%203.jpg)
(http://www.iansoady.org.uk/XBR500/images/cx%20tank%204.jpg)
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Looking good Ian, bet you’re chomping at the bit to get back in the garage eh. I know I would be. Look forward to the next instalment of pics.
Cheers, Michael
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Yes, when my back's recovered after struggling with the back wheel...... I do wonder why Honda and other manufacturers didn't adopt the QD arrangement like the Norton Commando one. Remove the spindle, drop the spacer, slide the wheel sideways and out it comes, leaving the chain and brake all connected up.
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Looking good there, I can see how it is going to change with the CX tank and the other things you are doing. I do like the original XBR tank, I always felt it fitted me well, but I also really like individual bikes that the owner has made their own. Starting to take shape and I would be really impatient to get out and start riding it, which probably explains why I never finish a job properly!
Glad the wheel straightened up ok, that's another job ticked off. So looking forward to the next bit of progress.
Other Ian
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The only issue I can see at the moment is the petrol tap wants to be in the same place as the side panel. Maybe I can get it moved?
Needs a new petcock bung and hole drilling. I trotted off, tank and bung in hand to a local shop where matey closed the old hole and welded in the new bung, similar to this one;
https://www.ebay.co.uk/itm/401082725021?mkcid=16&mkevt=1&mkrid=711-127632-2357-0&ssspo=C8p19QcbT0O&sssrc=2349624&ssuid=GT0R2p0dRG2&var=&widget_ver=artemis&media=COPY
Lots of different taps to choose from at this stage (before turning the bung yourself?)
Thanks for the pics and great commentary 👌
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Ooh, they're expensive! I was thinking cut out a square around the boss and get the welder to weld that in to a similar cavity further forward which I can cut with the angle grinder. Fortunately there is a nice flat bit where I'd want the tap to go. The tank is actually in very good condition and will get it blasted soon so I can make any adjustments. I think I will make some eccentric bobbins out of black nylon so I can make sure the front of the tank is well supported as it's only halfway on as it stands - and the forks are kissing the front of the tank on full lock. Hopefully eccentrics will let me drop it a bit and move it slightly backwards.
I offered up the RH side panel with the tank in situ and while it doesn't line up perfectly I think I can see how it will look.
I think I will slow down a bit while I consider options. I've only had it for 2 weeks!
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Good idea about the bung, given as you say, all that available space. Ideas are obviously flowing and I hope you are as much as a pig in the proverbial as I was!
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Just waiting for some disaster to occur.
I've been looking at the badge fittings - I don't want to use the big Honda badges as the CX would have had but a wing decal as on the XBR. The fixings seem to be spot welded to the tank in a recess but are a bit proud of the surface so will try to flatten them off using the angle grinder then fill back to a nice profile. I can't see how to remove the spot welds without the danger of damaging thetank underneath.
I've also been looking at removing internal rust - it's not bad but there is some - using electrolysis as in this article: https://www.classicbikehub.uk/Workshop/article/petrol_tank_rust_removal. I can't decide whether to do that before or after blasting the outside.
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How about a Dremel style of tool for tight spaces? You can get mini grinding wheels for them or stones of different shapes.
I don't suppose it really matters about the order, but I'd go for electrolysis first (can get messy, but might just be me)
Also, if you plan to seal the tank, that can also be messy. Here's my go and some good advice from members;
http://www.thumperclub.com/index.php?topic=9541.15
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Obviously I'm following in your footsteps Matt! I'll give the elctrolysis a go and have some soda crystals on their way. I think I will go for electrolysis then blasting then moving the petrol tap - if blasting reveals any holes I can get them welded at the same time. Yes, I have a dremel and will use that for the fine detail stuff. I must admit using angle grinders always scares me to death. All I need to do is get the retaining plates below the surface level of the tank.
I made up an oxalic acid solution a couple of years ago and tried it on rusty bolts - it did seem to clear the rust but left a strange green deposit. And it's apparently very toxic - watch out you rhubarb eaters.
Off to a paint matching place in Bromsgrove today with a side panel to get some paint & lacquer aerosols for the tank. I know it won't be petrol proof but my experience has been that once throughly dried the odd splash of petrol isn't a problem.
As a small experiment (and slightly off topic) I have used JB weld to stick 2 bits of mild steel together and left that submerged in a jamjar full of petrol for a week. The bond seems to be standing up but some of the excess has gone soft.
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I am always in awe of people who cut holes in petrol tanks, to me the skill level required to weld them back together is an inconceivable skill level to attain. I lack not only the skill, but also the confidence to think about making a perfectly leak-free petrol tank into a sieve! Glad there are people who will take on the job though.
Spartacian the amazed.
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My welding skills are virtually non-existent - quite apart from the fact I sold my Mig welder some years ago as it was just collecting dust under the bench. I'm quite happy to cut holes and let other people weld them up again however. There's an excellent specialist welder just round the corner from me.
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Ian. You could always cut the bottom of the tank out, that way you can get to the inside to grind any rust out. Plus then, when you get your expert welder friend to weld it back together you can move the petrol tap position to suit at the same time. Just a thought 🤔
Cheers...Michael
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I am always in awe of people who cut holes in petrol tanks, to me the skill level required to weld them back together is an inconceivable skill level to attain.
Spartacian the amazed.
Well being a fully qualified city n guilds plumber I can do your shower base and surround AND tig weld your petrol tank if so required. We can discuss my hourly rate at a later date 🤪😉😉
Michael.. the inconceivable
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TBH the tank isn't that rusty (he said hopefully) so I think I'll limit the amount of cutting and shutting necessary.
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Michael
How did you know that my shower base needs replacing!! You have two more useful skills than me there, I could make you a bracket which will fit where it touches and have at least one hole in the wrong place.
Mind you if you ever find yourself needing to be fed or medicated via a Percitaneous Endoscopic Gastrostomy I'm your man!
Spartacian the impractical but caring.
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I've been working on the tank mounting. Following Matt's (IIRC) advice I've got a length of 8mm allthread that just fits behind the little tags in a hole in the frame above and forward of the standard mounting position. The CX500 tank is wider between the bobbins than the original, strangely enough, so I've made spacers from black nylon to sit on the studding and push the bobbins out. This is well nigh perfect at the front, giving about 10mm clearance from the forks on full lock.
I've also been thinking about the side panels and discovered that if I lift the back of the tank about 10mm the panels will slip underneath and look almost as if they're meant to be there. I need to find some way of locating their front mountings however.
Also picked up a set of aerosols from Spraywell in Bromsgrove, matched to a side panel. I've never used 2 stage paint like this before. What can go wrong. The pack also includes an allegedly petrol and UV resistant lacquer. All for £60 - a lot but much cheaper than a professional job. Will it look as good? No......
Pics of the front tank mount: you can see the original bobbin mounts.
(http://www.iansoady.org.uk/XBR500/images/tank%20mounting%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/tank%20mounting%202.jpg)
(http://www.iansoady.org.uk/XBR500/images/tank%20mounting%204.jpg)
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Top job Ian... looking forward to seeing the tank and side panels in place 👍
Cheers, Michael
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Michael
How did you know that my shower base needs replacing!!
Spartacian the impractical but caring.
Ian.. you mentioned your shower base on another post. Reading someone’s mind is NOT a skill I’ve yet mastered 😜
Anyway ... I don’t want to hijack Ian’s thread so only XBR talk from here on in 😉
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How nice of Mr Honda to provide you with CX tank mounting points! 8) If you could please find it in your heart to struggle a bit with some aspect of the project, I for one would greatly appreciate it! ;D ;)
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Don't worry, wait till I start trying to paint the tank. The problem is that the original tank and rest of the paintwork aare to a very high standard which I don't think I'll be able to match.
In the great scheme of things this isn't a mega-project but as you say so far everything has fallen into place nicely.
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Ooh! Look what just dropped into my inbox - cautionary tale;
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Yes........
Going to try the electrolysis tomorrow. The tank seams do look pretty sound but who know.
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Confession time - following your thread, I took a peek on fleabay and look what jumped out at me for the W650. It's a KH100 tank. So I'm with you in more than spirit! Anyway, back to the singles...
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And being a KH.. it will have come with ready made tank badges too. Win. Win if you ask me. Looks good Matt. Y’ll just have to get used to going on shorter runs though eh 😉
Cheers, Michael
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Just like the CB200 tank then, eh?! ;D It being a twin, I can mess it right up without anyone here knowing. Pressure is all on Ian! ;D ;D ;D
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It certainly seems as though the CX tank is going to be a relatively straight forward fit which is good. I suppose the best way to get reasonable results with paint is, as you obviously know, good preparation and several thin coats rather than a thick one. Good luck and I hope it gives you the result you want.
Ian
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I can take the pressure, it's the hope that gets me (to misquote someone or other).
Further thought - dangerous - has led me to decide to change my order of srvice. I'll get the tank blasted first and do the tap position swap. When I've got 2 holes in the tank base it will give me a better idea of what the internals are like - they don't look too bad peering through the filler cap - and decide whether I need to go down the electrolysis route which TBH looks like a bit of a faff. The blasiting should also help to highlight any dodgy seams.
I couldn't get to sleep last night thinking of all the detail jobs to do......
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Try and go the vapour blasting route if possible Ian. Bit more delicate, so won’t do any unwanted damage. Well that’s the theory 🤦???
Cheers, Michael
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I'll put myself (or my tank at least) in the hands of Redditch shotblasters who I've used several times and they understand what's neeeeded. I will stress as gentle as possible although gentle isn't the word when you look inside their workshop!
I've been playing with various bits and bobs to see what things look like. I've cut the peak off the seat base and cut the foam back a bit - leaving plenty for the upholsterer.
The main problem is the side panels. Problem 1: I've lost the front mounting (rubber grommet) but think I can fit a plate there using P clips on the frame tubes. No mods to roiginal remember.
Perhaps a worse issue is the way they line up - or don't - with the base of the tank. My current thought is an infill plate behind the panels painted red to match, but a better solution would be to locate another pair of side panels and extend them to line up with the tank base.
Here it is:
(http://www.iansoady.org.uk/XBR500/images/dry%20build%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/dry%20build%202.jpg)
(http://www.iansoady.org.uk/XBR500/images/dry%20build%203.jpg)
(http://www.iansoady.org.uk/XBR500/images/dry%20build%204.jpg)
(http://www.iansoady.org.uk/XBR500/images/dry%20build%205.jpg)
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Hi Ian. Seat looks better already, I’m sure your upholstery will be able to work his magic to make it look like it was designed that way 🤞
Regarding the side panels. You could always use the ones you’ve got to make a plug from then slightly redesign the shape and make new ones out of fibreglass. A little time consuming but again once done they’d look like Mr Honda designed them that way
Cheers, Michael
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I couldn't get to sleep last night thinking of all the detail jobs to do......
Spoken like a kid at Christmas! Ian, I think you might get hooked on all this malarkey (but please don't touch the Norton)
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I've rebuilt / restored loads of British bikes (including the Norton) but almost always back to more-or-less standard. This is my first try at turning a sow's ear into - well, maybe not a silk purse.
I think I may start looking for alternative side panels although the fallback will be just an infill panel. I've tried with a bit of card. I could probably build up the infill so that it meets the top of the side panel. Plenty of time to think however.
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I've just had a thought. Some years ago I worked with a young man who was constantly running his hand over his tongue and we could never figure out whether he was licking his hand or feeling his tongue. You are making such a nice job of marrying different parts together that I wouldn't be surprised if at some point someone asks you why you put an XBR motor into a CX frame!
Really like what you are coming up with so the sleepless nights are paying off.
Other Ian
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Did you try the tank on the original front mounts with longer bobbins, like JOOLZ? Might bring you more level to the side panels.
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Yes, but then it wanted to be in the same place as the seat. I've thought of a way to make and secure infill panels (which will also provide the front side panel mountings) and if they're the same red as the tank and side panels maybe won't look too bad.
Another possibility is to try to find different side panels. The Norton Commando I had for 20 great years had nice triangular ones but I'm not sure about the angles.
Just dropped the tank off this morning at Redditch Shotblasters to be blasted clean. I asked them to be gentle..... £25 but better than hours of mucky work.
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I'm looking for something to pack up the rear of the tank by about 15-20mm - ideally some sort of rigid hard polyurethane or similar that I can carve up. Anybody know where I can get some?
Or I could use a bit of wood.......
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Did you try the tank on the original front mounts with longer bobbins, like JOOLZ? Might bring you more level to the side panels.
Im not sure it would give any more clearance to the standard side panels as you will be just moving the tank back, although raising the rear of the tank may give better clearance to the standard panels, the rear of my tank is raised by about 10mm
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That's a big thumbs up for you, Ian. Has my taxi arrived yet? ;D
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Aye Ian,
I'm looking for something to pack up the rear of the tank by about 15-20mm - ideally some sort of rigid hard polyurethane or similar that I can carve up. Anybody know where I can get some?
Screwfix.
Screwfix_memory-foam-support-kneeling-mat-black (https://www.screwfix.com/p/memory-foam-support-kneeling-mat-black/98651#product_additional_details_container)
This foam is ideal for any closed foam padding support that you desire. Glued with Evo-Stick. Can then be carved with either a hot wire, junior hacksaw blade, or similar. Sanded with 'production paper', choose your own grit.
I use it on top of a steel 'U' section, welded to the frame top tube to pad the fuel tank on the Ducati. I also glued three mats together, to form the seat foam on the Ducati, that was then covered with a peice if thin chip foam and finally, with some finishing foam to take the sharp edges off the seat outline once covered. At first it feels like a plank, but it is far more supportive than the squishy chip foam used on many seat remodelling/recovering jobs. The edges of the seat pan no longer cut into the back of my thighs and is far more comfortable than either the SRX mono or Honda Bros seats after a 100 mile jaunt.
There is also a similar product available from Toolstation, but this is of inferior size, when compared with the Screwfix offering and only a £1 difference in the price.
Toolstation_kneeling-mat (https://www.toolstation.com/kneeling-mat/p87433)
Happy carving and the health to give this beastie a canter.
Bill
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That looks good Bill but may not be rigid enough for what I want. I'll pop round and have a look.
Just about to go & collect the blasted(!) tank - wish me luck!
Actually come to think of it I may have some similar material in my junk pile - a back "protector" I removed from a jacket some years ago.......
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Got the tank back and it's in much better condition than I might have feared, with a few small dents but no rust damage. I've given it a quick coat of primer to keep it OK.
Other commitments call this afternoon....
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Evening Ian. Certainly NOT trying to tell you how to suck eggs here but primer is porous so I would advise popping the tank in a sealed up bin liner or something similar each time you’ve finished working on the bike until your ready for paint.
Cheers, Michael
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Yes, take the point Michael but hopefully will be doing something to it most days. My garage is reasonably dry so hopefully will be OK.
I'll be cutting out the petrol tap boss this morning & taking the tank for welding. Wish me luck.
I think I've got a partial solution for the misalignment of tank base / side panels but have yet to try it out.
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Used the scary angle grinder and dremel to cut out the petrol tap boss (which was tricky as for some reason the tank was double skinned there) and a hole for its new position. I did get a bit overenthuiastic with the angle grinder but should be easy enough to patch. It's thankfully fairly rust free inside and no loose bits so think I will just go with it.
Tank delivered to welder and hope it goes well.
(http://www.iansoady.org.uk/XBR500/images/tank%20cut%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/tank%20cut%202.jpg)
(http://www.iansoady.org.uk/XBR500/images/tank%20cut%203.jpg)
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Now had the tank welded up - £30 seemed a reasonable price, and a good solid job. I'll swill a couple of pints of petrol around just to check for leaks.
I've also picked up a pair of side panels cheap on ebay so will revise my earlier plan. https://www.ebay.co.uk/itm/115615789458
I'll extend the panels up to tuck behind the tank to fill that annoying gap, although still need a plan for the front mounting.
(http://www.iansoady.org.uk/XBR500/images/tank%20welding.jpg)
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One step forward....
I've just tested the tank with petrol and there's a very slight weep from one of the new welds. They did say to bring it back if any problems.....
Just as well I tested it.
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Shame Ian, things were going so well too. Just make sure you empty it first before taking it back 😉💥🔥.
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Hi Ian I have just re read this thread from 1st entry. You are doing a fantastic job and I now feel totally incompetent in the world of motorcycle restoration/modification. Keep up the good work and I know you will be pleased with the end result.
PS I actually liked it in original guise but I know you had the bit between your teeth from the word go to alter it
One of the other Ians
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Thanks other Ian.
To be honest none of what I've done so far has been particularly technical or needed special equipment. I do tend to spend a long time just sitting looking at it to decide what I want to do and how to do it although quite often I get half way through something then think of a better solution! Or, as in the case of the side panels, one presents itself. I'm determined not to alter anything original so it can always be easily reverted to standard as and when.
One thing that helps is having a lathe - I've bought a Monza type petrol cap and need to turn an adaptor to fit it onto the filler neck. Diligent internet search has turned up a fairly local company to me (Warwick) who provide a huge range of resins and talking to their technical people they've suggested this one to stick the adaptor in the tank neck. https://www.alchemie.com/epoxy-resin/ep575.html It's about £20 for enough to do dozens of tanks......
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Good score on the side panels!
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I think as I'm going to modify the side panels that I won't need to raise the back end of the tank as I can contour the panels to fit snugly. We'll see when they arrive. I'm also optimistic that the special glue I'm getting will be useful to stick aluminium infill extensions to the panels.
I was just thinking that despite the kind words people have offered, the mods I'm making are not that radical and nothing compared to some projects here - the blown XBR by Joolz to name but one. I stand in awe of that!
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Hi Ian
I take your point about some of the excellent projects done here and certainly there are people out there whose skills leave me speechless. However for me what has captivated me about this thread is its very ordinariness, you are not using superpowers to craft an unattainable goal, quite the opposite you are crafting something that given the time and money I could think of having a go at myself.
For me this is a good feeling, it encourages me to look at what I can do rather than stand in awe of what I can't do. I really admire people with skills I haven't got, as my comments about welding showed, but I also like to be part of a group of like minded people I can relate to.
One of the many Ians
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Just had the welds on the tank redone so will test tomorrow - hopefully OK now. Collected some sheet aluminium for making revised side panel mounts and a chunk of 2.5" diameter aluminium to make an adaptor for the Monza fuel cap I've bought.
A cheap petrol tap from ebay has arrived in the post and I've left its rubber seal in a jar of petrol to check that it's E5/10 proof. It seems quite a well made thing and for less than a tenner delivered what's not to like? https://www.ebay.co.uk/itm/314223108267
A bit chilly for garage work today though.
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The tap seal seems to have survived 24 hours in a jamjar of petrol without any visible effect so think it's safe. I'll leave it for a bit longer just to be sure.
Welding seems to now be petrol proof. I've made a fairly rich petroil mixture and swished it around inside in the hope that the oil will help to control any internal rust. A small amount of powdery stuff came out with the petrol so it would probably be sensible to include a filter in the fuel line.
Faced off the chunk of 2.5" aluminium for the petrol cap adaptor ready to produce vast amounts of swarf.
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Good news with the weld holding up this tie round Ian. 👍
Cheers, Michael
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Thanks other Ian.
To be honest none of what I've done so far has been particularly technical or needed special equipment. I do tend to spend a long time just sitting looking at it to decide what I want to do and how to do it although quite often I get half way through something then think of a better solution! Or, as in the case of the side panels, one presents itself. I'm determined not to alter anything original so it can always be easily reverted to standard as and when.
One thing that helps is having a lathe - I've bought a Monza type petrol cap and need to turn an adaptor to fit it onto the filler neck. Diligent internet search has turned up a fairly local company to me (Warwick) who provide a huge range of resins and talking to their technical people they've suggested this one to stick the adaptor in the tank neck. https://www.alchemie.com/epoxy-resin/ep575.html It's about £20 for enough to do dozens of tanks......
Looks interesting, I used JB weld to attach the filler neck to the tank, its still holding out after 6+ years of use
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I did a mini test of JB weld using my faithful jamjar full of petrol. I carefully joined 2 bits of mild steel taking care that the faces were clean and roughened, and then clamped and left for 24 hours before dunking in the petrol. The first week looked OK and the bond was still strong - couldn't break it by applying a lot of force - but after another week or so the surplus JB weld could be peeled off with a fingernail and when I put one component in the vice and twisted the other with pliers the joint failed.
Admittedly that was quite a harsh test as the joint was submerged. It would probably be fine if only exposed to vapour and the odd splash. I've successfully used JB weld for lots of things in the past - and will probably use it making brackets for my side panels - but thought it was worth going the extra mile (well about 15 to Warwick actually) to get specialised stuff.
I've spent the morning producing piles of swarf and now have the main dimensions turned on my adaptor - cutting a 16 tpi thread and boring suitable holes through it remain to be done.
(http://www.iansoady.org.uk/XBR500/images/adaptor.jpg)
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Top stuff Ian. Looking forward to seeing the tank with it in place 👍
Cheers, Michael
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Thread cut:
(http://www.iansoady.org.uk/XBR500/images/adaptor%20thread.jpg)
The cap in place loosely. The depression where the original flap hinge etc will be filled up to the smaller diameter under the cap itself:
(http://www.iansoady.org.uk/XBR500/images/cap%20in%20place%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/cap%20in%20place%202.jpg)
Have to stop now to prepare for a zoom this afternoon. But progress is being made. I'm expecting the new/old sidepanels in the next couple of days and have started away of attaching the front as they would normally mount to the sides of the XBR tank.
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Starting to look the part now Ian. Just wait until you’re pouring the first gallon of moving juice through that monza filler and roarting off down the road 👍
Cheers, Michael
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If the rate of progress on this thread is anything to go by, not sure I'd want to be following along as he roars off, down the lanes!
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My post seems to have disappeared! Never mind, here is a picture of a few hours' swarf production AKA making a petrol cap adaptor:
(http://www.iansoady.org.uk/XBR500/images/swarf.jpg)
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Pillow stuffing for masochists?
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The Monza filler looks good :)
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Yes, it's a nicely finished item from my local Classic Bike Shop in Redditch.
Here is the completed adaptor:
(http://www.iansoady.org.uk/XBR500/images/finished%20adaptor%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/finished%20adaptor%202.jpg)
And the very cheap petrol tap from ebay after sitting in E10 (labelled) petrol for a week. No appreciable damage which is promising. Again a nicely finished item and for well under a tenner including postage.
(http://www.iansoady.org.uk/XBR500/images/petrol%20tap.jpg)
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nice neat job that ..tommy
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Thanks Tommy.
Now I've checked the tank for leaks and swilled some petroil through it I gave it a good rinsing out with warm water. I also thought it worth checking all the petrol and vapour had gone so I put it safely outside, lit my small blowtorch and waved it over the filler. I was slightly amazed by the gout of flame that emerged - fortunately I was standing well back.
It was still burning 10 minutes later.........
(http://www.iansoady.org.uk/XBR500/images/flames.jpg)
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By stark contrast to your exciting exploits, I was assembling flat pack. Jealous doesn't even begin to cover it. Great that you got a pic to share!
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I aim to please....
Still waiting for my side panels which have been delayed by strikes I think - although good luck to the postal workers, not to mention nurses, rail workers etc.
I've been pondering how to fix the front ends of these when they arrive and have been considering using neodymium magnets rather than the bayonet type fixings. These would have the advantage of not needing very precise positioning as this would be taken care of by the other 2 corners using the existing locations. But we'll see.
A bit cold this morning!
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Looking at your picture there must be a joke in there somewhere about the cost of petrol and money to burn etc, but I can't think of one.
You certainly seem to be powering through the build which is great, keep it up. It will be a great day when you get to fire up the results of you labour and glide merrily down the street.
I'm dealing with a rear wheel puncture in the Mighty Midget, but counting my blessings as it didn't go flat until I was safely home and I have the use of my friend Jill's Lexmoto 125 so have suffered no inconvenience. Happy days.
Ian
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It will be a great day when you get to fire up the results of you labour and glide merrily down the street.
Ian
GLIDE.......Nooo. ROAR off down the street 😁👍
Cheers, Michaelican 😉
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Especially with the Goldie silencer....
Too cold to do much but have started looking at the seat / tank interface.There's an ugly gap where the seat would have met the back of the XBR tank:
(http://www.iansoady.org.uk/XBR500/images/seat%20without%20extension.jpg)
I've been playing about with bits of card to make a template to cut some alloy sheet to tidy it up. Not quite right yet but getting there. It needs to be a bit further forward. I've been experimenting with the special epoxy I picked up from Alchemie and it's brilliant stuff, glued the filler cap adaptor in very well, so I think it may work for the seat extensions as well. Although I may add a couple of pop rivets just in case.
(http://www.iansoady.org.uk/XBR500/images/seat%20with%20extension.jpg)
That white squarish thing just below the tank is the start of my side panel front attachment - there's a handy deflector just aft of the reg/rect which provided the fixing points to the frame. Again, no mods to existing stuff. I'm told the side panels will arrive today.....
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... and so they have. As it happens, the fittings that are broken on the panels are the front ones which I'll be modifying anyway. The panels are a bit rough but aren't cracked or broken so shouldd be a good basis for moving forward.
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All looking good Ian. Enjoying keeping up with this thread and the progress you’re making 👍
Cheers, Michael
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A bit of aluminuim will fill the seat gap ok but when you put the foam in that also covers up a multitude of sins as the foam sits a bit forward from the front of the seat base
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Yes, I'll stick a bit of foam forward of the upstand to close that gap a bit. I can't decide whether to lower it a bit further - I've already chopped about 80mm off it.
Firts tentative thoughts re side panel. That curved cut (which neeeds to be a bit closer to the upper edge) will avoid clashing with the tank, which is slightly raised in the pic, then I'll cut the lip off the front top edge and glue some 1mm alloy sheet behind it. If I'm clever enough I'll joggle the edge so it lines up with the existing front if the panel but P38 will cover a multitude of sins. It will also come into play to fill the old badge securing plates and I think I'll fill along the bottom edge to bring the profile down as I don't like that folded edge.
(http://www.iansoady.org.uk/XBR500/images/panel%20profile.jpg)
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Even though it's freezing out there, have made a start on filling and flatting the honda badge securing arrangement. The CX500 has ugly big raised lettering: I will put a gold Honda wing like what the bike came with. Although I have seen a Honda transfer in the style of the Norton curly N...... Dare I? https://www.ebay.co.uk/itm/144757011481
(http://www.iansoady.org.uk/XBR500/images/filled%20and%20flatted%201.jpg)
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Go for it I say, the bike will be pretty unique once it’s finished anyway. So I’d personally just add my own little slant to the final touches. I get Moto63 circular stickers made for my tanks whenever I do a bike.
Cheers, Michael
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Ian, when do you sleep? Or eat? Or leave the garage? I have this vision of the garage doors bursting open in several months and a wild-eyed man with an unruly beard running out yelling 'eureka, it's done!' then roaring (see Michael I do listen) off up the street never to be seen again.
Am I close?
Ian
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then roaring (see Michael I do listen) off up the street never to be seen again.
Ian
😁👍.... I did actually write “roarting” originally....but hey minor detail, what’s a T between friends I say😉.
Yes, I too have a similar vision of Ian bursting out of the garage 🤣🤣
Cheers, Michael
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Full respect to you for getting in the workshop in this weather. I'd go for the wings over the Norton style lettering.
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what’s a T between friends I say. Ooooo ta very much, milk and no sugar thanks.
Spatacian the thirsty
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Actually I'm not nearly as busy in the workshop as it sounds. Maybe I just work quickly? Mind you I have to these days otherwise my hands freeze to the tools. Being retired is nice as I can pick & choose my times although there are always other calls on my availability. And sitting in front of a warm(ish) computer is often more attractive than shivering in the shed.
I'll see how my paintwork comes out before deciding on the tank badge - if it turns out well I'll probably go for the wings, if not the fake Norton.
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Ooooo ta very much, milk and no sugar thanks.
Spatacian the thirsty
Being a self employed plumber, i do tend to drink a lotta Tea. Put that Guy Martin to shame I would😉
My kettle is always on and my garage door open especially for any members of the TC ??
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Nowt much to report today as too bloody cold! I've done some more flatting and filling and fashioned prototype "wing extensions" for the front of the seat to partially fill the nasty gap. Made of 1mm alloy sheet based on cardboard templates. I am slightly doubtful as to how close to the tank to make them - currently about 5-10mm gap which allows for some vinyl. I'll probably take a couple of pics and go and see my local friendly upholsterer. The last thing I want is to have it all painted up and the seat covered and find it all wants to be in the same place.
I like to flit from job to job so I don't get bored with any one thing.
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Is this the point that some projects stall and then get sold on as unfinished? You are clearly going well with this project and have a vision of the finished item, but I imagine it would be easy to fall into a lull when there's not the big, exciting jobs to do. Personally I have always tended to alter bikes a bit at a time whilst still riding them and this is because I know myself well enough to know I would get bored and lose impetus if I tried to do such a comprehensive job as you. All credit to people who can take your approach and keep up the good work.
Michael, as a painting and decorating apprentice in the 1970s I learned about the tea kettle long before I learned about the paint kettle! It must be a trades thing.
Ian
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Fortunately I am quite persistent and have never given up on any of the projects I've tackled so far - the motorcycle ones anyway. But most have been rebuilding / restoring a bike to more-or-less standard form although like you have also had "rolling restorations".
I can see pretty much exactly how this one will go and don't foresee any major problems although my goal of producing something that might have rolled out of Hamamatsu is pretty remote.
The main issue is likely going to be the paint job. It's candy apple red which involves first applying a coat of special silver after priming then applying a series of semi transparent colour coats. According to the paint supplier I do this till I have the colour I want(!) Then lacquer to finish off. Many steps to get wrong. One reason I'm not making any irreversible changes.....
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bikes coming along great ian i,m looking foward to seeeing the paint ,,just one thing i know its you build and its just my opinion but i seen a xbr with that norton style lettering on it but imho it looked terrible the wings suit the bike much better i think ,,tommy
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Will you be painting over the winter? I've always shied away because with my skills, I need all the help a dry, hot, windless summer day can provide. I guess you have a booth with halogen lamps or some such?
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I expect to be oainting after Xmas and am aware of possible temperature problems. What I've done in the past is to bring the paint and object to be painted into the house to get warm first (and even put aerosols into a bowl of warm water). That usually seems to work quite well as long as it's not actually freezing as they stay warm long enough for the paint to go off.
But....
This paint is candy appple red which I hadn't realised and which is new to me. It starts with a silver coat then a semi transparent red which you build up till - according to the shop - I get the colour I want. All sounds a bit hit and miss to me. Most of my experience is with brushed coach paint like this (although the tank was an aerosol of coach paint). I think you'll see why I'm going for a professional seat covering:
(http://www.iansoady.org.uk/FB/images/rebuilt/IMG_6538.jpg)
By the way I think you're probably right Tommy. Gold wings. And maybe a gold coach line like the Fanny-B.
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I've attached the little "wings" to the front of the seat pan using pop rivets. I tried the magic epoxy resin but it wouldn't stick to the plastic. On trying it all out it looks as though the side panels will actually tuck up under the seat and tank quite nicely if I raise the front mountings by 10mm or so, which is good news. I must say things are falling into place very conveniently.
(http://www.iansoady.org.uk/XBR500/images/seat%20wings%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/seat%20wings%202.jpg)
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. I must say things are falling into place very conveniently.
We all need just a little bit of luck from time to time Ian, just to compliment what ever skill base one has. 👍
Cheers, Michael
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Just came across this pic of a 1992 GB250 (Japanese only I think) which is very much the look I'm after (apart from the red frame!). That tank is very similar in profile to the CX500 one. I think my side panels will look better however.
(http://www.iansoady.org.uk/XBR500/images/GB250.jpg)
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Oooo that is flippin' lovely. I love the red frame, I used to paint the frames of my trail CZs red as I'm sure it made them lighter and better handling. I think the GB250 looks so useable and simple, if your XBR turns out anything like that I might have to be guilty of a little envy.
Ian
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I don't expect you to be too envious but let's see what happens. Far too cold in the garage but lay awake trying to work out the best treatment for the side panels.......
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I don't expect you to be too envious but let's see what happens. Far too cold in the garage but lay awake trying to work out the best treatment for the side panels.......
Isn't it just!? I have been out in my garage working on a new sculpture of a Puffin for Hilary for Christmas as they are one of her favourite birds and I have had my hands in cold water. They are now the colour of the GB250!
I don't mind being a little envious, it's what spurs me on to make the Mighty Midget better. I see something I really like on a bike and then think whether I could adapt/adopt a similar principle on the MM, which is of course my favourite bike ever.
Ian
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Have you sorted out your oil burning problem yet?
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Hi Ian
No sadly I haven't, though it now seems restricted to just smoking for a minute or two when started from cold or when left for an hour or so outside the bike shop whilst I have lunch.
The overall consumption seems to have slowed down to an almost acceptable level, though I don't tend to ride above 50mph as if I do it starts to get thirsty.
I'm torn between just putting up with it, going through the motor and replacing anything that can affect oil use or simply buying something else that hasn't got this problem. I love the Mighty Midget but must admit that pulling off in a considerable cloud of blue smoke when leaving home or a lunch stop and having to constantly think of checking the oil level is getting a bit stale now. I still have use of my friend Jill's Lexmoto 125 and must admit that just being able to go out without any concerns is very seductive.
Whilst reading Alex's and your own tales of old bike mending and remembering my experiences has made me realise those antics are only fun when you are young enough not to care and have no choice. These days I'm all for convenience, though still want a bit of 'thumper magic'.
Ian
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Stalled a little bit due to my soft attitude to having my fingers frozen off and now my wife's computer has crashed so I'm on IT support duties for a few days. I think it's the hard drive gone west so have ordered a new (refurbished) PC and will then have to transfer across if I can, or revert to a backup if necessary. Just when it's warm enough to go back in the garage! But I may be able to fit a little bit of tinkering between IT stuff. As they always say, never trust a programmer with a screwdriver (or spanner in my case).
I have been thinking about the seat base extensions and think they should come a bit further forward. So tasks for Christmas are:
- Revise seat extensions
- Carry on filling and sanding the tank
- Finalise side panel configuration and fixing method
Hopefully getting the seat recovered and starting painting in January / February.
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So, while waiting for Electra's new computer to arrive so I can get on with configuring it. I know what I'll be doing over Christmas.....
Revised the seat extensions to come closer to the tank. Started to cut the RH side panel - not without some trepidation. But I think it's come out quite well so far. This is the semi circular cut made with dremel mini cutter and sanding drum:
(http://www.iansoady.org.uk/XBR500/images/side%20panel%201.jpg)
This shows it in place and also the revised seat:
(http://www.iansoady.org.uk/XBR500/images/side%20panel%202.jpg)
A little more work to do to make sure there's clearance then I can start work on the side panel attachments - my current tentative plan is to keep the rear bayonet / O ring, to use a neodymium magnet for the front upper. The bottom one I haven't worked out yet. The hole in the side panel is about 15-20mm away from the location tab on the frame. Maybe just something that would hook over the tab?
Nice not to be freezing my whatsits off.....
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Moving briskly on...
I think I've finalised the side panel arrangement. I cut the relief deeper to give clearance and tried to get it symmetrical on both sides although not perfect. The panels rotate around the rear bayont fixing and actually line up very nicely with the frame tubes. I've made a bar from 5mm aluminium alloy which uses the bolts (suitably lengthened) that hold the baffle between the reg/rec and air intake:
(http://www.iansoady.org.uk/XBR500/images/side%20panel%204.jpg)
Drilled and tapped 6mm and with a backup nut JB welded as I only have cheap rubbish metric taps and the thread in the alloy isn't brilliant.
(http://www.iansoady.org.uk/XBR500/images/side%20panel%203.jpg)
Then drilled the side panels appropriately and glued a reinforcing plate of 1mm alloy:
(http://www.iansoady.org.uk/XBR500/images/side%20panel%205.jpg)
which lets the panel sit in place very nicely.
(http://www.iansoady.org.uk/XBR500/images/side%20panel%206.jpg)
The panel is very firm without a positive location at the bottom edge so I'm just going to stick a bit of old inner tube to the back of the panel where it meets the original fixing bracket. I've filled the recesses with P38.
Speaking of which I've never liked the way the lower edge of Honda (and other Japanese) petrol tanks is finished with that flat flange so am blending it to make a smooth transition from the tank side to the bottom edge. This is attempt 1.
(http://www.iansoady.org.uk/XBR500/images/blended%20tank%201.jpg)
Now off to the shops for another tin of P38.......
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As a break from the interminable filling and sanding, I ordered a pair of adjustable footrests from Ali Express a couple of weeks ago and they arrived last week. The parts that fit the big footrest plates are 1mm or so too wide so removed that with a file. They seem to be reasonably well made and the alloy quality judging by filing it is reasonable. I'm a biot in advance of myself here as I haven't really tried it for size but my experience with other Hondas is that they tend to be a bit tight on the seat / footrest dimension and after having one knee and one hip replaced my joints aren't as flexible as they once were.
At £25 or so including VAT and carriage they're cheap enough and I've also ordered a liitle flyscreen from the same place. These are the footrests: https://www.aliexpress.com/item/1005001769995799.html?spm=a2g0o.order_list.order_list_main.11.21ef1802CJNFGm
(http://www.iansoady.org.uk/XBR500/images/footrest.jpg)
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I have to say I admire your devotion to attending to detail. I suppose this is the key to the difference between a really good special that looks as though it could have come from a factory and a dodgy looking cut-and-shut. Needless to say I have produced several dodgy cut-and-shuts and not one really good special. I have no patience.
I think I rush for two reasons. First I have little confidence in my mechanical abilities so tend to want to finish a job so that I know I could do it (if that makes sense). Second I think a bike in bits is a bike crying about not being out on the open road.
I do think that when you have finished all of this painstaking detail work will show and you will have a stonker of a bike.
Ian
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Thanks Ian. I do enjoy getting the details right but I have several advantages. I'm retired so have time, a reasonable pension so not strapped for the odd few quid (although still very parsimonious so don't like wasting money), I have a decent workshop and tools, and it's not my only transport so not too much time pressure. I've also been working on bikes and cars for over 50 years so should be getting better at it.
It currently stands me in at around £2,500 of which £500 is since buying it. I think all that remains to be paid for is the seat remodelling although we will see. The upholsterer has been off this week but I will drop the seat off with him next week after all the festivities cease.
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Hi Ian
My wife retires in March and as I say to her, 'enjoy it, you've earned it'. Same for you really, isn't it great to be in a more fortunate position than maybe 30 years ago? People our age have worked long and hard to be in a position of enjoying a little more leisure time, we aren't lucky, we've worked hard to be where we are.
It is also great to use that time to do highly disreputable things like tinker with and ride motorbikes, long may the grey revolution last!
Ian
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I've just reduced down from working 4 days a week to 3 in August and now do 1 day a week from December. Still learning what to do with all this leisure time. My wife retired 18 months ago (3 years younger than me) and she loves it. It certainly takes some adjusting to. Roll on the spring when we can do more riding. I'm currently spending time sorting through the remains of stock I acquired from an old chap who spent his life working in the motor cycle trade. There only 3 crates piled up but today I've finally sorted out the last of it. I think I will be going to an autojumble in the Spring-probably at Stratford race course .
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The bit I haven'tbeen looking forward to - painting. I'm starting with the side panels. Fortunately I rang the supplier before starting as I hadn't realised that the base silver, dye coat and lacquer all need to be applied within a short period of time or they stand the chance of delaminating. so:
This is the silver base coat.
(http://www.iansoady.org.uk/XBR500/images/painted%20panel%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/painted%20panel%202.jpg)
And this the dye (colour) coat with lacquer - in something of a panic I didn't photo before applying the clear coat.
(http://www.iansoady.org.uk/XBR500/images/painted%20panel%203.jpg)
It looks a bit milky in the photo but in real life OK - although not as "candy" as I was expecting. We'll see how it looks tomorrow when it's all cured. At worst I can do it all again..... Note that those little reinforcing tabs are hidden under the tank when assembled.
Also took the seat to the upholsterer yesteday and expect that back in a week or so.
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All beginning to come together Ian. Look forward to seeing the panels, tank and seat in place 👍
Cheers, Michael
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That is looking very nice indeed. Clear coat always starts off looking a bit milky then clears to leave a nice finish.
There is something deeply satisfying about seeing paint applied and then it becoming a hard, shiny surface. One of the things I miss, the only thing I miss, about giving up my original trade of decorating many years ago is that when me and my gang of miscreants walked in to a dirty, neglected church or village hall we always walked out of a clean, re-painted building which looked loved again.
Its the same with bikes, see an old frame (or side panel) with rust and flaking paint and turn it into a lovely, shiny work of art.
Nice work.
Ian
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All was going so well but... went to check this morning and various imperfections were showing through. Obviously I hadn't followed the rule "preparation is 90% of the finish". But never mind, back to flatting off again (properly) and starting with primer again. I'm glad I tried on the side panels not the tank......
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Feeling your pain on this one, Ian, but as you say, thank goodness you knew to go with the side panels first.
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This time round I can't decide whether to try one panel first to minimise heartache or do them both again. Decisions decisions....
I gave up on cosmetics today and did the valve clearances to .005" and .007" being a compromise between the original spec and the revised one to stop cutting out. Now it probably won't start and will still cut out (not that I've even ridden it yet to find out...)
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Trying again. I made sure the paint was at room temperature and took care to shake very well. I suspect one of the problems was that I was trying to put too much lacquer in one pass and it sank through the colour and metallic coats. At least that's my theory. This is 2 coats of silver, 3 of colour and 3 of lacquer with around 15 minutes between each.
They're looking much better although I have my fingers crossed. A bit orange-peely but when it's had a good chance to harden I'll give it a go with rubbing compound. The light makes them look very orangy in the photos but in real life they're very similar to original. Hopefully I still have enough paint for the tank although there's still a way to go with that. Flatting to the right profile where the hinged cover went and around the filler tower is tricky.
(http://www.iansoady.org.uk/XBR500/images/painted%20panel%204.jpg)
(http://www.iansoady.org.uk/XBR500/images/painted%20panel%205.jpg)
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Painted panels in position. Second time lucky - they're not perfect but 90% there. Now I know how to do it I can always refinish if necessary. The colour match to the under-seat infill looks pretty good at least in artificial light.
I've bought a pair of Honda wings from ebay: https://www.ebay.co.uk/itm/144619676803 - which look good, and I've contacted the supplier who says he can do me custom side panel decals from a png file. I don't have, and don't much like, the standard ones which in any case seem very rare.
(http://www.iansoady.org.uk/XBR500/images/painted%20panel%206.jpg)
(http://www.iansoady.org.uk/XBR500/images/painted%20panel%207.jpg)
I've also fitted the little flyscreen I got from aliexpress. It's not brilliant quality but looks quite good. It would probably have been better smoked but for £15 or so I can't complain. It probably needs to be a bit lower.
(http://www.iansoady.org.uk/XBR500/images/flyscreen.jpg)
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I've bought a pair of Honda wings from ebay
You’ll soon be flying high Ian 👍👍
Cheers, Michael
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Yes, looks like it'll be ready before I will be ready to ride it!
No doubt I'll come across some awful problem before long however.
Oh, by the way you can see the lowered footrests in the first 2 pics.
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Paint looks good! Also impressed with the screen at that price.
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Starting to look good Ian. :)
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Just got the seat back from the upholsterer (Bernard at MB Trim here in Redditch, https://www.mbtrim.com/about). An excellent job at £90 and quickly turned round in a week.
Here it is on the bike. The black paint on the tank is a guide coat to highlight the remaining (many) imperfections so filling and sanding not complete yet......
Coming on well though.
(http://www.iansoady.org.uk/XBR500/images/finished%20seat%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/finished%20seat%202.jpg)
(http://www.iansoady.org.uk/XBR500/images/finished%20seat%203.jpg)
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Really starting to take shape now Ian. Should hopefully be perfect timing for the lighter nights and hopefully sunnier days creeping in 👍
Cheers Michael
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Really great price on the trimming! Thanks for the contact details.
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bike coming together nice ian ..tommy
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Not much progress recently - too cold in the shed! Apart from another round of filling / flatting / priming on the tank which is now getting somewhere near what I want. But now leaving it till next week.
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Don’t blame you Ian. Blinking freezing in my garage, minus 4 yesterday. Fortunately I only needed to nip in to get something, I wasn’t working in there ????
Cheers, Michael
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Honestly you nesh pair, I've just spent 4 hours outside. Then my wife relented and unlocked the door!
Seriously I am with you, I spend no more than an hour at a time in my garage and even then I have on a hat and warm fleece, as well as trousers etc obviously.
I expect once the weather picks up you will also pick up the pace Ian so just enjoy the warmth inside until the right day comes along.
Ian
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My excuse is that it's too cold for the paint to go on properly. But the real reason is as you both suspect....
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... but the kitchen is quite warm.
The people who'd done the Honda wings said they could make up side panel stickers to my design but stopped answering email. So a search brought up an Etsy supplier.
I created a side panel logo in MS Powerpoint and exported it as a png file. Then used paint.net to make the background transparent. Now I've never used Etsy before but for a very reasonable £5.70 a lady called Sarah made a pair for me from my "artwork". And they've come out very nicely. Shame I couldn't get them quite straight.....
(http://www.iansoady.org.uk/XBR500/images/side%20panel%20logo.jpg)
Slightly different to the ones on the original panel but I think they look quite smart and more elegant than the Honda blocky ones although they would have been easy enough to . The question is should I try to lacquer over them? My current thought is no as I don't want to risk destroying all my hard work.
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Hi Ian
Looks smart and as long as they're both at the same angle surely it will be fine. As for lacquering if you can do a test spray to make sure the sticker material won't react I would go with a coat of lacquer. The reason being I used some automotive pin striping tape on the Might Midget but it lifted and only stayed put after I replaced it and sprayed over it. Maybe the weather and wind got underneath it.
Ian
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I'm with Ian ! Looks very smart, the decals. Are they laquer-resistant?
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I don't know - should have asked the supplier, or got some offcuts to try. I don't want to have to redo it all (again!).
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I don't know - should have asked the supplier, or got some offcuts to try. I don't want to have to redo it all (again!).
Hindsight Ian, it’s a wonderful science and one that we ALL wish we could master from time to time.
Looking good tho 👍
Cheers, Michael
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Loving the look, that seat has come up a treat
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Thanks Joolz, I'm very pleased with it. There's a bit of a gap - 5mm or so - between the back of the seat and the moulding which I may ask the upholsterer to fill later on but that's just being picky.
In other news I tried a little dab of lacquer on the side panel stickers and it didn't seem to have any bad effect so I've given the panels a couple of coats which look to have gone on nicely. I warmed the can in hot water before spraying which I think might have achieved a slightly better finish.
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I took advantage of the slightly warmer weather to spray the tank. I have to admit I was a bit scared of this as it involves 2 coats of silver, 3 of colour and 3 of lacquer - all to be applied in 10-15 minute intervals. But I'm really pleased with the reults. Apart from a little imperfection on one front corner - a bit of dust? it's looking pretty good. All that filling and flatting was worth while.
I have a pair of Honda wing decals and am pondering whether to add some gold lines. Possibly in a Manx Norton style.
Here we are:
(http://www.iansoady.org.uk/XBR500/images/painted%20tank%204.jpg)
(http://www.iansoady.org.uk/XBR500/images/painted%20tank%203.jpg)
(http://www.iansoady.org.uk/XBR500/images/painted%20tank%202.jpg)
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Quite apart from your decent paint job, I didn't think your side panel was going to look THAT good. Big congratulations, Ian!
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Thanks Matt, I'm very pleased with how it's all come together - after a lot of false starts! Thanks as well to you & Joolz (and others) for helpful ideas etc.
Now I'll have to see if I like riding it......
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Wings applied. For some reason the photos seem to exaggerate the orange peel effct. It isn't as bad in real life. Honestly.....
(http://www.iansoady.org.uk/XBR500/images/wing%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/wing%202.jpg)
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Aye Ian,
This re-finishing compound works very well on "orange peel" rattle can paintwork: Farecla G3 Pro Colour Restorer 500ml
Use the foam pads that are designed to apply the compound and I found worked very well on my Ducati 450 side panels, sprayed with Holts "Ford, Rosso Red": Farecla G3 Pro Applicator Waffle Pads
Both are available off the shelf in Halfrauds.
Good health, Bill
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Thanks Bill, as I say looks much better in life for some reason. When I finish various details I'll roll it outside to take some better snaps. But will bear your recommendation in mind....
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Just put a gallon of petrol in and started up for the first time since I bought it. It runs very nicely and sounds good - I've fitted a mute in the end of the Goldie silencer but will see how it runs with that.
Being a confirmed softy I will not take it on the road till warmer times.
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Great result Ian. 👍..... I’m going to kindda miss this thread, enjoyed watching your progress with. Hopefully you will have many happy S,miles on it👍
Cheers, Michael
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I couldn't resist shoving it out of the garage to take a couple of snaps in daylight.....
(http://www.iansoady.org.uk/XBR500/images/finished02.jpg)
(http://www.iansoady.org.uk/XBR500/images/finished07.jpg)
(http://www.iansoady.org.uk/XBR500/images/finished12.jpg)
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Very tidy Ian.
Go on, give it a whirl! ;)
Good health, Bill
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Looks a treat! 👍
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Nice one Ian.
Enjoyed your thread and admired your skill.
Hope to see the bike one day
Kev
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Thanks for all the kind words. It's been very helpful to know that people have enjoyed what I've been doing especially when things weren't going well. It's taken almost exactly 3 months and has cost round about £600 on top of the purchase price of £2,000. It's amazing how the costs mount up but I think it's been worth it.
Now I'll have to find something else to keep me off the streets.......
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Yes well done-an interesting thread.
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Now I'll have to find something else to keep me off the streets.......
Ha, ha! You might be hard pressed to find an alternative as satisfying. When you posted about lying in bed with all the permutations going around in your head, I thought you might get hooked. More so now that you've achieved such good results.
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Now I'll have to find something else to keep me off the streets.......
You can come to work with me Ian if you like, I can show you how to bend copper pipes, lead burn (weld) The pays not brilliant but always plenty o tea or coffee on tap 😉
Cheers, Michael
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Thanks but no thanks.... My adventures in plumbing have not been great successes. I vividly remember the winter of 1982 when we had snow all up the back of our terraced house and the pipes froze solid. No central heating, just a coal fire in the living room and a gas fire in the front room. By jove we were tough (I digress). We were also very hard up.
Anyway I came down with a bad dose of flu just before the thaw set in and what happened? What you might expect, leaks appeared everywhere. I spent days crawling about lifting floorboards and remaking popped joints - fortunately none of the pipes had actually split. I swore then that if I ever had enough money to pay someone else to do that sort of job that's what I'd do. And I do.....
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... well it is now (sort of).
I was sitting in the garage admiring my handiwork when I noticed the state of the exhaust front pipes. They're stainless and quite badly disoloured (see pic 1). Some years ago I had the stainless pipes on my Guzzi V50 professionally polished and it cost nearly as much as chroming!
So I decided to see what could be done with elbow grease and carefully selected materials. I started with 1200 grit wet & dry lubricated with T-cut then moved on to wire wool then sctotchbrite. I finally finished off with chrome polish applied and buffed up with a soft cotton cloth.
Now while not up to professional standards it was well worth a couple of hours work.
Original:
(http://www.iansoady.org.uk/XBR500/images/exhaust%20original.jpg)
After polishing:
(http://www.iansoady.org.uk/XBR500/images/polished%20exhaust%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/polished%20exhaust%202.jpg)
(http://www.iansoady.org.uk/XBR500/images/polished%20exhaust%203.jpg)
(http://www.iansoady.org.uk/XBR500/images/polished%20exhaust%204.jpg)
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A great result Ian and money saved-well done.
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Nothing more satisfying than a good result after a bit of elbow grease. Look great.
I’ve found crunched up silver foil to be a good addition to the polishing armoury.
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Good result Ian 👍..... just one more thing now to put that elbow to good use. Pour yourself a nice single malt and use ones elbow to sip it and savour it. 🥃
Cheers, Michael
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Already done Michael. Cheers!
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... that adding pinstripes to the tank would be a good idea? It looks a bit blank without. Ideally I'd like something like a Manx Norton pattern but getting curvature on wider tape is tricky. A couple of mock-ups:
I think further down the shoulder looks better.
(http://www.iansoady.org.uk/XBR500/images/lines%201.jpg)
(http://www.iansoady.org.uk/XBR500/images/lines%202.jpg)
This would be my ideal (in gold) but too hard:
(https://www.racingvincent.co.uk/03%20Photos%20-%20Backdrop/Screensavers/DOHC%204b.jpg)
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I'd think the Norton stripes would be paint?
Pin striping... try keep it warm so it's pliable
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Yes indeed they would have been, and hand applied to boot. My attempts on my ES2:
(http://www.iansoady.org.uk/Norton/images/es2%20at%20webbs%20lane.jpg)
Done with One-Shot signwiriter's enamel brush applied between 3mm 3M tape. It works well but gold paint is a different matter. Here is the same technique I used on a Sunbeam I restored some years ago:
(http://www.iansoady.org.uk/Sunbeam/images/IMG_3692.jpg)
Unfortunately the gold lacquer I used was far from petrol resistant even with halford's allegedly petrol proof lacquer.
With the XBR I have spent much time and effort on the red finish so want to use a simpler method hence using pinstripe tape. I did use the tape for a restoration of a Francis Barnett a couple of years ago but only 3mm narrow stuff so the bends worked fairly well. However you can see an imperfection in the tight curve behind and below the knee pad. I wouldn't get away with that using the 6mm wider tape hence my thoughts of keeping it simple.
(http://www.iansoady.org.uk/FB/images/rebuilt/IMG_6534.jpg)
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Pinstriping mockup looks really good! With your previous results painting the Norton, everyone will be expecting another first class job. No pressure. 8)
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I always like to have a clock on my bikes so I don't miss closing time! I'd forgotten that I'd ordered this one from ebay. It comes with a handlebar attachment which is obviously no use for the XBR so 40mm of aluminium alloy from Rapid Metals and an hour or so on the lathe produced a nice little mounting to fit between the speedo and rev counter. Looks quite good I think. About £6.50 for the clock (it comes from China so takes a long time t arrive hence my forgetting it) and a couple of quid for the alloy.
Components - the supplied clip is to the right, my manufactured mount to the left:
(http://www.iansoady.org.uk/XBR500/images/clock%201.jpg)
In place matching up quite nicely:
(http://www.iansoady.org.uk/XBR500/images/clock%202.jpg)
I can fit the original mount to the Norton and swap the clock back & forth.
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Yet another good result Ian.... but don’t look now but I think you’ve missed closing time ?😉
Cheers, Michael
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Neat job as always Ian.
I could do with a clock like this for some of my bikes. Could you provide a link please?
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This is it Martin: https://www.ebay.co.uk/itm/195144145547
Can't guarantee how long it will last. It looks exactly the same as ones sold for £30+ by various dealers.
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Thanks Ian.
I bought one of the £30 ish ones for my RE Interceptor 650 , it lasted around 12 moths and cost a small fortune for a new battery so I agree it's worth a risk at that price.
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the bike looks well ian .tommy
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Spot on, love the look of the bike
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Thanks both, I think I've pretty much achieved what I set out to do. I'll tax it in March and hope it's as much fun to ride as it has been to build.
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Have you got the bike on the road yet Ian? Weather has been extremely poor round here so I won't be surprised if the answer is in the negative!
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Taxed Martin but on the odd fair days we've had have had other commitments, but hope springs eternal.
I know, you're just waiting for me to decide I don't like it so you can make me an offer I can't refuse......
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Taxed Martin but on the odd fair days we've had have had other commitments, but hope springs eternal.
I know, you're just waiting for me to decide I don't like it so you can make me an offer I can't refuse......
Hmmmmmmmmmm....!!!!!
It wasn't an entirely conscious thought but.........
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Go on Martin, the ES2 is Ian's first love! ;)
Good health to you both, Bill
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Go on Martin, the ES2 is Ian's first love! ;)
Good health to you both, Bill
My wife won't like it.....
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Well, after weeks of trying and failing to get the XBR running properly I have eventually tracked down the problem to..... the CDI unit. A replacement from a Dutch company has done the trick after I spent fruitless hours trying to get it to work as it arrived with no instructions and wrongly wired. I've left a suitable review on trustpilot.
I also bought a cheap (£10 or so!) CDI and coil from ebay and it seems to work just as well although haven't road tested it. I will try probably later in the week.
I have to say that the bike rides very well - the raised bars and slightly lowered footrests make it comfortable, handling is excellent, brakes good and of course it looks so much better (to my eyes) with the CX tank. It doies need a bit of tweaking - stumbles slightly off idle and is reluctant to rev over 6,000rpm but that's not my style anyway.
A reminder:
(http://www.iansoady.org.uk/XBR500/images/finished02.jpg)
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Aye Ian, pleased to read that the diagnostics are not failing you.
As for the "Dutch company....."? That wouldn't happen to be HPI from Belgium?
I hope that you can get the carb sorted, sounds as though coming off the pilot jet and onto the slide is the problem with the bottom end stumble, whilst the top end could be that Gold Star "silencer" having too small a diameter hole in the internal core. An Armours one, of similar design, throttled the mid to top end of the Ducati for that very reason.
Treat it like the Norton ES2 and let it breath! ;)
Good health, Bill
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Thanks Bill.
It has a CV carb which I'm less familiar with - if it was an Amal I would be thinking slide cutaway but it doesn't have one. TBH it's not that bad - just a slight miss.
The hole down the middle of the Goldie "silencer" is about 1.3/14" (45mm) all the way through which should be enough. It certainly has a healthy crack - I did have a mute fitted which did the opposite of what I wanted which was removing the low frequencies but keeping the high ones. It even has a version of the Gold Star "twitter" on overrun.....
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Oh, by the way, the Dutch company was Carmo. They list their product as "plug and play". Hardly......
I wouldn't be surprised if it was merely a repackaged cheap Chinese item.
https://uk.carmo-electronics.com/webshop/improved-cdi-tci-ecu-replacers-units/cari-cdi02a-xbr500
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Morning Ian,
MMMmmm! CV carbs. I think that the SRX600 50:50 job is quite enough of a mystery for me, I have not had to deal with CV alone set-ups, so they really are a dark art.
Maybe try one of those Chinese Mikuni round slides to see if it tidies things up, although I haven't gone searching for alternative carb set-ups. You could always retain the OME carb, just in case.
Blazing sun at present, so finish creosoteing and then a canter. ;)
Good health, Bill
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TBH it's running well enough for now and I have to say I've had enough (for the present) of delving into it. Funnily enough I've just bought a Chinese Mikuni copy for the Tri-Greeves but feel it's too small a bore although it is nominally the same as the monobloc it should have. I do have one of these but it's in pretty terrible condition and would cost a fair bit to fix. I may but a slightly larger Chinese carb as well. At £20 or so even if they don't work at all they won't bankrupt me.
I have to say I've been pleasantly surprised by the quality of the cheap CDI unit I bought and will probably try it out later in the week as it's a 2 minute job to swap over.
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Hi Ian
Don't read this the wrong way because it is a compliment; having seen your latest photo of the XBR I am reminded of my own lack of talent in special building! That is a lovely bike and I am sure you will solve the running issues soon, after all XBRs are simple bikes and you have mucho skill.
I have looked hard at the Inazuma and am in danger of starting to cut it about to achieve a look I have in mind, but I know if I do it will turn into a dog's dinner and ruin a perfectly good bike. Good for someone else that is. I may run it for a short while longer, but I really think I should sell it before I ruin it.
Ian
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Don't read this the wrong way i think I should sell it before I ruin it.
Ian
What is it the SAS say “he who dares wins”
Well admittedly you’re not the SAS🗡 (or least I don’t think you are 🤔) but I say get that angle grinder working overtime and make the bike you want 😉🛠
Name withheld... just in case you ARE the SAS
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Michael
It is true that I am a trained killer, hang on I meant to say it is true that I am a drained pillock.
I appreciate the encouragement but unlike your good self and others on his forum I only know how to cut things up, I haven't the skills to put them back together. I never had much use for welding etc when administering medication via a P.E.G feeding tube.
I think my plan to avoid ruining a decent bike must stand.
Ian
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so Ian.... is it going on the market? i've never owned a honda (excluding my 'easy start' lawn mower) and i'm a sucker for a good looking thumper :D
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I'm beginning to think it may be a keeper.....
But I've thought this before.
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well, having sorted all the problems out you may as well enjoy it!
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I am so far. But you never know how I might view a generous offer!
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well, in that case here's a couple of quid (which will obviously top Bill's best bid ;) ) keep us posted :). oh... and don't go thrashing it about and clocking up mega miles or that bid might have to be reviewed .
pip pip