151 Title speedo drive

I figured it was time to post some garage updates. Things have not slowed down and the garage continues to be just as active as it has always been. So busy that it is hard to put down the tools in order to update the blog. Well today is the day that I was able to upload a pile-o-pics to show what kind of work has been taking place on the 1965 Honda CB160 rebuild.

The last update showed that the bike finally got torn down and the fabricating continued to take place. Eventually it got to the point where I had to direct my attention to the bodywork and painting. Both things that I do not have a high level of confidence in performing. However I have no choice. My goal is to prove to myself that a decent bike can be built all within the confines of my 4 garage walls. So I trek on and tackle the aspects that require a certain amount of learning on my part.

I finally was able to paint all the components. I spent an entire weekend setting up my collapsible paint booth and spraying everything that required paint. It was a huge step that I completed and which also got me 1 step closer to the reassembly phase.

So I have posted the pictures and provided captions to help show what I have been up to over the past couple of months. Things continue to move along and progress is smooth. Enjoy the show.

151 Lower triple mod

The lower triple initially had the steering lock tumbler mount cast into it. My original plan was to keep the steering lock however the tumbler was to far gone to save therefore I opted to remove all evidence that it ever existed. I cut and ground the casting off on in the center of the triple. In order to mount my aftermarket steering stabilizer I needs to mill a flat surface on the triple for the stablizer bushing to mount flush on. My mill chuck was to big to get the job done so I used the drill press to clean up the surface.

151 Triple thread repair

The stabilizer mounting threads were stripped out so I ended up performing a thread repair. Years ago I got onto Time-Sert kits and have fallen in love with them. I will never go back to a Helicoil again.

151 Speedo drive adapter

In a previous posting I outlined how I was going to use a GPS based speedo signal. Part of the reason for doing so was to eliminate the front speedo drive cable. With no cable I no longer need the speedo drive which mounts onto the front axle. Since the drive also acts as a spacer I needed to machine a new spaacer to take its place. I could have made a fairly plain, yet functional, drive fairly quickly however I wanted to give the new component some good looks. I opted to machine a rounded, concave, cosmetic groove into it using my rotary table and my mill.

151 Finished initial cut

A pile of shredded aluminum was what I was left with once I was content with the groove depth.

151 Finishing speedo on lathe

The remainder of the adapter was finished up on the lathe.

151 Completed speedo adapter

On the left is the original speedo drive and on the right is the freshly machined spacer intended for taking the drives place. Still needs powder coating.

151 Throttle housing 5mm thread

Back in the sixties Honda built there bikes using a JIS (Japanese Industrial Standard) thread pitch for all of their bolts. Some of the thread pitches were different then what eventually became an industry standard years later. The 5mm bolt is one of the threads that changed. Since I updated many of the fasteners on the bike I opted to update the thread pitches as well. I installed a couple of industry standard 5mm Time-Serts in the throttle housing so that I could now use readily available SS socket head bolts.

151 Frame blasted

So with much of the fabrication work completed it was time to shift my focus to paint. The frame mods had all been done and therefore it was time to start the paint prep work. As much as I like to keep all my work “in-house” I opted to send the frame out for blasting. The simple fact is that I could not fit the frame in my blast cabinet and I was not about to blast it outside as the mess is not worth it. The company that performed the blasting did a great job.

151 Fiberglass prep

Bodywork is not one of my strong points however it was not going to happen on its own so I just sucked it up and did it. Once I got into it the progress clipped along at a good pace. The aftermarket fiberglass components purchased from Glass From The Past were in good shape. There were some minor pinholes that required touch up using glazing putty.

151 Centering front fender

I had forgotten to trim the fender mounting holes prior to tearing the bike down. I was forced to temporarily rebuild the front end in order to trim the fender up to ensure it would be centered on the front wheel.

151 Prepped for paint

Here are all the components (minus the frame) that are going to recieve the paint. All ready to go into the paint booth.

151 Liquid supplies

I am shooting 2 colors. Some of the components will be getting sprayed with Hot Rod flat black and the tank and seat pan will get some color put on them.

151 Primer shot

With the primer coat applied I was able to confirm the fibergalss parts were in very good shape.

151 Fixing pinholes

I had missed a few pinholes on the seat pan during my initial prep. Since the pan is such a huge player in the look of the bike I opted to touch things up and respray the primer before it went in for the base coat.

151 Frame flat black

Here is the frame and front fender hanging in the paint booth with a fresh coat of flat black applied. No runs!

151 Retro brown

The retro brown color was mixed up and the tank and seat pan were about to come alive.

151 Brown seat

The brown sprayed on great. Each component got three coats of top coat. The plan is not to apply a clear coat as the vintage/retro look is what I am going for.

151 Brown tank

The lighting in the paint booth is great for painting but not so good for photography. At least you can see the results of the sprayed tank.

151 Brown cowl

I am very happy with the seat cowl, it looks like glass.

151 Painted matte black

After a weekend of work I was able to get all my components painted. Here are all the flat black components. I will post more on the colored parts later.

151 Powder coat pile

With the painting complete I still had to make a few more powder coating runs. Here is yet another pile of components getting coated.

151 Swing arm getting powder

I opted to powder coat the swing arm instead of painting it. Powder coating is so much more durable. I was intially concerned that my flat black powder coat may be a slightly different shade then the Hot Rod flat black sprayed onto the frame. It turns out the colors are incredibly close to the point were you can’t see a difference.

151 Powder coating hardware

Some parts fogged with powder prior to baking.

151 Powder coated pile

Here is one pile of completed poweder coated parts.

151 New balls

With 90% of the refinishing complete there was nothing left to do but reassemble. The steering head recieved all new, OEM Honda, inner/outer races and ball bearings.

151 New rear sprocket

The rear wheel recieved a new 38 tooth aluminum sprocket from Sprocket Specialists.

151 Swing arm install

Swing arm installed.

151 Rear sets installed

Rear sets installed.

151 Rear detail

Rear wheel and rear suspension in.

151 Rear end supported

Finally got the bike to stand on one leg.

151 Ready for an engine

Front end is installed and now the bike waits for the engine (sitting on the bench). I had previously fabricated a different kick stand which bolts to the lower engine case therefore the bike won’t have a “third leg” until the engine is in.

151 Taking shape

With the help of a couple of friends we were able to slide the engine in place creating no damage in the process.

151 Engine installed

So here it is, progress keeps going. I continue to go full steam ahead. I will try and not wait so long to get the next installment of the 65Revive project posted. Stay tuned.

Comments
  1. raceman says:

    nice to see some of your work again
    i’ve missed that

  2. Jason Garber says:

    Keep it coming Gord. This is some awesome work and I love the pic/text/pic/text/pic/text format.

    • gordsgarage says:

      Thanks Jason, glad you like the format, it makes things easier for me. After 150 posts I finally figured out how to categorize my pictures better to make the uploads way faster. I’m a slow learner. The picture/caption format speeds up the entries. How is the new workshop going?

      Thanks!
      Gord

  3. Luis Rodrigues says:

    AI CARAMBA!!!! Nice work. If envy is a sin, I’m doomed to go to hell. How about using the All Balls Bearings (http://www.allballsracing.com) to replace the original ones? I tried those on my 83 VT750 Shadow and I can tell you that it was a real nice and noticeable change in handling.
    keep those pics coming.

    • gordsgarage says:

      Thanks for the comments Luis. Sometimes I think I should post my intentions prior to executing them in the garage. The main reason for this is because guys like you have great suggestions after the fact. I took a look at All Balls Bearings, wish I would have gone that route but I didn’t know at the time. When the bike is due for maintenance I will upgrade.

      Thanks!
      Gord

  4. Brian smart says:

    Thank you for sharing , beautiful work and hope you get years of enjoyment from it BS

    • gordsgarage says:

      Thanks Brian, I enjoy the process. The bike will reach completion soon and I am guilty for looking at the motorcycle ads for another bike to rebuild. I have too many other projects I want to do so I will hope that self control will kick in and I will not find the perfect bike to buy. I am looking forward to actually riding the bike come spring as I have never rode it yet.

      Thanks!
      Gord

  5. Dodge says:

    Thanks for the update Gord, fascinating to see your work as always. Looking forward to the final installment(s)!

    • gordsgarage says:

      Glad you follow along Dodge, I appreciate the comments. The next CB160 post should hopefully wrap up the build. I am disappointed that I did not document some of the custom fabricated details however, as most people can relate too, once I get working it is hard to stop and take the time to shoot the pictures. Anyway…I will try and post lots of details yet.

      Thanks!
      Gord

  6. Dan says:

    First, great to see the update and progress. Thanks for sharing the learning process.

    One comment on the brown painted parts. You mentioned that you didn’t clear coat so they would have a flat finish. If the paint is a base/clear system be aware that the base doesn’t have any UV protection and fading might be an issue. They do have non gloss clear coats that will give you the look you are going for and also provide the UV protection for the color coat.

    Keep up the good work!

    • gordsgarage says:

      Thanks for the support Dan. You are correct that I did not clear coat the parts however it was not for a flat finish. I didn’t clear coat because I did not want the depth that clear coat brings to paint. The brown is glossy however it does have the look that it is under clear. However you bring up a good point in regards to the UV stability of the base coat. I am unsure if it will fade.

      There is actually a story behind the color choice and I am not 100% sure I am completely satisfied with my choice. I will not bore you with details however…I had contemplated painting the frame with my color choice but then decided against it. I decided I would only paint the tank and the seat pan and the main reason was that if I decided I did not like the color, or I want to change the color, all I need to do is repaint the 2 components. If I integrated the brown into other areas of the bike it would be difficult to fix my color choice at a later date. If the paint fades and I am forced to repaint and clear coat I am not stressed. The tank and seat are easily removable and repairable.

      Thanks! I appreciate the heads up.
      Gord

  7. mikesplace2 says:

    Wow, your work is always amazing and inspires me to try just a little bit more for quality in all of my projects. Your thoughtfulness in sharing your work is very generous and appreciated.

    • gordsgarage says:

      Glad you enjoyed the posts mikesplace2. It’s funny that you comment on the quality. I certainly strive to be detail, and quality, orientated however there are always flaws and things I am not happy with. It is a constant battle to know when to accept something that is not perfect. Things never work out 100% to ones liking however experience shows that experience pays off. Mistakes and sub-par work is an important step in reaching a higher standard in future projects.

      Thanks for the comments!
      Gord

  8. Good, very good.

    Parabéns, meu amigo. O trabalho está de primeira linha.

  9. Dutch P.Boss says:

    Hello Gords,

    That works looks good, i really appreciate it.
    Good luck with your work.

    Peter.

    • gordsgarage says:

      Thank you for taking the time to comment Peter. My goal is to leave nothing unfinished. When the bike is complete it will be complete! I am getting close. There are obstacles to overcome and forethought helps but it does not catch everything. I have had some challenges to overcome during re-assembly and have yet to evaluate what may require fixing once the bike is running and test ridden.

      Stay tuned!
      Gord

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