Posts Tagged ‘kick stand’

Title Petcock

So I was able to get back onto the CB160 cafe racer project. Building the monitor stand was a good break as it allowed me to regain some focus on the 65 Revive situation. I had got my way through the kick stand project and I was happy to have got that challenge over with. Building of the kick stand was a necessary step in the master plan in regards to the exhaust system.

Getting into position

Decided to flip the bike upside down to make the fab work a bit more accessible

The bike is going to get a full custom stainless steel 2 into 1 exhaust system. In order to accommodate the exit chamber for the CO I needed to clear room under the engine and frame. One factory component that needed to be removed was the center stand as it sits exactly where the exhaust will need to be routed. So with the side stand previously fabricated I was now able to start chopping up the factory frame.

Center stand has to go

This is the mess I am dealing with. I realize it is hard to decipher the details based on the picture however much of what you see needs to go.

With both the center stand removal and the future exhaust work required I had thought about raising the bike up onto a couple of saw horses. This would have required a second assistant but at the time I was ready to start work there was no one in sight. I figured the bike has no liquids in it, except for the shocks, so I opted to flip the bike upside down and rest it on the rear frame rails and the original handlebars. I am glad I did as it made the frame mods so much easier to execute.

Starting to clean up

I needed to get a better idea on where to chop up the frame so I started to cut tabs and supports off in order to gain a better perspective.

I had not previously brainstormed plans as to how I was going to accomplish the center stand removal and frame mods so I opted to just “wing it”. Obviously the first order of business was to unbolt the center stand. With the stand removed it was evident the number of extra tabs and mounts that were welded into the lower frame section. Part of building a cafe racer is all about cleaning up all the unnecessary equipment so the plan was to strip everything that wasn’t required off of the frame.

Chopping junks

No going back now! I fired up the plasma cutter and chopped up the side supports then I broke out the cut off wheel and trimmed up the center tube.

One of the things to consider before chopping up the frame is how the modifications will impact getting the bike, eventually, registered and insured. I am unsure of the rules in my local area concerning motorcycle frame modifications however it is my unofficial understanding that cutting and welding a frame is a big no-no unless you have the right credentials. Anything that could be considered a safety factor when modifying a frame is something I want to stay away from. In the case of the center stand frame supports there is nothing that would be considered structural therefore I felt confident in stripping away some of the unnecessary frame.

Shredded stand

Here is all the sacrificial metal stripped from the bike. Was able to shave off a bit of weight.

I started by grinding off the old center stand mounts, brake pedal pivot, and rear foot peg mounts so that I could get a better view of the extra frame section I was dealing with. Once I could see things in more of a 2D image was able to light the plasma up and chop off some unwanted frame section.

I had previously purchased some Moto-bits rear sets that use the mounts for the rear foots pegs. As I stared at the frame section that included the rear peg mounts I decided to clean it all up and make it look like the rear sets were not an afterthought.

Using a round section of .625” cold rolled steel I machined some 8mm threads into the ends in order to mount the rear sets to. I had already chopped off the factory rear foot peg mounts and planed to replace the supports with a solid, one piece, section of steel in order to mount the rear sets to.

New rear set support

Here is the mocked up support for the rear sets that will get welded and, in turn, add support back into the lower frame section.

So from here on in there is not much to say or exciting pictures to show. Basically the frame got chopped, the new section of machined steel for the rear sets was set into place and things were welded up. I think the frame mod came out very well since it really cleaned up the underside. People may never notice that the change was made however it is the small details that make the difference. Quite often it is the subtle highlights, the ones people can’t pick out, are what creates the visuals. So as uneventful as this task was it is, at least, completed and I can now move onto the exhaust fabrication.

Center stand gone

Mission accomplished! New support rod welded into place and the side frame members got rounded, cleaned up, and finished off to give a clean look. I suspect the modification will look good when the frame is blasted and painted.

Title belt sander

I feel like I need to state the obvious, this kick stand project is dragging on. I can make excuses but what’s the point? The only person that is affected by the lack of progress is myself. I have collected many parts that are tempting me to switch gears to a different fabricating aspect on the bike my head is telling me to get through the kickstand and reach completion before moving on.

Milled for mounting

Mounts TIG welded

Although the main support shaft looks to be built from 1 solid piece it is actually a hollow section with the two ends welded on. My main concern was to keep the weight low.

I had previously worked at getting all the angles figured out. I do not possess the skills to be able to create a 3D working model in a CAD program and so I needed to rely on old school methods and just had to puzzle it out. The project was at the point where the previously built components required welding and the addition of known components had to be built and the stand cleaned up.

Pivot stop

Pivot parts joined

So I started to tack components together so that I could do some preliminary test fitting. The kick stand itself went together nicely however the mechanical aspect of the over centering spring had yet to be determined. I had plenty of hours into trying to make things work. The pictures I have included in this blogs posting do not tell the whole story. There was plenty of trial and even more error.

Stand stop

Stand cleaned up

This extra tab is the stop for when the kick stand is in the lowered position.

I had initially planned on building the over centering aspect based on the millions of other kick stand designs. What was the point in trying to reinvent the wheel? Well it turns out that I positioned the pivot point of the spring in the wrong location. The kick stand would snap down into the lower position but it would not stay in the retracted position. I know why it didn’t work however trying to change it so it would function was not easy.

Stand test fit

2 inch foot plate

Building the kick stand “foot” using 2″ solid round bar.

I was very cramped for space. I am trying to build the kick stand as cleanly, inconspicuous, and self contained as possible. I struggled with finding a solution to position my pivot points correctly. It was time for a total re-think. A new approach was needed and thinking outside of the box had to come into play. In order to make room for the over center pivot point I was going to have to abandon the conventional methods. Typically an expansion spring is used which requires the over center pivot to be placed above the kick stand pivot. In my case I decided to explore the idea of using a compression spring and therefore I would be able to place the over centering pivot below the kick stand pivot where I would have more room.

Stand alone set up

Bike lean

I am unsure what is standard as far as bike lean goes. My stand allowed for just under 5 degrees. It looks right and hopefully it will be enough so that a wind gust won’t knock the Honda over.

So as I played with this idea the plan finally came into clear view. It was about time! I was able to track down a short version of the typical hydraulic struts used on automotive hoods as the hood props. I found a short version that is used on Porsche Cayenne SUVs that return the park brake pedal to rest position. The length was perfect and the tension felt adequate.

Machined ball

Hydraulic and balls

So off to the lathe I went to machine up the pivot balls required for the mini strut to snap onto. After lots of fitting and mocking up I was able to determine where my pivot points had to be and proceeded to build the brackets. Knowing I may have to scrap the whole idea if it doesn’t work I tack welded everything together and proceeded to perform a full function test. Awesome! The pivot point turned out to be perfect. The kick stand both lowers and rises into its rest position on both ends of the scale. It is secure and safe.

Drilling the stand

So finally I have reached a point of satisfaction. Not only is the kick stand fully functional but I think it also looks fantastic. The strut is hidden in behind the rest of the stand and the complete assembly tucks up out of the way. Nothing is obtrusive or ugly and having the strut on the stand gives it a super cool “trick” look to it all.

Ball fitted

So for now I am going to check this on off my list. The stand still requires powder coating however I am holding off until the exhaust is complete. There is a chance I may need to weld a support for the exhaust to the stand. The difficult part is complete I can finally move forward with more exciting aspects of the project.

Completed kick stand 2

The completed kick stand in the retracted position. Nice and clean.

Completed kick stand 1

Title muffler

The planning of the next phase for the 65 Revive project continues to take place. When I build projects that require raw materials, like metal, I can usually obtain everything I need locally and therefore the collecting of the materials do not consume much of my time. In the case of the CB160 cafe racer build I find myself having to work 3-4 weeks in advance since many of the components need to be ordered and shipped.

GFTP Parts

GFTP order. The “ears” on the front fender will get trimmed up.

Rock guard placement

Rock guard set in place. The portion that extends above the frme will get trimmed down.

Well I am getting closer to being able to cut, grind, and weld since most of my crucial “fit” components have showed up. Previously I had done my “best guess” as to the proper seat dimension required to give the “cafe racer” look but also ensure that the bike fits me and is comfortable to ride. I had put in an order from Glass From The Past for an upholstered seat, a front fender, and a rear rock guard. The parts arrived and passed initial inspection. The fibreglass finish is fairly rough and will certainly require some high build primer, and maybe even some glazing putty, to smooth things out before painting. The front fender and rock guard will also require some trimming to give them the required “look”. I had chosen to have the seat upholstered and spent the extra few dollars for the genuine leather cover. The upholstery work looks great, super clean, and nice lines. I am not qualified to critique stitching however I have no negatives to report.

Seat upholstry

Seat pad unbolted

The seat pad unbolts from the fiberglass seat pan to allow for pan body work and painting.

Part of my planning process involved spending lots of time mentally designing the custom exhaust. The plan is to change the factory dual exhaust into a full custom 2 into 1 setup. When it comes to planning out angles I do much better if I can physically work with the components to make them fit. Unfortunately, in the case of the exhaust, I need to order all my bends therefore I did what I could to design the system using Vise-grips, angle gauges, and protractors. I did the best I could to pre-determine all my required angles and then took a deep breath and put in an order with Columbia River Mandrel Bends. I opted to go for 16 gauge stainless steel pipe. The plan is to build a race style system and leave all the TIG welds exposed to give the set up a real raw look to it. All my exhaust components showed up as ordered. It will be interesting to see if my grey matter design will turn into a reality.

SS mandrel bends

My complete order of 16 gauge stainless steel mandrel bends. Hope I guessed right.

Another crucial component required to finish off the exhaust is a muffler. I stumbled onto Megs Mufflers website and was immediately sucked into all their products. They offer everything in order to build your own custom mufflers and look to supply quality components. The CB160 will eventually have to go through a mandatory government inspection before I will be able to register it. Part of this inspection involves the muffler and its noise level. My intent with the bike is to make it 100% legal as well as have a finished product that won’t annoy my neighbors. I opted to go with Megs “Quiet Core” Street Series muffler. It is the quietest one they have plus it sports the “look” I want. It’s a brushed 304 Stainless steel unit. The build quality looks great and the size should match the bike great.

Megs muffler

Megs quiet core muffler. 18 inches over all length.

So as I was waiting for all my orders to show up I decided to start working on the first actual bike modification. The center kick stand is going to interfere with the way the exhaust system is going to be routed. I expelled a substantial amount of mental energy trying to come up with a solution that will allow me to maintain clean lines yet still serve a purpose. In the end I decided that the center stand has to go and get replaced with a side stand. Unfortunately the CB160 lacks the typical “down tube” that most bikes have. The down tube on my Honda is the actual engine therefore custom building a side stand and welding it to the frame was not an option. Instead I decided to incorporate the old foot peg mounts on the lower engine case casting. Since I am relocating my pegs the original cradles on the engines underside were no longer required.

Side stand components

Roughed out side stand components.

So away I went with not much of a game plan. I have never custom built a side stand and therefore needed to brush up on the physics surrounding the operation. Once I knew what requirements would have to be met I started to cut, grind, and mill. Normally I would have dedicated a complete blog post to the build however my head was more into building than picture taking. So basically all you get is a glimpse of the unfinished side stand. There are still some angles to figure out and final welding to do but it all seems to be coming out fine. The stand looks as though it will tuck up out of the way very cleanly yet still be allowed to maintain full functionality.

Side stand mock up

Kick stand idea

Still lots of work to do on the stand.

So it looks like the new year will allow me to make some progress now that I have the necessary material to perform the tasks at hand. I am looking forward to seeing the bike begin to morph into my own creation. I welcome the challenges that will come and the hurdles that will need to be jumped.

Seat resting rear

Seat resting