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60's Honda CL 160 Rebuild as Racer

keeping the cable-driven speedo?

No. I'm on my way to Metal Supermarket in a bit to pick up some aluminum rod to make a dummy/spacer for the speedometer drive. I'll slot it back in for steet duty. The speedo won't be useful on the track - I'll be fabricating some mounting hardware for a front number plate instead. That was actually the main motivation for putting the front end together - to figure out the best mounting scheme.

any sanitary way to make that b'wards F brake operational?

if so, please do that - most bikers won't notice, while those who do
are likely to see the more legit trix on your build

I take it you like the look? I just slotted the wheel in quickly for a mock up, not worrying about orientation. The cable would not work in any sano fashion. I'm a sucker for aesthetics, but utility comes first.
 
Went to Metal Supermarket this morning and headed to the shop. Got a few wheel spacers done (one replaces the speedometer drive unit) and the end caps for the rearstand. I've put one in place so you see what it's for, but I haven't pushed in it all the way. It's a press fit, and once I put it in, it ain't coming back out.

I also gutted most of the switch gear and repurposed it as a kill switch. I removed the horn (?) button and will route the wires through that hole, using a grommet to protect the wires.

The screws that hold the unit together were getting a bit stripped so I went to the store to get some replacements. I measured them as M5x0.9. It turns out the fastener supply store only has M5x0.8 - Honda used a nonstandard thread pitch! So I pulled out the Dremel and just slotted them for a flathead.

Discovered I had a tiny bit of oil leaking out of the bottom of one of the forks so I just JB welded that bolt in the bottom as it never needs to come out. Problem solved.
 

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Then I got to work on the tank again. After a LOT of sanding it's ready for a thin second coat.

The stator needed a bit of cleaning (see? I knew I wasn't done!) and the wires were looking pretty gnarly. After I stripped off the calcified casing I discovered that the wires were in ok shape, they were just a little stiff in places. I'll see if some heat won't help.
 

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Discovered I had a tiny bit of oil leaking out of the bottom of one of the forks so I just JB welded that bolt in the bottom as it never needs to come out. Problem solved.

That's not the drain bolt is it? Won't you need to access it to service the forks?
 
My tires finally came in, and man are they sticky. I was very surprised. A guy named Bob (still don't know his last name) will be helping me true my wheels tomorrow night, so hopefully I'll get the tires on as well.

Turned out a few more bits at the shop today, another wheel spacer, a few fittings to hold the wheels on the rearstand, cut some tubing for the rearstand, etc.

I also sliced open my exhaust pipes. I'm going to just keep the first few inches of each of the extensions - these attach to the header pipes, not the exhaust ports. You can see them mounted in my first post in this thread. When I cut through the first pipe I was flabbergasted. Yes, I think that is the right word. There is a bullet shaped insert stuck in through the back of the pipe. It very nearly fills the entire pipe and its only openings are a small band of perforations. I cannot fathom how this bike was able to run with such a restrictive system. It seem like sticking a potato up someone's tailpipe. Honda, no doubt, had something in mind and I will see if I can't figure out what they were up to. Spark arresters of some sort?

On an aesthetic note, I decided to start working some of the painted bits into a condition that I prefer. They were too clean and shiny (ish) and it wasn't sitting right with me. Here, I tried to get the fork ears to resemble aluminum (they are sheet steel) so they'll match the rest of the fork and be a blend of old style (painted fork ears over the triples) with new style (aluminum tubes through the triples). I included an aluminum rod for comparison.

I was hoping heat would help the metal bits acquire a better look but nothing happened when I held them over the stove. Then I remembered: I used a base of silver engine enamel! It eats high heat for breakfast. Nevertheless, I have ways. Ways and means.
 

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When you see Bob tonight (I`m bringing pizzas!) ask him how many racers ignored him when he told them the pipes were stuffed down to keep some low rpm torque on the street. We were at Bonneville and he told a guy running a 175 this, and about replacing the 4" long intakes to get the motors to rev, and was dismissed as an crank.

See ya tonight.
 
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Twitch, what are you doing for brake shoes?
I just ordered new Ferodo Shoes for my Titan, and I realize that they don't make them for the CB160, I'm wondering if the CB160 front drum was used on any other models that might be listed under Ferodo's site?

Just a thought... I should have the Ferodo shoes in by the weekend and I'm expecting a decent improvement in stopping power...
 
I also sliced open my exhaust pipes.

I just hope a mohel was present when you sliced off the tips of your mufflers...

13MohelWine.JPG
 
These guys can rebuild your shoes with Ferodo 2525V road race material, not sure on cost. They do some of the Group W 160 racers. Supposed to be a great upgrade.

http://www.vintagebrake.com/index.html

First I'm going to see how the brakes on this bike are. If they need help I'll take them to a brake place to get relined.

Vintage Brake is GREAT, but it will break twitch's budget.

I've run Ferodo's before and they were great. I'll post up after I get to (hopefully) try them out on the Titan.

Rather than relining, it would be good to know if stock shelf stuff can fit on the CB160. Vintage Brake lists the VESRAH shoes for the CB160 not the Ferodos, I might do a little research as I am dangerously close to starting work on the wife's CB160 (not a racer).

Link for searching Ferodo's catalog for motorcycles (can be difficult to locate this page!):

http://www.ferodoracing.com/catalogue/search.php?search=motorcycle_vehicle&cat=brake_pads
 
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Ok, cranked out a few more bits today. First I finished cutting and notching all the tubes for the rearstand. So that's it - all the parts for that are finished and await welding.

Made up an aluminum version of the bit that holds the rear brake cable, I'll mount it on an extension on the rearset. More on this later. The original piece pictured (in black) was part of the frame - I cut it off.

Made a tank breather vent that I'll weld on in the near future.

I also remade a wheel spacer. Check out that hand sculpted shoulder :cool

And then I took my wheels, attaching them to my body by literally strapping them to my back with my bag (as they couldn't fit in my bag), and headed down to Bob Guyse (sp?). Bob trued my wheels with some difficulty, and pronounced that they were "totally fucked." Luckily "totally fucked" for him is "totally fine" for me. :) And I learned what to look for when shopping for 160 wheels next time. That's right, there will most certainly be a next 160 build.

Not only was Bob a gracious host, he was a wealth of both information and stories. And he curses in front of the women folk. :thumbup
 

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And some parts arrived :)

I'll get the tires mounted tomorrow, and then see what else I can do. I may even take a few hours off during the day. Man, I seem to work more when school is out of session than when it's in.
 

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Great to meet you David. Bob is a character alright. You got his immediate respect for riding over with the wheels in your backpack. Glad you got to meet Curt (First Buell) too.Here he is explaining why the wheels are TF and then the hidden secrets of Superhawk cylinder heads. His series on how to cheat is worth the price of pizza alone.


Bring more stuff over,it keeps Bob young.
 

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^ Straightening rims with a Crescent wrench. Good times. I used to do that all the time on my MTB wheels. Until a Cane Creek rim blew out on me. :(
 
man, Bob is the best!
kinda like a less-wound-up, John Force-style storyteller of the 60s/70s Bay Area cycle scene

when we first met at '09 BUB Bonneville event, Bob's vocalizing made my trip all the more memorable -
pizza maven Jim [CerealKLR] is also lotsa fun

David [twitchmonitor] proved a rapt, notetaking pupil, with his feet on the ground & a willingness
to do/make/learn whatever's necessary to get his 160 project going well [as his fotos herein attest]

I think David was shocked to learn that this very thread's the 1st thing I check each a.m. -
why not, his 160's the real deal
 
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^ Straightening rims with a Crescent wrench. Good times. I used to do that all the time on my MTB wheels. Until a Cane Creek rim blew out on me. :(

Oh, not to worry. He didn't actually do any "straightening," he was just demonstrating - he didn't think the wrench would even help! :laughing
 
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