I do know, I know. I promised you wiring on this installment, and it’s been so lengthy because you’ve seen something about our Honda CB550 avenue tracker venture that you just forgot the place we even left off. I might make some excuses, let you know I’ve been busy, however how about we skip all that and get to the purpose?
Whereas wiring is definitely the following large hurdle standing between us and using off into the sundown, there was a boatload of fabrication and homework that wanted to be accomplished first. We would have liked to seek out properties for our electronics, affix our quantity plate and customarily make a bunch of issues really perform, and that wanted to occur earlier than I began worrying about operating wires.
As a cheerful little accident, that lets us dedicate the following installment to wiring, and wiring alone (hopefully earlier than later).
Pandora’s Quantity Plate Our Honda CB550 is less complicated than most within the electrical division, however we nonetheless wanted to finalize some issues earlier than we constructed the wiring harness. The method began with a radical learn of motogadget’s set up directions for the mo.unit blue (the spine of our new electrical system) to know what unique electrical parts we’d be holding and the place they’ll stay. We’ll get into that extra subsequent time. The large issues we had been nonetheless lacking embrace a headlight, taillight and indicators, they usually’d all show to be extra sophisticated than a nut-and-bolt affair.
We’d labored an LED off-road mild into our entrance quantity plate, nevertheless it wasn’t mounted to the plate, and the plate wasn’t mounted to the bike. I had concepts, however that every one modified after I realized we’d want to deal with a great little bit of {the electrical} behind the quantity plate. So the quantity plate must mount the headlight, home the mo.unit and, ideally, be adjustable so the headlight may be aimed. Oh, and our new motoscope tiny speedometer wants to slot in someplace as effectively. No drawback, proper?
Our resolution to this puzzle sounds advanced, nevertheless it all works fairly effectively. We constructed standoffs for the quantity plate off the triple clamps, with the underside being a hinge and the highest incorporating a riv-nut for adjusting the plate/headlight. A weather-tight field for electronics makes use of these identical mounting factors, and the hinge permits straightforward servicing of the mo.unit. We’ll in all probability toss some leather-based washers in throughout ultimate meeting to quell any rattling.
To complete issues off, we fabbed a standoff for the LED headlight to appropriate its angle additional, and bent up an aluminum mount for our motoscope tiny speedometer.
Remaining Legalities Just like the entrance finish, the tail of our Honda CB550 tracker venture was lacking some street-legal tools. Lowbrow Customs had despatched us a common license plate mount and taillight meeting, and motogadget provided us with their microscopic mo.blaze tens indicators. Now they simply wanted to seek out their without end properties.
I initially hoped the license plate mount might work behind our new Tuffside Avenue Tracker seat, however there’s simply no area for it between the tail and the wheel. We opted for the swingarm as an alternative and started working with a number of tabs and a few metal spherical bar. Whereas it was initially designed to mount on a fender, our new bracket expertly adapts the license plate mount to the swingarm, sustaining the brake mild and plate illumination.
Subsequent had been mo.blaze indicators. You can place these tiny blinkers wherever they usually’d work, however I didn’t need it to seem like an afterthought. The Honda had holes on each side of the again body horns, however they caught too far down and positioned the blinkers out in area. So we axed them with the angle grinder, eliminating the unpleasant chunks of metal protruding from the tail. With the body capped on each side, we grabbed a pair tabs from our stash and tucked the blinkers in tight.
Entrance Finish Odds and Ends The entrance finish of our Honda CB550 has made enormous strides, with a model new entrance wheel, a suspension overhaul and our shortened metal fender, however a number of essential objects remained. The manufacturing facility speedometer drive would now not be used since we’re swapping to a motogadget speedometer, and omitting it required whipping up new axle spacers.
Subsequent, we wanted to account for the brand new wheel pace sender that got here with our motogadget motoscope tiny. The method is so simple as mounting the sender on a bracket and making certain it’s inline with a magnet mounted to the entrance wheel. I carved up a little bit chunk of scrap aluminum and utilized the bolts that safe the entrance fender and brake meeting. Sharpening it in all probability wasn’t the very best transfer, because it highlights each flaw within the steel, nevertheless it’s adequate for who it’s for.
The final piece of the puzzle was the entrance brake. Honda outfitted the CB with a two-piece disc brake up entrance, and it’s really a cool piece for those who look previous the chipped paint and corrosion. Since this venture is all about making one thing from nothing, I wished to see how a lot we might enhance it with out swiping the corporate card.
As you in all probability guessed, the brake rotor went straight to the drill press, and I stored it easy with an alternating sample of countersunk 9/32” holes. I stored the sample straight, hoping for a period-correct look. You may be the choose of that.
The very last thing to do was media blast the rotor to even out the end, and I despatched the Tokico caliper via the blaster as effectively. With the entrance finish reassembled, I actually dig the best way all of the aluminum components go collectively up entrance. It’s clear and reserved in my view, and suits the rugged character the bike has adopted.
Pegs—The Welder Makes One Measurement Match All We had a rad set of Punisher XL foot pegs in inventory courtesy of Biltwell—a serious angle adjustment in comparison with the rubber monstrosities our Honda was sporting from its previous life. The problem is that Biltwell had Harleys in thoughts once they made these pegs, not Hondas, so that they’re designed for a a lot completely different clevis.
As a substitute of turning down some goofy spacers and making use of some tack weld stops to make the pegs sit proper, I made a decision we might resolve all our issues with the welder. We lopped off the body aspect of our OE clevis and TIG-welded it to the peg aspect of the Biltwell clevis.
With that, we’ve got factory-style peg fitment on the body aspect with out sacrificing the pivot adjustability Biltwell designed into these pegs. The completed product seems legit—who’d have guessed customized CB550 Punisher XL pegs could possibly be that straightforward?
Middle Stand Delete Certain, a middle stand is nice for propping your bike up properly within the storage, however the place this Honda goes, it’s nothing however lifeless weight and visible litter. It’s a chunky, heavy piece—in all probability essentially the most over-built a part of this bike. Fortunately, a spring and a few pinch bolts rectified that scenario, and our Honda is a number of kilos lighter for it.
Whereas I used to be at it, I made some light changes to the aspect stand as effectively. It had a little bit rubber foot added to it, which I assume provides a margin of security and cushions the stand for those who set the bike down rapidly. Good as that’s, it’s been hitting the pipe for many years, so it needed to go.
Pipes Once more? Yeah, the pipes nonetheless weren’t completed. I spent an unreasonable quantity of firm assets hacking up these janky aftermarket exhausts to show the megaphones into reverse cones. However I by no means really affixed them to the bike.
Anybody who’s ever labored on a Honda is aware of there’s an obscene quantity of {hardware} that mounts the pipes to the engine. There’s the finned flange with two nuts, two collars per pipe and a copper crush gasket—and now multiply that by 4 pipes. Since we had been lacking all of it, Partszilla made a killing off me.
With the pipes secured on the engine aspect, we wanted to determine body mounting that was sturdy and serviceable. I initially wished to make use of the outdated heart stand mounts since they had been tucked neatly out of sight, however that bought sophisticated in a rush.
Within the spirit of getting it accomplished and transferring on, I opted for a pair of 1/4-20 riv-nuts within the body and beefy tabs welded on the pipes. The tabs are extra seen than I’d desire them to be, however they don’t impede elimination of the pipes, which is already sophisticated sufficient, so I’m proud of it.
So there you’ve gotten it, a bunch of random duties that lastly get us the place we should be—able to run wires. I received’t declare to be a grasp of something, however I’ll be the primary to say that wiring is my kryptonite. I suppose it’s an evil I can keep away from now not.
Bike EXIF thanks Motogadget, Tuffside, Bridgestone, Lowbrow Customs and Biltwell Inc. for supporting our Honda CB550F tracker construct.
