Honda CL77 Scrambler project

[willis]

It’s been a while, so time for an update. My motor is done and will be headed back to me in a few weeks. Nothing else has changed on my end, so today I thought I’d better address the frame and prep it for powder coat. There are several spots with some pitting that I’m certain would show after powder. So today I stripped it the rest of the way down and broke out my 4” grinder,wire wheel and flap wheel. All went well except for the swingarm. I need to get the rubber bushings out of the shock mounts and it looks like there are also bushings in the pivot. I’ve got some research to do as these bikes are still very foreign to me. I also spent a little time on the front wheel. These wheels are pretty crusty, so I will likely paint them for the time being. They are too far gone for rechroming and replacements are not in the budget right now. The wire wheel cleaned it up pretty well to prep for paint in the spring.

 

[willis]

It’s been frigid cold here in northern Indiana and temps in the garage a pretty chilly. Yesterday I decided to set up a little temporary workbench in my unfinished part of my basement and break out my new ultrasonic cleaner. I bought this about a month ago but had yet to use it. I opted for a larger 6L unit as the price difference wasn’t much more than one half its size. I decided to work on my front end, so I dug out my bearings, throttle sleeve, top clamp and some hardware to clean up. Everything went well and followed up on the aluminum bits with a little scotchbrite. They can still use a bit of polish but I’m unsure exactly how shiny I want it to be.

On another positive note, my rebuilt motor is heading back to town this weekend. I should take possession on Saturday. Time to get my ass in gear!

 

[Mailman]

I should take possession on Saturday. Time to get my ass in gear!

I can’t wait to see you get going on this!

 

[JJames]

Looking good. Maybe some light polish. Just my taste, but I feel like some folks over- polish.

 

[willis]

I got my motor back yesterday and am I pleased. It turned out very nice. Re-bored .50 over, vapor blasted, head decked, replace two valves and guides. Carbs are also rebuilt and ready to go. Keeping the factory points ignition too. This should be ready for instal and start right up with minor tuning. Now to get my ass in gear on the rest of the chassis.

 

[Mailman]

Beautiful!

 

[willis]

Prepping to send the frame out for powder coating. I needed to get the shock mount bushings out of the swing arm. My futile attempts in my shop were obviously not going to budge it. Hell, I dont even have a vice in my new shop yet. But it’s good to have friends with nice tools and fabrication skills. Though he had a vice big enough, which would have been my attempt because I’m a hamfist meatball mechanic, he clamped the swingarm onto his welding table and made a little jig to press it out. I was surprised when the angle iron started flexing under pressure. But a few solid whacks with a bfh and it popped right out. No way would I have gotten them out unscathed.

We were about to pull the swingarm bushings too when we realized that what we thought was rubber were actually some sort of leather of fibrous square o-rings. The pulled right out with a pick but parts diagrams don’t even list a part number. I’m sure a standard o-ring will work fine though as they are not sealing anything.

 

[Jim]

Those are felt seals, Rob. Plain ol' felt. You can most likely source the right size at McMaster/Carr or some similar store.

 

[willis]

Frame and swingarm are out for powder coating and hoping to have them back by this weekend. In the meantime i have turned my focus over to the wheels. I recently picked up a pretty decent rear wheel on Ebay for a fair price. Spokes are not shiny, but not rusty either. I also found a great deal on a straight front rim hoop only and will have it in the next two weeks. I went out on a limb and also purchased a new set of chrome spokes on Ebay from a seller in Taiwan. There really aren't many options for these other than Buchanan's. My engine builder says he has used these in the past, but those were fro a Superhawk with 18" wheels. I pulled the trigger and giving them a shot. Ordered on a Saturday night and DHL delivered to me on Wednesday night. 4 days for international shipping!!! So now my biggest dilemma is how far am I taking this? This was never meant to be a restoration project. Part of me thinks it makes sense while the wheel is torn down this far to go ahead and paint the entire hub before I lace it up. Then the sensible part of me says to just paint the inner part between the spokes with an aluminum colored paint. This would keep corrosion at bay and make it easier to clean in the future. Then I can just polish the outer parts to whatever level suits the build. This can always be refreshed or fully polished if the build ever changes direction. My weather here is forecast to be in the 60-70's all week making for an ideal time to do whatever painting i need to do. I need to make a decision in the next few days before my weather turns cold again. These are the things that keep me up at night....

 

[Jim]

Then the sensible part of me says to just paint the inner part between the spokes with an aluminum colored paint. This would keep corrosion at bay and make it easier to clean in the future. Then I can just polish the outer parts to whatever level suits the build. This can always be refreshed or fully polished if the build ever changes direction.

That's how I'd play it. A nice gloss silver in there and it'll clean off with a garden hose and look new again.

 

[Mailman]

Yup! What he said,

So now my biggest dilemma is how far am I taking this? This was never meant to be a restoration project.

In my humble opinion, you’ve got a relatively rare and desirable bike there, between the engine rebuild and powder coating and new chrome spokes, you’ve already done a lot of the heavy lifting. I’ve never gone all the way with re chroming parts and stuff like that. I’ve never even replaced rims and spokes. But things like recovering the seat and rebuilding forks and carburetors and some minor cosmetic work can go a long way. It doesn’t have to be ready for display at the Barber Museum to be a nice rider.
But I know it can be a slippery slope, knowing where to stop is hard for me.

 

[willis]

A slippery slope for sure. I just have to keep reminding myself that it doesn't all need to be done right now. Get it together as a nice rider and then I can chip away at it over time.

 

[willis]

Alright, I couldn’t hold back this afternoon. I had the hub mostly cleaned up so this afternoon I took the wire wheel to the hub and then gave it a thorough cleaning. Taped off the inner area of the hub and hit it with Rustoleum Professional Enamel primer and Aluminum paint. Very happy with the results. I’ll wait a few days for the paint to cure before I give the rest of it a light polish to even out the finish.

 

[Mailman]

That came out great , I like it!

 

[Kevin Werner]

SHIT... only 3 months to find a decent XS650 to ride...

Frame and swingarm are out for powder coating and hoping to have them back by this weekend. In the meantime i have turned my focus over to the wheels. I recently picked up a pretty decent rear wheel on Ebay for a fair price. Spokes are not shiny, but not rusty either. I also found a great deal on a straight front rim hoop only and will have it in the next two weeks. I went out on a limb and also purchased a new set of chrome spokes on Ebay from a seller in Taiwan. There really aren't many options for these other than Buchanan's. My engine builder says he has used these in the past, but those were fro a Superhawk with 18" wheels. I pulled the trigger and giving them a shot. Ordered on a Saturday night and DHL delivered to me on Wednesday night. 4 days for international shipping!!! So now my biggest dilemma is how far am I taking this? This was never meant to be a restoration project. Part of me thinks it makes sense while the wheel is torn down this far to go ahead and paint the entire hub before I lace it up. Then the sensible part of me says to just paint the inner part between the spokes with an aluminum colored paint. This would keep corrosion at bay and make it easier to clean in the future. Then I can just polish the outer parts to whatever level suits the build. This can always be refreshed or fully polished if the build ever changes direction. My weather here is forecast to be in the 60-70's all week making for an ideal time to do whatever painting i need to do. I need to make a decision in the next few days before my weather turns cold again. These are the things that keep me up at night....

That's how I'd play it. A nice gloss silver in there and it'll clean off with a garden hose and look new again.

I did this on my Red Bike.

 

[willis]

Back from powder today. Spent the afternoon cleaning threads and putting the steering races back in. Long way to go, but let the madness begin. Hope to get the motor in the frame tomorrow.

 

[Mailman]

Beautiful! I see it’s sporting a new sleek little head light.

 

[willis]

Another big hurdle today.

Had a buddy stop by and he helped me put the motor in. He’s had experience with the 305 in the Superhawk variety. It was actually his brother that rebuilt my motor. He’s been pushing me along to get my 77 XS Scrambler done too. So while he was here we put my upgraded 8 plate clutch pack from Gary in.

 

[Mailman]

He’s been pushing me along to get my 77 XS Scrambler done

I always loved that bike too!