Rebuilding again '81H

[Garagamus]

First off, I know...I already rebuilt it once and changed the color twice. Doing it again cause I'm bored and can do it better. This will be the only "build" thread since I'll be taking lots of pics, (except for technical questions).

1st major question: I'm relocating all the electronics from between the side covers to under the seatpan and bump. Because I don't know a heck of a lot about said electronics, Is there any assemblies, besides the battery, that should not be placed next to anything? I don't want to get everything laid out only to find that while I'm riding, I'm also potentially creating an arc and setting my underwear on fire....

[DGXSER]

Are you talking about the fuse box, starter solenoid, and flasher for the turn signals?

Just keep in mind the seat pan is metal, so you will want some form of non-conducting separation between the seat pan and the connections to the fuses, and the solenoid especially.

[Garagamus]

Good to know. I fabbed up a metal pan that's about 1 1/2" deep that's going directly under the seat for all the bigger units. Thinking it would probably be a good idea to line it with the same rubber I use on my toolbox drawers. Most of the relays and solenoids still have the original rubber sheaths around them and I was planning to weld some tabs in the pan to hold them in. I really can't make a larger pan for everything since "flat" space ends quickly before the seat bump begins as the base rises to clear where the inner fender sat. Too bad the frame on the XS sits so low, it would have been nice to make one long flat seat pan from tank to taillight.

[CKlamer]

Maybe this will help here is a picture of mine.

[Garagamus]

Looks awesome Klamer, unfortunately the hoop I welded on has a narrower taper to it, (just wasn't thinking about how far back or how wide the battery would sit while welding it on), alas mine will have to go right in behind the seat back rather than the back of the bump. Although I can get the ignition unit and fuse block behind it I guess. Finished the shallow pan under the frame rails last night and at least everything has a place now once the seat is on. Looks amazing with nothing between the back tire and engine except the rear brake resevoir.

CKlamer, did you discard the whole plastic inner fender assembly? I think it looks better without it, but I may leave the mounting tabs for the battery box on in case I have to fab up a smaller inner fender for rain protection. Although, once the seatpan is buttoned down, water shouldn't have an easy path to the electronics or seat of my pants.

[CKlamer]

Yes I had a local machine shop make me some inner fender protection along with an aluminum chain guard.
Had to have the protection since my carbs have no protection and I couldn't have my back tire throwing crap in to them.

But here is a picture of me and the bike at the Barber Vintage Festival they let me drive down in to the paddock area.

Other than having the engine built I did all of the work or had all of the work done out of my garage.



Yes I had an engine builder that builds race engine put my engine together mainly because I wanted a complete race engine.
She has been completely resleeved and bored out to over 900cc and then ported and polished throughout the spectrum.
My engine builder says she is close to 985cc engine now.

She started as a 1981 CB750K.

[Garagamus]

So, a little bit of progress for the weekend since my new fuse box showed up. Managed to clean up the electronics rats nest nicely. Everything fits and nothing will touch bare metal. Think I'm going to have to fab up a new splash guard where the inner fender sat though. At least now, I can see daylight where the side covers used to be. (good used pair of '81H side covers and lock cylinder up for sale though...)




Next is to add a half inch to the top frame rail to get the new seat a little higher, and be able to put a removable watertight cover over the electronics.

[MaximPhil]

Nice work Garagamus. You will need something to replace the inner fender too
Phil

[Garagamus]

I've seen some cool ideas from DTT's site (Do the ton), mostly full panel between the two frame crossmembers or a cut fender a little wider than the tire down to where the battery box bolted in. Haven't decided yet. The panel is easy, but kills the minimalist look, while the fender/splash guard will take some finesse but look better in the long run. I don't think there's room between the seat bottom and the tire for some sort of sweet swingarm hugger for the tire that won't get obliterated when I hit a decent bump. (Meaning....I'll probably end up trying both prior ideas).

[fredintoon]

I've seen some cool ideas from DTT's site (Do the ton), mostly full panel between the two frame crossmembers or a cut fender a little wider than the tire down to where the battery box bolted in. Haven't decided yet. The panel is easy, but kills the minimalist look, while the fender/splash guard will take some finesse but look better in the long run. I don't think there's room between the seat bottom and the tire for some sort of sweet swingarm hugger for the tire that won't get obliterated when I hit a decent bump. (Meaning....I'll probably end up trying both prior ideas).

Hi Garagamus,
longer shocks would lift the wheel enough for a hugger fender to clear.
I have a NOS set of 14" shocks I'd sell cheap.
If you are concerned that the metal seat pan will need insulation to keep it clear of the electronics; sandblast the underside and apply a layer of fiberglass.

[Garagamus]

I may just take you up on the shock offer. Send me a PM of what you want for them. I want to make the seat higher anyways because I'm a tad over 6' and I know the cafe seat won't be anywhere near thick enough, (or retain its looks) to lift me up the extra inch or two I need so I can shift with my foot, rather than move my whole leg...the joys of getting older

[Garagamus]

A little more headway with a little time to work on it. finally have the electronics sorted out and ready for re-assembly. Took most everything off but the engine and repainted the frame gold, think its going to look pretty sweet with the new bump seat and paint (metallic dark brown with white double stripe down the tank). Still have the front end to work out with the square to round headlight swap and fork gaiters.



Still working on the splash shield and battery support.

[fredintoon]

I may just take you up on the shock offer. Send me a PM of what you want for them. I want to make the seat higher anyways because I'm a tad over 6' and I know the cafe seat won't be anywhere near thick enough, (or retain its looks) to lift me up the extra inch or two I need so I can shift with my foot, rather than move my whole leg...the joys of getting older

Hi Garagamus,
didja get my PM and do you need those 14" Street Stroker shocks?
Getting older? Yeah, right; I got children older than you look to be.
BTW, where did you get those Britstyle Yamaha tank decals?
I have a project they'd look good on.

[Garagamus]

The British style Yama logos are actually freehand painted. I had one guy while getting a coffee, actually turn around in traffic and come back to the parking lot thinking it was a vintage norton he had stumbled upon. I'm going to try and put together an actual decal before spring. I recently left oil field work to try my hand at a bodyshop/collision centre, tons of toys to mess around with and a legit paint booth. Learning the body trade is a slow go at 43, but my title there is a 3M paint protection and graphics installer. I figure if I've got access to a state of the art plotter and a boatload of vinyl, I should be able to come up with some pretty cool decals. Still on the fence regarding the shocks. I'll probably end up taking them off your hands, (once I've paid for all the air tools for the new job).

[Schming]

Hi Garagamus,
didja get my PM and do you need those 14" Street Stroker shocks?
Getting older? Yeah, right; I got children older than you look to be.
BTW, where did you get those Britstyle Yamaha tank decals?
I have a project they'd look good on.

Hi Fred, here's a site that has similar decals:

http://www.omarsdtr.com/gfx16.html

HTH