LIGHTS!  Played with some battery acid and got that bad boy all charged up and installed.  Got the new LED turn signals and tail light all wired up as well as the new headlight.  I also got a new rear brake light indicator switch that connects to the rear brake foot pedal.  The old one was not working.   Nice and bright and fun to see some "life" in this motorcycle!  The turn signals do not flash right now because they are LED bulbs and don't pull enough of a load to trigger the stock flasher relay, so I need to get a new electronic flasher relay to replace the stock one and we'll be in business.  The speedometer and tachometer light up nice as well.  Also working well is the starter!  I can't wait to get some gas lines run and fire this thing up...Work on the new seat is well underway.  Stay tuned.
-Bocaj

I love getting new parts in the mail!  The new sprocket keeper and bolts showed up yesterday and I found some time to install it right away along with cleaning up the area under the sprocket cover.  With the sprocket securely attached and my clutch adjustment put back together I could mount the drive chain and put the sprocket cover back on the engine.  The foot control shifter can now go back on too.  
-Bocaj

Huh...that's weird.  So, as I progress on this build, the corners I cut are very vibrantly shown to me.  This time it was when trying to put the chain back on the sprockets to run the rear wheel.  As I was fishing the chain up and over the sprocket that comes out of the engine right next to the clutch connection, it was feeling very loose.  Then...off it came, right into my hand.  What the s*$t is this!  So, I had to take this small cover off to be able to see what was going on behind it in this mysterious Bermuda Triangle where parts just fall off in your hands...  Sure enough, that means taking the exhaust off and the foot controls off as well.  When I finally got the cover off I found more mud wasp nests and a wad of crap the size of my fist.  But more interesting is what I did not find...no keeper plate or bolts for the sprocket.  So, I ordered a new one that should arrive shortly.  Goes to show ya, the one place you don't look on your build is where your problems will be hiding...be thorough and take your time.  The end result will benefit.
-Bocaj

As sometimes happens while being creative, I've changed my mind.  After doing some serious sitting and staring, something just wasn't looking right to me.  So, out comes the grinder.  I removed the chopped rear fender and the new taillight and cut off the rear seat bracket making a nice flat surface to mount a new seat pan.  I also removed the old seat swivel mounts and got rid of the old seat pan which I had been planning on recovering.  So, next I needed to create a new seat pan...This cardboard cut out is the first draft and will eventually be transferred to a sheet of metal and mounted to the frame.  A nice thin pad of some type will complete the look.  After sitting on it with the new seat design I can feel quite an improvement in the comfort of the hand controls.  Just lowering the seating angle a couple inches really helps the comfort of the whole design.  The idea is to get a side mount tail light with a license plate bracket for the right side of the bike and leave the seat nice and simple and clean.  I'm liking this new direction and am glad I made the jump into some more fabrication with it...when sparks are flying you know you're having fun!
I also got both of the carbs rebuilt and installed with their new filters...oooh shiny! 
-Bocaj

I finally got the front tire and wheel all fixed up and clean.  I put a new tube in it as well.  The brake pads are still in good shape so I kept them.  Now it looks almost done...because it is.  Next I have the carbs to rebuild and then fuel to run.  I just got my new petcock in the mail.  After that, some wiring and it should fire up.  The last thing is the seat.  Things are getting down to the nitty-gritty.       

-Bocaj

I've completed the back end by chopping the rear fender by 5 inches on both sides, adding new directional lights and a new tail light. I like the results. I've also popped the rear wheel back on which was necessary to see the whole picture. Lots of balancing with that thing...Front wheel is next, then electrical and finally fuel. Stay tuned...
-Bocaj

I have successfully reassembled the switches and have them nicely fitted back on the new handlebars. Gave the levers a face lift and slapped those on too. New grips and mirrors to finish it all off. Next order of business was to attack this nasty rear wheel. Lots of loose spokes and rust. It ended up looking like new after a couple hours of cleaning. New brake pads and springs and it's all set to be installed. Once the wheel is back on I can start to fit my rear fender and rear lights.

-Bocaj

I got my new headlight bucket and threw a coat of paint on it. Added a flat black racing stripe down the center for a little accent. Also got the wire harness fished through the hole in the bottom of the new bucket. Its all snugged up and in place so I threw the new H4 style headlight assembly in to see how it is looking. As well as the new turn signals and the new clubman handlebars that fit well and look nice. Next task is putting the switches back together that I took apart to get the wires out of the old handlebars... Springs and ball bearings all over the place!.. Also need to get the new grips and mirrors on the handlebars. After that I can wire everything up and test it all out. Looking like a motorcycle...

-Bocaj

The weather finally warmed up which means I can get back into the garage. After 24 inches of snow and a good two weeks of sub zero temperatures, it was hard to imagine how great a 40 degree day feels. So, I made the best of it. I got the front end all cleaned up and put back together. It is back at home on the frame. Looking good so far.

-Bocaj

Although you were a lovely orange, you are gone forever. I've got some front end parts sanded down and shined up including the headlight ears. I like how they turned out and I really like the speed and tac. They look completely different without that old black paint.

-Bocaj

12-01-2010

Alright, time to tear down this front end. Those last two bits of orange have got to go, and that nasty front wheel needs a good cleaning. I started by removing the wheel. Followed by the handle bars and hand control wiring. Gauges came off next followed by the headlight assembly. Sadly the headlight bucket is plastic and pretty rotten. It's beyond repair and I will need to get a new one. It should be fun to try to get this rats nest of wires shoved into a new bucket. Finally I got the forks to slide right on out leaving the orange headlight ears to be removed. Easy as that! I see sanding and polishing in my future as I plan to make these headlight ears match the tank and other bare metal parts. I will also refinish the handle bar mounts to bare metal and will get that nice chrome shorty front fender sparkling.

-Bocaj

10-25-2010

I've got the exhaust pipes all shined up, looking good and back on the bike. They turned out nice and there are very few spots that didn't come out. There was some plastic melted to the right side pipe where it comes out of the engine block. Some steel wool on a mouse-sander took care of that. Finished it off with some chrome polish.

-Bocaj

08/19/10

I painted subtle stripes on either side of the tank where the Honda emblems are. They turned out nice and with the tank back on the frame you can get a feel for what the finished bike will look like.

-Bocaj

08/11/2010

Time to get this tank looking like the cherry on top that it is. I used some paint stripper on this deal which was super messy and smelled horrible. I got the rest off with good old fashioned sand paper I still have half of it to go and then I can add some clear coat and a graphic. I painted the underside with some flat black to protect from rust. Looking good so far...

-Bocaj

08/04/2010

I've got a few more parts finished including the rear foot peg brackets and the chain guard. So I slapped the swing arm back on to see how it is shaping up so far. I have decided to get some new shocks for the rear as the chrome on the springs is pretty well effed. Surprisingly, new rear shocks are pretty reasonable. So, rather than spending the time and effort to rebuild these old ones, I'll just get some new ones when the time is right...my butt will thank me later.

-Bocaj