2strokeworld

The 2-Stroke Garage => Haus of Projects => Topic started by: NoRiders on December 01, 2019, 03:16:33 PM

Title: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on December 01, 2019, 03:16:33 PM
Hi all, thought I'd introduce myself. My name is Colin and I live nr Oxford UK. I've been dicking with cars n bikes for a good few years now, 45 to be exact.

I'd owned a '82 CBX550 for nearly 20 years before hacking it about a bit.

(https://i.imgur.com/skBYsPU.jpg)

That's not why I'm here though. I had acquired a bare Honda 400/4 frame which I got a V5 in my name so I could play with it.
I fancied a bit of ringadingding in my life so thought to build myself a two stroke flat tracker style run around.

I love a rummage around a swapmeet, and found a pair of Paoili forks and Honda NSR125 6xspoke alloy wheels....which was a start.
A facebook deal landed a Suzuki SB200 engine inc carbs, needing a crank rebuild.

A quick fit up looked promising, engine mounts weren't too far out, infact the rear upper was the same and the front just needed mounting plates cutting out. The underside mounts will need some work but nothing too involved...so it was good to go on the concept.

(https://i.imgur.com/cROA5tT.jpg)

Needing a tank I fancied the look and style of a Honda CB200, loving the chrome strips and padded centre section....which would run into the seat I had in mind nicely.

Microns turned up next, they're for a 350LC but I think I can make them work?

(https://i.imgur.com/j1JqEeT.jpg)

Now this is where it get tricky....the NSR wheels are staying, but trying to make them work with the Paioli forks - disc/caliper alignment mounts all conflicted and meant engineering beyond my simple garage/shed means....so, NSR125 forks were drafted in to KISS....and a few attmepts at taper bearings sees them fitting a treat. The entire front end is NSR and should work well.

(https://i.imgur.com/g9wtKsC.jpg)

So, I now have the basic layout, including the seat unit. Did I mention the Suzuki GS1100E alloy swingarm? This is lovely piece of kit and it was defo going on whatever it took. It took a custom spindle turned out of stainless and slimmer needle rollers as well as a small cut across the spindle width to fit the 400/4 frame.

I now need rear spindle (Yamaha Diversion 600) tophat spacers making up to complete the rear end. A brake torque bar to secure the rear caliper and a brake pedal too.

(https://i.imgur.com/rCGnIsu.jpg)

Bars, levers and switches are sourced and should work, tank is close to being mounted along with the seat unit which will have a removeable padded seat (in mid blue suede) to acces oil tank and battery.

Due to the footrest placement being out of line with the kickstart swing, I thought to find a starter motor kit.....I actually found a GT200 engine, complete except for the barrel (which I have) along with 22mm GT carbs and 5x speed box of course. So full GT spec lump which worked out well.

Here's a few random images to bring you up to date, thanks for reading so far.

(https://i.imgur.com/Ko9XkK0.jpg)

(https://i.imgur.com/MCMFSWC.jpg)

(https://i.imgur.com/UMjMKsS.jpg)

(https://i.imgur.com/wE187oN.jpg)

(https://i.imgur.com/PHcm4Y8.jpg)

I plan on updating this thread as I go....I'm pushing this build to have a finished, running MOTable bike by Spring 2020. Lots to do as each part really needs to be thought through....one off builds are very very work intensive as I have found to my cost haha!

That's all folks.

Title: Re: Newbie from UK - Suzonda 2smoker
Post by: Gil Gallad on December 01, 2019, 04:32:08 PM
one off builds are very labour intensive is an understatement, especially when you don't have access to milling/cnc machinery, lathes etc. i'm just doing a shed build, suzuki gt350 engine - yes, i know they never made one, so i built one, 64 x 54 bore and stroke - and put it in a kawasaki gpx250 rolling chassis. i love it, but there are times i wish i'd never started it  ;D
cheers, gil.
ps, got a good mate who lives near oxford [wantage] and he loves 2 strokes as well.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: Hawaii-Mike on December 01, 2019, 05:08:34 PM
Interesting projects!  The CB400F gas tank is a classic.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 01, 2019, 06:32:39 PM
one off builds are very labour intensive is an understatement, especially when you don't have access to milling/cnc machinery, lathes etc. i'm just doing a shed build, suzuki gt350 engine - yes, i know they never made one, so i built one, 64 x 54 bore and stroke - and put it in a kawasaki gpx250 rolling chassis. i love it, but there are times i wish i'd never started it  ;D
cheers, gil.
ps, got a good mate who lives near oxford [wantage] and he loves 2 strokes as well.

I have a tame turner who can/will knock me up a few parts in stainless which is very handy. He made a very neat tacho drive blank on the CBX and the swingarm spindle on the Suzonda. He'll make the rear axle spacers I need too.

Your project sounds interesting....I'll check it out. Is it on here?

Wantage is 20 mins from me.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 02, 2019, 04:55:27 AM
Interesting projects!  The CB400F gas tank is a classic.

Thanx...if it turns out as I plan it'll be OK I reckon. Might turn a few heads down the biker cafe.

I had to have the CB400/4 tank on the CBX as it is a classic, slabsides, flat bottom and flip cap  8)

I also love the CB200 tank for it quirkiness.....I'll cover the padded section with the same mid blue suede on the seat pad.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 02, 2019, 02:13:53 PM
Exhaust mounts arrived...poly in blue....thinking it'd do the job, not the prettiest though and it looks a bit cumbersome.

I will trim it a touch and it'll be against a grey frame too.

The Micron rear mount tab might need a slight bend to align surfaces and look less shit.

(https://i.imgur.com/8BaXpQN.jpg)

I'll need to glass in some timber risers/spacers to have the seat unit sit where I think it suits best. Lines up with the tank snugly and sits right at the rear IMO.

So this might be the final position for both tank and seat unit.

(https://i.imgur.com/se1l9mV.jpg)

Small steps....thanks for checking in  ;D

Title: Re: Newbie from UK - Suzonda 2smoker
Post by: m in sc on December 02, 2019, 02:17:32 PM
they seem to be hanging really low. id pie cut the headpipe, get the belly closer tot he frame and rethink that mount at the back.  :twocents:  I like where this is going though.  :metal:
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: zedixe13 on December 02, 2019, 04:05:14 PM
I had a CBX550 for over 17 years , in Canada you could still get a new 1983 in the crate in 1990 at your dealer for $1600. CAD
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 02, 2019, 06:41:13 PM
they seem to be hanging really low. id pie cut the headpipe, get the belly closer tot he frame and rethink that mount at the back.  :twocents:  I like where this is going though.  :metal:

Yeah, I have you right. There's a spigot bolted to the barrel which the downpipe slides onto, I think I can alter the angle to change the position of the exhaust and get the rear up while still clearing the frame. The tight point if where the expansion chamber meets downpipe. Then I can remodel the rear mount so it's a cleaner fit. Thank you
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: PIOUGHD_RD350 on December 03, 2019, 11:29:04 AM
Micron pipes are so sexy!
I had a pair on a RZ350 that both went to the right aide.
I kinda wanted to leave the bike in the living room. So, I could just stare at the pipes.
Haha
You have a great build going.
Great job and vision!
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 03, 2019, 12:47:38 PM
Micron pipes are so sexy!
I had a pair on a RZ350 that both went to the right aide.
I kinda wanted to leave the bike in the living room. So, I could just stare at the pipes.
Haha
You have a great build going.
Great job and vision!

Ha..I agree, these are meant for a RD350LC so I'm cobbling them together. I'm thinking along the lines of fresh flanges with pre bent angled pipe cuts to allow the system to sit at a different angle out of the barrel. Just found an ace website that sell mandrel bends, flanges etc...everything I'll need to piece something workable together I hope.

(https://i.imgur.com/mbDk07m.jpg)

Slice this up to give me the angle I'd want
(https://i.imgur.com/6SQpTgx.jpg)

The exit spigot is fixed by the twobolt flange, the system slides onto the spigot, the end is double skinned, and held with two springs. By elongating and angling the spigot I hope the system will sit at a more suitable angle.

(https://i.imgur.com/bS02Oix.jpg)

(https://i.imgur.com/TEGHXkQ.jpg)

I'll fiddle and see what'd be needed....thanks for your comments, cheers
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: m in sc on December 03, 2019, 01:02:57 PM
ID CUT THE SPIGOT, RE-ANGLE RIGHT AT THE HEAD, THEN WELD IT BACK ON.  :twocents:
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 03, 2019, 01:18:06 PM
ID CUT THE SPIGOT, RE-ANGLE RIGHT AT THE HEAD, THEN WELD IT BACK ON.  :twocents:

I think it needs to extend a touch longer so the system can rock up n back and still clear the frame cradle. A nicely curved angle on an extended spigot would look/work better rather than a sharp cut n weld I reckon. Total cost around £50 not cheap but it'll look more like it was meant to be there.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: m in sc on December 03, 2019, 01:26:53 PM
true. many ways to approach it, should be good.  :toot:
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 03, 2019, 01:45:03 PM
true. many ways to approach it, should be good.  :toot:

Ha...keep a look out ;)
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 08, 2019, 09:35:20 AM
My new garage toy*....

It's just stored there on the shelf and will be bolted to the workbench when in use...:)

(https://i.imgur.com/NLpMcII.jpg)

Reckon I could do some damage with a step drill ;)


* A 60th birthday pressie from my lad.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 09, 2019, 01:02:13 PM
So, my free of charge headlight pod arrived today (thanks to a very generous fellow biker) .....balanced it in place to see how it looks and I reckon it's gonna work out just right....when painted white to match the bodywork.

Just need a new headlight and bezel.

(https://i.imgur.com/n3zIFjT.jpg)

(https://i.imgur.com/JJhgE8B.jpg)

(https://i.imgur.com/sIabf3o.jpg)

Who can guess the donor bike?
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: 85RZwade on December 09, 2019, 11:41:15 PM
 :umm: Honda CT90 or 110?
Wade
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: Gil Gallad on December 10, 2019, 07:29:28 AM
looks very similar to the suzuki k10 headlamp shell. i've got a couple of bezels for this shape. if you measure the dimensions where the bezel goes i might be able to help you out  ;D
cheers, gil.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 10, 2019, 12:39:24 PM
:umm: Honda CT90 or 110?
Wade

Close....it's off a CD175 (74-79) :)
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 10, 2019, 12:41:32 PM
looks very similar to the suzuki k10 headlamp shell. i've got a couple of bezels for this shape. if you measure the dimensions where the bezel goes i might be able to help you out  ;D
cheers, gil.

Again...close....CD175 (74-79). Has the two 'corners' so quite an unusual shape which I like.

So you might have a bezel/surround in the same shape? I'd be interested if it's nice condition, doesn't have to be perfect but it is 'on show' so to speak...what yer got? :)
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: Gil Gallad on December 12, 2019, 07:59:00 AM
i've looked at your headlamp shell and also a couple of cd175 bezels on fleabay and the suzuki bezels are totally different. so unfortunately i can't help you this time  :whatever:
cheers, gil.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 12, 2019, 11:59:03 AM
i've looked at your headlamp shell and also a couple of cd175 bezels on fleabay and the suzuki bezels are totally different. so unfortunately i can't help you this time  :whatever:
cheers, gil.

Hey no problem, thank you.

I just missed out on a low price Micron alloy billet fork brace....grrr.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 12, 2019, 05:28:07 PM
Minor update:

When your tame turner turns up some trick bobbin axle spacers and tophat collets out of stainless......nice.

These....

(https://i.imgur.com/eTl1zDD.jpg)

are going here...

(https://i.imgur.com/PHcm4Y8.jpg)
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: 85RZwade on December 13, 2019, 08:14:48 AM
Lovely pieces, nice bit of progress there.
Wade
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 13, 2019, 08:46:50 AM
Lovely pieces, nice bit of progress there.
Wade

Thanks Wade, he does some lovely work for us all in our VW aircooled club. The small things actually get the job moving as without these the rear wheel assembly cannot be completed....I wanted to try and get the bike running, rolling and stopping before the big strip down!!  :vroom:
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on December 21, 2019, 10:48:17 AM
A small but significant update....my neighbour, a prolific and experience bike builder/restorer/owner has agreed to build the GT200 lump in January with me helping. The best of both worlds as I really wasn't looking forward to doing it myself....now at least I can say I had my hands in it.  :clap:

I shall now refine/finish the engine mounts in readiness, amongst other jobs. The engine rebuild is a major part (obvs) and I can rest easy knowing it'll be in good hands.

Think I might get on with the frame clean up now as well.

(https://i.imgur.com/xJOkGfk.jpg)
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on January 18, 2020, 04:42:23 PM
Snagged a good few bargains at Kempton Pk Bine Jumble (Swap meet for our American friends) so still on course, just slow progress.

Here's my stash
(https://i.imgur.com/m0RLGhA.jpg)

Alloy for brackets/mounts
New 400mm shocks with correct eye/eye dimensions. I know they're not the best but they'll do for now.
(https://i.imgur.com/STPp37u.jpg)

(https://i.imgur.com/YMPHxGI.jpg)

Funky rear light which may be used
Rubber bobbins to rubber mount the seat unit
Rose joints for the rear brake brace
Rightside starter/run/kill switch - nice n slim

(https://i.imgur.com/MZehxoX.jpg)

Alternative brake lever
41.5mm Exhaust off cut with the correct bends for the collet extenders

(https://i.imgur.com/Nhw4sEr.jpg)

Various other items which all amount to a very good day out.

Title: Re: Newbie from UK - Suzonda 2smoker
Post by: 85RZwade on January 18, 2020, 11:08:59 PM
Nice finds, I like the shape of that taillight
Wade
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: Old Brit on January 19, 2020, 04:33:14 AM
This is starting to look very cool indeed  8)
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on January 19, 2020, 07:59:32 AM
This is starting to look very cool indeed  8)

Thank you. Is it my serpentine exhaust you're liking?
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on January 19, 2020, 08:02:00 AM
Nice finds, I like the shape of that taillight
Wade
Yeah, not seen one ever before, I liked the smiley face, so haggled a £10 ($13) bargain and just might use it as it's a bit different and a bit retro ;) Spotted at least two others at the meet....figure that out  :umm:
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on January 19, 2020, 09:11:36 AM
true. many ways to approach it, should be good.  :toot:

Well, it may appear slow but things are working out....a recent visit to a biker swap meet turned up quite a few goodies including an offcut of exhaust pipe that just might work.

(https://i.imgur.com/Nhw4sEr.jpg)

The curves can be cut correctly to provide the curve I need....just need to find an oversized pipe to act as the flange retainer....felling this could work out.

In other news I have selected a pair of rear shocks at 400mm (15.3/4") long with the correct top and bottom eye dimensions to suit eh Honda frame 16mm and Suzuki swingarm 10mm.....I had thought the top mounting posts would need extending but they appear to fit nicely.

(https://i.imgur.com/YMPHxGI.jpg)

(https://i.imgur.com/STPp37u.jpg)

Also found a halogen H4 headlight bowl that could be made to fit the CD175 rim and housing....more on that.

Another option on a rear brake lever could work too.....

(https://i.imgur.com/rnqH5Nw.jpg)

...and, this rightside starter/run/kill switch for £2 ($3) fits snugly and cleaned up nice. Works well with the Domino throttle too.

(https://i.imgur.com/MZehxoX.jpg)

I plan to sit the fibreglass seat unit on rubber bobbins (exhaust style) fitted into Rivnuts in the subframe and bolted through to I have a rubber mounted seat......the unit needed setting up about 3/4" so these bobbins will work I reckon. Need something to support the rear of the seat unit now.
Two M10 rose joints will help form the rear brake torque bar, a bit of relieving, some threaded bar and they should be good to go?
Alloy bar/plate is for forward upper engine mount and various mounts like the rear brake master.

(https://i.imgur.com/m0RLGhA.jpg)

So, I have a way forward in quite a few areas....got to get the engine rebuilt asap.

Thanks for checking in.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on January 25, 2020, 10:14:03 AM
A day of good n bad news.....good news: My bike building neighbour, Andy, has popped round to check out the GT200 engine and agreed to help me rebuild it with my refurbished crank. Alls I got to do it clean the lump and get it to him next weekend....whoohoo  :whoop:

Bad news: The supposed Honda CD175 headlight bowl and surround didn't fit the CD175 headlight pod I have......schoolboy error, I fitted a H4 bowl to the surround....and then found it didn't fit!! Gahh!!

The replacement upgraded Koito H4 bowl looked great, compared to the Stanley original.

(https://i.imgur.com/wN2yMeD.jpg)

...just a shame it didn't fit...bugger :(

(https://i.imgur.com/W7L4tHW.jpg)
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on February 14, 2020, 05:54:58 PM
Quick update: Stuff's been happening, albeit slowly, but surely.

My bike building engineer of a neighbour, Andy has agreed to rebuild the GT200 engine...it's been a while since he got inside a 2stroke so he's intrigued.

I have an SB200 crank that I had rebuilt with new seal n bearings, ready to slot back in the SB case....however, since acquiring the GT200 lump I thought tio drop in the refurbed crank into the GT case...5x speed and electric start so why not?

Hmmm...got the engine split and pulled the GT crank only to discover the two are not the same....the GT crank is about 12mm longer on one side, the drive spigot as to accommodate the tacho gear, hence the extra length...but the SB doesn't have a tacho so no room on the drive spigot for the gear....rather than spend another £250 we've opted to use the SB crank and forego the tacho...I hadn't planned to run one anyway. Details....it's all in the details.

I'm hoping a newly rebuilt engine will spur me on to work on it again....life really is getting in the way...plus add in a hefty slice of 'can't be arsed' and I'm hoping to recover some enthusiasm. :)

Thank for checking in.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on February 21, 2020, 01:53:42 PM
Engine build update:

It's been apart, found a couple of issues....kickstart mechanism wasn't installed correctly by previous builder and centrifugal mechanism in the starter clutch as missing parts.
A new kit cured the starter issue and a quick resiting of the kickstarter sorted the problem. I doubt I'd have spotted the kickstart problem....so kudos to Andy.

(https://i.imgur.com/eykbcSi.jpg)

We had to use Wellseal on the generator case as no new gasket is available by all accounts?

As I'm going for efficient, but not overly polished, functional competition look I'll probably not paint the side cases. I've painted the primary sprocket case in the steel paint I use...but not done a 100% job, more of a quick blow over as it was rough.

What oil delivery feed lines should/could I use? I'll try my usual dealer, but anyone got a suggestion?

Thanks for checking in.



Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on March 30, 2020, 06:00:45 PM
Despite the virus situation and me feeling under the weather (not the virus) an update:

Andy, my neighbour, delivered on the engine rebuild...a briliant job that I knew he'd do.

One or two issues when we split the case down
1) GT and SB cranks are not the same. The GT has a tacho so requires a crank mounted gear cog.....this means the GT crank is aprox 12mm longer on the drive spigot end. A momentary set back until we realised the rebuilt SB crank I had will still fit the GT case...phew. I wasn't going to run a tacho  so didn't need the gear cog.
2) The kickstart mechanism on the GT engine wasn't fitted correctly so it would never have worked - fixed that.
3) The starter centrifugal mechanism was missing a good few parts - a new kit was ordered and installed.

Apart from those all was well, new pistons & rings, centre honed barrel, new clutch plates (there was an extra disc inside) and new case seals saw everything stitched up nicely.
We even span it up on the starter and it turned over a treat.

(https://i.imgur.com/ITRgtfr.jpg)

(https://i.imgur.com/wwSqmxO.jpg)

After a layoff I'm back in the saddle so to speak and having a go at finishing loose end jobs with an aim to have the engine mounted and rear end completed.

To that end I've carved out a pair of front upper engine mounts from 3mm alloy (soon to be 3mm steel)....came out OK given I used a hand held 1mm cutting disc angle grinder, my new pillar drill and bench belt sander.

(https://i.imgur.com/c54ntzG.jpg)

I've ordered 100x50x3mm steel box section to fashion the lower front engine mounts I have an idea for, hope my idea works out?

I also cut a 37mm long rear axle spacer to finally tighten up the rear axle, the split pin hole lines up with the castle nut now so all good.

(https://i.imgur.com/7fBUxP1.jpg)

With the axle bolted up and can now focus on the caliper torque arm. I've chosen to use M10 threading with a rose joint on the swingarm mount and a simple U section to fix at the caliper mount end. The threading will be sleeved in steel tube with lock nuts of course.

Once I have the engine mounted securely I can then concentrate on the exhaust and the modified spigot I have to form.

Much more to do but this is a positive step after a short lay off.

Thanks for checking in :)
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: Czakky on March 30, 2020, 07:34:03 PM
These updates help us all through the confinement! Well done.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on March 31, 2020, 12:44:24 PM
Thanx Czakky.....I'm so pleased this is in my garage at home as access is handy.

I hope to make regular updates from now on as I feel this islation situation will drag on a for a good few weeks yet.

We're hunkered down here, Oxfordshire UK and getting through each day.....just had my daily stroll exercise and shop in one.

I'm hoping for a metal delivery within a day or so, that'll see me getting on with the lower engine mounts and brake torque arm.

Think I'll look at the rear brake mount bracket and lever next....  ;D

Image just for something to look at...

(https://i.imgur.com/UMjMKsS.jpg)
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: Czakky on March 31, 2020, 08:45:17 PM
We never got that CBX in the states. Is that the stock front brake? Sealed and vented disc? Some crazy stuff happening in the eighties!
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 01, 2020, 06:41:28 AM
Haha...yeah. Background as I understand it....Jap bikes in the 70 that had stainless discs struggled in the wet with brake performance. Italian bikes ran cast iron discs and were much better performing, however, iron discs looked cruddy when rusted up.
So, Honda designers came up with a complex hidden iron disc system, where the disc ran on the outside of the caliper, the caliper sat inside the disc centre so the entire assembly could be wrapped up in what looked like a drum brake cover.
This worked to some extent, but meant to drop the front wheel out the entire assembly had to be, largely, disassembled...a complete PITA.

I'd owned the baby CBX550 since 1996, it'd sat in various garages/covers for years, it's be started every 4-5 years, blessed is Mr Honda as it always fired right up with fresh gas and battery.

This model was something of a ground breaker, back in '81 and considered a sports bike in it's day. 572cc (hence the race number) twin cam, 4x carbs, rear air monoshock, front hydro/pneumatic anti dive forks, fuel gauge...etc

So, one day I was sat contemplating the world when the idea struck me to give my baby a lift.....I used the enclosed front brakes as the inspiration to make it look at least 10 years old than it's 1982 birthdate, something like an old Brit bike...

I think I've achieved this to some extent....at meets it always gets fellow bikers rubbing their chins and pointing...haha, I sit back and check them out as they try to figure WTF is this? :)

I'm hoping for the same reaction when the Suzonda hits the road.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 05, 2020, 11:43:57 AM
While I await incoming parts (reverse operation rear brake master cylinder and 30x50mm steel box section) I was itching to get something positive done!!

so, I installed the tank front mount, which consisted of a length of M8 threading, through a hole I drilled in and through the headstock gusset with two cut down common white rubber door stops to act as shock rubbers.

(https://i.imgur.com/818hPEp.jpg)

Turned out OK I reckon....tank aligns well enough with the seat unit and fork/headstock/yoke and I hope to have got the tank inclination and angle right too.

(https://i.imgur.com/IWgSQYW.jpg)

The rear mount will be a block of flexi rubber, possibly a car exhaust mount rubber with a bit of squish in it and the rear of the tank held down using thick rubber bands (cut down inner tube?)....quick release ;) . I'll have to have a scrounge around my local exhaust place...once the isolation thingy is over.

A little step forward.....  8)

Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 06, 2020, 01:35:16 PM
Finally, the correct metal arrived, I'd ordered the wrong size for the job of making the U bracket that I'd intended to use at the caliper mount end of the brake torque arm.

I cut n drill later, with a bit of bench sanding and tweaking saw the torque arm coming together as I'd planned.....very satisfying.


(https://i.imgur.com/lRi1rFY.jpg)


(https://i.imgur.com/aJyWqMd.jpg)


The bones of it is M10 threading, into a female M10 rose joint bolted to the factory housing at the swingarm end with a thin-wall 10mm i/d steel tube to give it a better look than bare threading..

The rear U mount is shaped 30x50x2.5mm box section and bolted through the caliper mount using a longer than stock M8 shouldered bolt straight out the other side with a lock nut....should hold it correctly I reckon.

Anyone think differently? I'd welcome any critique.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: 85RZwade on April 06, 2020, 04:00:48 PM
None here, looks great. How much clearance between tire and brake arm?
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 07, 2020, 06:49:32 AM
None here, looks great. How much clearance between tire and brake arm?

Thank you. I'm quietly pleased with it to be honest. Took a bit of figuring and 3rd time lucky on the simple U bracket.....my engineering skills are rudimentary at best haha!

Tyre clearance is 15mm (1/2" approx) so enough with the 130 section tyre....I may increase the size to 140 or 150 which will be tight but still clear by a gnat's :)

Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 07, 2020, 04:54:47 PM
Bit more done today....made a start on the lower rear engine mount tabs. The twin tabs will be welded to a steel tube sleeving the footpeg and brake lever mounting spindle that passes through the frame.
They'll need finishing, but fit snug.
So pleased to make use of my new pillar drill to drill 10-12-14mm holes.

(https://i.imgur.com/z8ZR3xS.jpg)

Cant upload an image as file is too large....later.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 08, 2020, 07:25:45 PM
Found some time after dinner to sort through some of my stash, looking for a braided brake line long enough to reach the front caliper.....and....viola!!

Found one of the screw to union type, off a pair of Brembos I won't be using, and it fits perfectly.

Just threw the caliper together as I fitted the union. Needs cleaning and painting, then it'll bolt straight on.

(https://i.imgur.com/BpHHfxz.jpg)

I think I've got an idea for a fork brace and guard mount.....more anon
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 09, 2020, 06:29:47 AM
My son mentioned to me that I never show the workings or method of some of my shed engineering efforts.....he's persuaded me to show the process of making a simple engine mount...so here goes.

I could see that I needed a U bracket with two tabs (ears) to reach the forward lower engine mounts from the lower factory frame mounting points on the cradle. So, rather like the factory, I devised a length of threaded bar, a steel tube sleeve and that I'd use steel box section to form the U....keeping it simple but strong I hope.

Steel 50x100x3mm box section bought off ebay and chopped to the width I needed using an angle grinder an 1mm cutting disc (my go to tool)...

(https://i.imgur.com/jmTd110.jpg)

A quick go on my bench belt sander ( the best £20 I've spent) saw the burrs knocked off it..

(https://i.imgur.com/GoLAZSQ.jpg)

My idea was to have the steel sleeve run through the lower U to maintain strength in the U and fix it in position between the cradle rails.....so holes were bored using my birthday gift of a hobby pillar drill and step drill bits.

(https://i.imgur.com/DStBPWF.jpg)

(https://i.imgur.com/aQUmA2W.jpg)

..and, no I hadn't forgotten one...:) ...just needed to measure off the first hole to get it positioned correctly.

(https://i.imgur.com/delJGxr.jpg)

So, with a bit of fettling, I ended up with this.....ready to weld.

(https://i.imgur.com/o2Q42Jm.jpg)

...and this is it in position (ignore the broken case mount, the GT engine is sound).....I think I'll brace the centre across the tabs when I weld it.

(https://i.imgur.com/FRQVssT.jpg)

I'll be trimming the sleeve to add a washer to each end before buttoning it up.

This is my metalworking basic tool kit....shed engineering :)

(https://i.imgur.com/OUmfwEy.jpg)

Sorry, if this is telling you how to suck eggs, but it is saves for posterity and may be useful to other novice builders. :)





Title: Re: Newbie from UK - Suzonda 2smoker
Post by: 85RZwade on April 09, 2020, 09:38:04 AM
Good to see the details of your progress, and hats off to your son for the encouragement. You're right about the belt sander, they're more handy than you'd think.
Welding time, make some smoke!
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 09, 2020, 03:31:17 PM
Good to see the details of your progress, and hats off to your son for the encouragement. You're right about the belt sander, they're more handy than you'd think.
Welding time, make some smoke!

Thanx Wade.

I fancied painting today....

(https://i.imgur.com/uQF1KC1.jpg)

Not brilliant, but not bad.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 11, 2020, 10:48:48 AM
The conundrum that was the rear brake master cylinder, type, style, position and operation has finally come together. Lots n lots of thunking and I drummed up this cobbled together hotch potch of parts...

(https://i.imgur.com/ZMRq2ip.jpg)

I spotted this reverse crank operation and it instantly gave me the option that I was trying to find.

(https://i.imgur.com/kWs4pFh.jpg)

The reverse m/c allowed me to mount it upright and the crank operation still connects to the brake pedal. The alloy mount is where I got a bit creative....right in the way was the original 400/4 rear brake pivot shaft tube, butchering it out would've been just that, so to avoid cutting it, I employed it as the principle m/c mounts point.

I used some M10 threading and sleeved this out with regular nuts and a reversed flanged nyloc that sits in the tube snug, with 15mm of threading showing, enough to hold the 3mm alloy mount and take a flanged nyloc. The other end is a simple nut/spring washer to hold it all.

To avoid the bracket turning on the single bolt I've used a long M6 m/c mounting bolt which sits on the rear footpeg subframe.

It looks a bit messy at the moment, the footpeg extender frame will be painted out and I have in mind a guard of some sort for the brake mechanism but once everything is painted and tidied it'll hopefully look a bit better.....we'll see.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 11, 2020, 01:07:34 PM
Update: I paid the linkage and fittings some attention....getting there ;)

(https://i.imgur.com/H9yRhbe.jpg)

Plus added a heel protector...to burnish or to satin black?...hmmm?

(https://i.imgur.com/3jnc8FX.jpg?1)
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 12, 2020, 02:57:11 PM
A day of detailing:

I routed the braided flexi I had kicking around, from the m/c up and over to the swingarm guide tags and caliper, as the banjo was flat I had to offset how it sat by going between the torque arm and wheel...not happy with that.

(https://i.imgur.com/htatjke.jpg)

Happily, my job lot of braided lines I got for the Honda produced a suitable hose with a slightly angled banjo...this allowed it to sit where I wanted it and for it to pass between the shock and torque arm...much better.

(https://i.imgur.com/EyfWriw.jpg)

I then set about sorting the front braided line.....again, a line that came with a pair of Brembo calipers suited perfectly...and as I was attaching it to the master cylinder I had to smarten that up a touch. I used the same method as on the Honda, burnished the reservoir cap, fitted it back with buttonhead allens, satin blacked the body and fitted with stainless allenheads...clean, simple...not too fussy or blingy.

(https://i.imgur.com/5WKoHbb.jpg)

(https://i.imgur.com/fluXMqR.jpg?1)

Clutch lever came out OK too

(https://i.imgur.com/vulRls6.jpg)

I'll be using grey Renthal grips which should set it all off nicely I reckon. I'll fit a single mirror.

I've ordered f/r pads...so once fitted I just night give them a bleed :)
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 13, 2020, 06:19:58 PM
Sometimes, it's the little wins......

(https://i.imgur.com/U6zlNTH.jpg)

dealer wanted £6+ for a locking tab...bugger that, I don't mind spending when it matters, but a piece of thin metal...nah! I knocked this up in 15 mins....it'll do :)

Carry on....
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 16, 2020, 06:05:21 AM
Had a good day yesterday and got on with stuff...

The oil reservoir tank arrived, looks excellent quality and good value too (£26 ebay)...the dimensions were the closest I could find with the largest capacity for the given space, namely the redundant 400/4 factory airfilter box. I planned on keeping as much of the structure as possible, stil need to house a battery and the electrics mount to bespoke brackets on the leftside....so careful slicing was in order.

So I had to shoehorn in the tank......by slicing down the sides of the airbox and removing a piece from the battery side (I can use a thinner battery, 60mm rather than 75-80mm) I could retain the tank mounting flanges...

(https://i.imgur.com/hxg5jPv.jpg)

(https://i.imgur.com/2HDafP3.jpg)

My careful measurements worked out....the level sight gauge just fitted through the oval air flow outlet ;)

Quite a big slice out of the side, but need's must as they say.

(https://i.imgur.com/8JkgWyl.jpg)

Anyhow, a bit of cutting n shutting later and it fitted snugly and in position looks like it'll work. Just a shame not much of the tank will be seen.

(https://i.imgur.com/1lQHAny.jpg)

Here's the sight gauge which can bee easily viewed from 'outside'....that'll work.

(https://i.imgur.com/uvK2YZB.jpg)

I'll need to figure out a way of reconnecting the airbox sides to retain some strength, thinking about making 90* angled slip on corner clips, so I can release the tank if I have to. No sense permanently boxing it in by welding....hmmm?

(https://i.imgur.com/TNbb4yb.jpg)

Just need to bore an access hole for the lower oil feed and sort a breather as well as plug the outlets I'll not be using.

I had a think about the seat unit and how I'd mount it. Access to the oil tank is crucial and I had thought to fix the unit to the subframe with a slide off seat pad and access hole in the fibreglass for top ups.
However, in the mocking up, I thought the entire seat unit could be lift off, which would retain strength and structure and be just as easy for access.

I'd saved the seat subframe 'bridge' off the CBX project and pressed it into service here as the centre mount. Two timber strips, glassed in eventually, will form the front side support and raise, to align with the lower fuel tank edge, the unit to the correct angle.

(https://i.imgur.com/oPGeiTD.jpg)

The rear support is just that, a support rather than a mount.

(https://i.imgur.com/F6ZYnJ8.jpg)

I made this out of a bath tub support 'foot', massaged into shape and bolted to the stock bridge, it'll act as a rear unit support and cushioned with a rubber T to aid lateral seat position.

I'll explore the options on using an over centre latch on both side of the centre bridge, so clip on clip off would be possible. I'll locate the bridge on rubber feet and some form of locator so it doesn't shift sideways while in use. MOre to follow...

With the seat unit at the height it will finally be, I could mock the rear light unit/reg plate position. I'll form a x bracket from the subframe ends which will also hold the indicators. I might even form a cover plate/tunnel from light unit to bridge to cover and fill in the void. The angle of the plate mount will be altered so the plate becomes a splash guard, it's too upright at the moment, needs a few degrees more.

(https://i.imgur.com/sK1Z9wx.jpg)

The eagle eyed among you might have spotted the factory inner rear guard in place, I plan to use this to minimise spray and keep shit away from the carb intakes.

(https://i.imgur.com/5YLt2yL.jpg)

I couldn't resist proppoing the headlight shroud in place to see the overall look....me likey :)

Thanks for checking in.



Title: Re: Newbie from UK - Suzonda 2smoker
Post by: economan on April 16, 2020, 06:50:45 PM
I Christen your build the  " Johnny Cash Special "  ( one piece at a time )  :celebrate:

I also likey, good job and thanks for sharing.
Title: Re: Newbie from UK - Suzonda 2smoker
Post by: NoRiders on April 17, 2020, 05:01:49 AM
I Christen your build the  " Johnny Cash Special "  ( one piece at a time )  :celebrate:

I also likey, good job and thanks for sharing.
Haha...it certainly feels like that.....bits n pieces & parts from all over the state...:)

I keep switching from one area/system to another as they're all related and the effect of adding/working on one part has a direct affect on another....and so it goes...round n round.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on April 17, 2020, 01:32:02 PM
Playing around with ideas about how to secure the mount on the seat unit and came up with a shoe arrangement that the feet of the bridge can sit in, there's a backstop and along with a pair of over-centre latches (on order) I should have a quick release secure seat unit that'll remove in seconds.

(https://i.imgur.com/6QVMP2b.jpg)

I used for the shoes cuts off an ex drawer runner I kept in my scrap bin. They'll look OK when painted and are largely hidden, they'll do.

I plan on fitting two ¬ shaped location lugs along the front side edge which will also prevent sideways movement.

Thanks for checking in...

Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on April 21, 2020, 11:49:38 AM
Bit of a set back on the numberplate mount....I don't like it!!

Mounted the light unit in a semi-tucked position, so reasonably good vision from most angles. But, the plate is ugly and awkward hung like that.....not sure, but think it might be better lower down??

(https://i.imgur.com/13OESvC.jpg)

(https://i.imgur.com/e1i9tUY.jpg)

Black plate...

(https://i.imgur.com/LTveabI.jpg)

Am I being a dick?....maybe a smaller plate, the smallest I can get away with.....not even sure of the bright yellow (UK regs state this is the colour combo, with black lettering) and size does matter from a legal standpoint and a visual one too.

Got to take a step back and rethink this.... :whistle:

In other news, a rather nifty device turned up....a pressure operated rear brake light switch....

(https://i.imgur.com/bbVIPQw.jpg)

much neater than a cumbersome mechanical switch and associated paraphinalia, I like it...hope the Chinesium in it works?



Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on April 22, 2020, 06:06:48 AM
One step forward and two steps back......number plate position is vexing me...not entirely happy with any of the options, but once the mock plate was trimmed and positioned exactly, excess mount metal disguised and trying to envisage it painted up....I think I've finally found a position I can love with.

(https://i.imgur.com/NGT2YbY.jpg)

If I introduce a slight curve to the plate that may help too.

Toying with a black background white digit reg plate, not strictly UK legal, but not out of place and I've had zero trouble on the Honda, save for MOT time,, and this won't require one...ir I choose too, I'll get a yellow/black plate just for the pass.

I've abandoned the over centre latch idea I had to securing the seat unit and will employ a single Dzus fastener to engage with the bridge support under the rear end.....not a smooth finish but Dzus look cool, so I'm OK with that. Twist n turn version ordered.

Also ordered the fibreglass kit to bond in the timber spacers along with h/d 42mm exhaust clamps as I have an idea how to manage an extension to the Microns.....more anon.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on April 23, 2020, 05:32:37 AM
The 2mm aloominum sheet arrived so I had to bash it into shape pdq....came out nice I reckon....even allowing for my bench belt sander to fail mid job!!

(https://i.imgur.com/02XULU4.jpg)

Just got to layer and shape the 15mm yoga mat, doubling it up to 30mm would look the part and a quick trial sit and it should be ok for cafe hopping ;)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on April 23, 2020, 06:10:30 PM
Seat's nearing completion.....shaped n smoothed the dual layer yoga mat using 60 grit by hand....my detail sander wouldn't work too well on it.

(https://i.imgur.com/0VBOTB7.jpg)

I was looking to get the front edge snug against the tank, but the rear tankmount sticks out 15mm, so an opening, like a mouth was needed. The double layer allowed me to open up a suitable gap using something to hold the form....and, while out on my daily exercise walk, I spotted a broken pair of ear defenders in my neighbour's rubble pile. Spotted the potential....shown here.

(https://i.imgur.com/GvY6Vnu.jpg)

(https://i.imgur.com/JE0tdwL.jpg)

Liking the little hump..



So much smoothing and I'm happy with the overall shape...ready for the upholsterer to work his magic.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on April 26, 2020, 07:39:20 AM
The tank is away for vapor blasting to remove the old paint and surface rust (hope it's just surface).

(https://i.imgur.com/gtpssTT.jpg)

I'll hit the bare metal with a coat of this etch primer before repairing a few minor dents...then off to paint.

The Dzus fastener worked  ;D

(https://i.imgur.com/PN7wl2i.jpg)

So I now have a quick release seat unit, so access to the oil tank is easy.

Number plate arrived, size is good although digits are smaller than I expected. Also, don't remember ticking the 'border' box...but hey ho, it looks OK tbh.

(https://i.imgur.com/iEH07Ia.jpg)

Hoping in the yellow/black it'll tie in with the paint colour scheme. Just got to get used to it being stuck out like that......so much better without I reckon.

Upholsterer jacked up for this week sometime....using Williams F1 team blue suede as my trimmer does all their work. This is a swatch that was left over from a project....should be just the right shade of blue, that'll do for me.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: m in sc on April 26, 2020, 08:08:53 AM
... off topic a bit.

Did you work for the Williams F1 team? Particularly pre 94?
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on April 26, 2020, 10:30:21 AM
 :pop:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on April 26, 2020, 06:24:59 PM
... off topic a bit.

Did you work for the Williams F1 team? Particularly pre 94?

Sadly, no.

They're based about 8miles away.....me and my partner had our first date at the conference centre, she was a theatre school principle and invited to a talk put on my the UK army about military familes....the F1 museum is interesting.
This is the topiary outside the reception.

Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: m in sc on April 26, 2020, 06:54:58 PM
thats awesome.
I have a good friend, locally, that did for many years as a fabricator. that's why i asked.  His KZ650 is currently in my garage downstairs being put back together by us.

He actually taught me how to tig weld.   :science:

Back on topic: totally digging the project.  :metal: I love stuff like this.  :toot:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on April 26, 2020, 10:48:40 PM
 :agree: Colin, you've made so much progress in just a few weeks, and your bike is coming together very nicely. Almost a shame to cover that yoga mat!
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on April 27, 2020, 06:22:35 AM
thats awesome.
I have a good friend, locally, that did for many years as a fabricator. that's why i asked.  His KZ650 is currently in my garage downstairs being put back together by us.

He actually taught me how to tig weld.   :science:

Back on topic: totally digging the project.  :metal: I love stuff like this.  :toot:

Are you local to Oxfordshire then? I'm in Abingdon.

I've found the enthusiasm to get stuck in...making the most of our splendid isolation. Tinkering as I await parts to arrive. Cheers  8)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on April 27, 2020, 07:07:29 AM
:agree: Colin, you've made so much progress in just a few weeks, and your bike is coming together very nicely. Almost a shame to cover that yoga mat!

Thank you, yeah I feel like I've made good progress, still lots to do but having the tank blasted (I'll miss the red/black colouring though) and the seat trimmed feel like I'm seeing the end in sight....and yes, the yoga mat turned out OK as I did consider keeping it raw.....for a pure competition bike it'd work...just not too sure on the durability. Same for the alloy oil tank...encasing it as opposed to mounting it in full view......but it didn't make sense to over design it tbh.
Thanks for keeping interested :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on April 30, 2020, 05:59:46 PM
Seat pad is with the trimmer....sneak preview of the material.

(https://i.imgur.com/UK6OnPE.jpg)

Exhaust clamps arrived and did what I needed, to hold the spigot extension in place....it'll do for the initial fire up....I'll have it TIGd later.

(https://i.imgur.com/XUg4pL5.jpg)

(https://i.imgur.com/aviVrzr.jpg)

Front brake is now loaded with pads and ready for a good bleeding....wish me luck.

(https://i.imgur.com/9c3c0Yp.jpg)

The freshly vaporblasted tank has turned out well. No visible holes as the rust was surface. Giving it a coat of U-Pol Acid8 etch primer, filling the dents and getting it to my painter asap.

(https://i.imgur.com/RVlEXMF.jpg)

(https://i.imgur.com/loobt9U.jpg)

(https://i.imgur.com/3uWvtci.jpg)

Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on April 30, 2020, 06:06:25 PM
A job I was happy to have completed was making the alloy oil tank fit inside the Honda airfilter/battery/electrical housing....a cut n shut saw it slide into place, needs a slimmer battery which is available, and the electrical mounts are all still in place.

The sight glass work and I'll get a 12mm breather filter.

(https://i.imgur.com/U9SoCT9.jpg)

Trying to fashion a fork brace/fender guard mount out of the CBX mount I kept. It's working OK but I really wanted an alloy billet Micron fork brace.....we'll see.

(https://i.imgur.com/CN2m4Oh.jpg)

Getting some done :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 01, 2020, 05:22:25 PM
Progress.

The tank now has a coat is etch primer, U-Pol Acid8......came out nice.....ready for the P38 repairs.

(https://i.imgur.com/l0jinSZ.jpg)

Fuel cap - fitted a new OEM seal as the old one was perished...tricky to install but got it in the end.

(https://i.imgur.com/fVZmns3.jpg)

The new OEM headlight surround arrived and accepted the Koito H4 lamp easily. Much brighter looking, I'll source a H4 LED bulb to avoid overloading the electrics.

(https://i.imgur.com/F03zOSR.jpg)

The overall look is coming together, I like it :)

(https://i.imgur.com/cCStpDj.jpg)

Spoke to the powedercoat guy, on Monday I'll be checking out shades of white, making a choice and using the RAL number on the bodywork too.

Thanksfor checking in :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: toffee on May 02, 2020, 08:01:55 AM
Hi Colin, great progress this does have similarities to my own project.
So much fabrication and relocating of things.

well done on the progress so far.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 02, 2020, 10:26:46 AM
Hi Colin, great progress this does have similarities to my own project.
So much fabrication and relocating of things.

well done on the progress so far.

Thankee sir....picked up the pace for sure.... :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 02, 2020, 01:48:03 PM
I was in desperate need of essential 'forced air' vents...

(https://i.imgur.com/1ZUXNCE.jpg)

(https://i.imgur.com/4q2Yp33.jpg)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on May 02, 2020, 03:28:59 PM
To keep your oil tank cool!
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 03, 2020, 05:19:39 AM
To keep your oil tank cool!

Essential cooling at the anticipated warp speeds I'll be travelling at...coffeeshop to bar n back
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: Czakky on May 03, 2020, 10:01:02 AM
Plus you just added a bunch of lightness!
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: thatguy on May 03, 2020, 10:41:51 AM
Awesome............Speed Holes!!!


(https://i.imgur.com/PkRmUi9.gif?noredirect)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: sav0r on May 03, 2020, 10:50:06 AM
We always called them weakening holes, but they look great with that stainless mesh!
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 03, 2020, 11:40:14 AM
Awesome............Speed Holes!!!


(https://i.imgur.com/PkRmUi9.gif?noredirect)

haha...that's another name for my race lightening flow vents :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 03, 2020, 11:42:57 AM
We always called them weakening holes, but they look great with that stainless mesh!

 ;D Weakening holes they may be...but they're for cooling and they're cool.

Tip: I was seeking out stainless mesh, but got confused by the options and choices out there.....in amongst the mesh searches were kitchen/cooking sieves...blimey, I have one of those in the garage....boom....free mesh that was just right size/thickness.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: JB Weld on May 03, 2020, 08:04:05 PM
Very nice project. So many innovative mods. Can't wait to see the end result.  :whoop:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on May 04, 2020, 01:10:19 AM
I was going to get on a plane and pop over to Jolly Olde to see it in person, but you know...travel restrictions.  ;)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 04, 2020, 05:45:17 AM
I was going to get on a plane and pop over to Jolly Olde to see it in person, but you know...travel restrictions.  ;)

Haha...you'd be more than welcome....to stand on our doorstep ;)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on May 04, 2020, 08:53:14 AM
 :'( ouch!
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 04, 2020, 09:00:22 AM
:'( ouch!

Haha..we're into our 6th week of isolation and feel we have to abide by the govs instructions....I neither want to become infected or infect anyone else. Visitors are always welcome :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 04, 2020, 09:01:51 AM
Very nice project. So many innovative mods. Can't wait to see the end result.  :whoop:

Thank you....it's a lot more work than I anticipated, first time doing something so difficult tbh, so it's taken a lot longer and cost a lot more than I had hoped.
I too am looking forward to it finished.... :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: thatguy on May 04, 2020, 10:41:34 AM
Very nice project. So many innovative mods. Can't wait to see the end result.  :whoop:

Thank you....it's a lot more work than I anticipated, first time doing something so difficult tbh, so it's taken a lot longer and cost a lot more than I had hoped.
I too am looking forward to it finished.... :)

Projects are like that. Multiply by 3 for time and 5 for cost enables an accurate estimate when considering one. Even so that rarely stops me.  :whistle:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 04, 2020, 02:09:43 PM
Very nice project. So many innovative mods. Can't wait to see the end result.  :whoop:

Thank you....it's a lot more work than I anticipated, first time doing something so difficult tbh, so it's taken a lot longer and cost a lot more than I had hoped.
I too am looking forward to it finished.... :)

Yeah, most, if not all, of my other auto related projects have done exactly that, cost more in time, effort and money....why do we do it*? :)

* I love it really ;)

Projects are like that. Multiply by 3 for time and 5 for cost enables an accurate estimate when considering one. Even so that rarely stops me.  :whistle:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 04, 2020, 02:12:22 PM
Wheeled it outside for a good look....tank to seat like will work and liking the Micron angle and the look of the engine nestled in the frame too.

Spoke to the powdercoat guy today, chosen RAL 9010 white satin for the wheels...the body work in the same colour but pro sprayed 2pack.

(https://i.imgur.com/uym5WJT.jpg)

(https://i.imgur.com/8cZRZu3.jpg)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: economan on May 04, 2020, 03:34:12 PM
Looks like you just need an "adapter kit"  :umm:   and you should be smoking about the alleyways.
One piece at a time, eh. ?
I love it  :clap:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: thatguy on May 04, 2020, 04:38:05 PM
Looks like it'll be a fun ride.

BTW WTF is a V5?
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 05, 2020, 01:23:21 PM
Looks like it'll be a fun ride.

BTW WTF is a V5?

I'm hoping it'll be a blast...coffee shop to coffee shop ;)

The V5 in the UK is the reg documents including the registration number. So all paperwork intact and good to go. Considering the frame was part  of a deal,  and was absolutely bare, I trusted the guy who told me it was his mate's bike they slowly stripped when the engine blew up.
There's many that would call it sacrilege to dick with a 1977 400/4, but it was neglected and I've given it a new lease of life is the way I see it.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: sav0r on May 05, 2020, 03:30:10 PM
A new lease is correct. My father turned a '66 Austin Mini into a hot rod, rear engine, tube frame Mini. People give him shit for chopping up a 'priceless' Mini. The thing was destined for the crusher had he not saved it. A lot of people don't get that though. The cool thing is that you get to have your jollies along the way.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 05, 2020, 05:19:15 PM
A new lease is correct. My father turned a '66 Austin Mini into a hot rod, rear engine, tube frame Mini. People give him shit for chopping up a 'priceless' Mini. The thing was destined for the crusher had he not saved it. A lot of people don't get that though. The cool thing is that you get to have your jollies along the way.
100%..this.

The original bike in the deal was another 400/4 that's sat outside under a torn tarp for 15yrs. Gave it to my lad, he got it running in an afternoon and bratted it...
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on May 06, 2020, 01:15:07 AM
 :agree: we love them, and in the end they're just machines. If they're not being used as they were intended and bringing joy, what good are they?
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 06, 2020, 07:35:41 AM
:agree: we love them, and in the end they're just machines. If they're not being used as they were intended and bringing joy, what good are they?

Exactly....it seems the same folk who decry any modification and slate anyone who dares to move away from factory are quite happy to store a bike (or bikes) away from sight and never get around to riding them, so they sit forlorn, neglected and not played with (like a mint model car in it's original box)....but that's OK? And, where were they when this frame was rotting in a shed?

I shall carry on my butchery... ;)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 08, 2020, 05:55:07 AM
A quick update:

The oil tank breather arrived, sits nice and tops off the assembly.

(https://i.imgur.com/j4OU91N.jpg)

One thing I was determined to avoid is...rough edges on fibreglass pieces, seen too many nice paint jobs ruined (IMO) by a rough edge, so sanded mine to contour and smooth them...I'll ask my sprayer mate to pay attention to them too.

(https://i.imgur.com/0hQYGLd.jpg)

The tank required minor filling to a few dents, I tried to ease the dents out with leverage, but the tank metal is tough/thick. A skim of P38 did the trick.

Before
(https://i.imgur.com/UIfUGHO.jpg)

After
(https://i.imgur.com/m4YCo9K.jpg)

Off to the painters this weekend I hope. Done a deal with my mate, he sprays for the cost of materials and oven, I give him a day decorating his house as I'm a house painter...cool barter :)

Using stainless P clips to mount the headlight cowl....paired up they provide a sound anchor as there's not much weight or stress on them. Fashioned a 3mm alloy tab which came out OK, and suits the overall style.

(https://i.imgur.com/AOGGMBF.jpg)

(https://i.imgur.com/WGABIHW.jpg)

And....a late delivery saw this alloy billet Micron forkbrace arrive....had to fit it didn't I?

(https://i.imgur.com/czfk0Mo.jpg)

(https://i.imgur.com/1fdQm8v.jpg)

Also, another P clip to tether the brake line worked out well I reckon. It's a bit of a lump tbh and takes some getting used to....I shall sit n stare at it for a good while ;)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 08, 2020, 07:03:59 PM
Tackled a job I wasn't looking forward to...the leftside exhaust. Turned out, as I chose to do it the correct way, it was relatively simple to make another spigot, this one was straight as the pipe had to sit slightly outward to clear the side stand mount....so that's got that connected...

(https://i.imgur.com/ifTBshx.jpg)

...and, the alignment of the rear silencers looks to be OK too....bit of fettling on final build up will see them right.

(https://i.imgur.com/omUwwnk.jpg)

That's all folks :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: JB Weld on May 08, 2020, 08:25:06 PM
I really enjoy watching the progression of this build. Great job so far!
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on May 08, 2020, 09:13:08 PM
Roger that. I'm always pleased to see that Colin has given us something to appreciate  :affirmation:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 09, 2020, 09:59:02 AM
JBWeld & Wade, thank you gents. Pleased that you get something out of my witterings, wrangling and wrenching :)

I'm trying to keep the momentum going best I can...awaiting parts is one thing and now paint.

Now that the exhaust is sorted, I'll probably dig out the MIG and have a goat the engine mounts, then slot the engine in to align the drive sprockets.

This coming week, I hope to have the old tyres removed so the wheels can be powdercoated.

Thanks for checking in.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 10, 2020, 02:27:53 PM
Logic suggested I had better install the actual GT200 engine, so I can align drive sprockets......with a bit of jiggery pokery they align perfectly. I have adjustment in the mounts, but the fit is great.

(https://i.imgur.com/m6sfwPg.jpg)

Still need to remake the front upper out of 3mm steel. The NGK plug caps are a nice touch :)

Couldn't resist positioning the carbs - so I can measure how large I can go with filters - 60-70mm should be fine.

Also, in final prep for paint, I repaired a cracked side panel...using an electric soldering iron/gun and a cut down pop rivet stem, embedded by melting....I reckon this will be strong enough to hold.

(https://i.imgur.com/Zwo5Jv7.jpg)

(https://i.imgur.com/Ia94m0D.jpg)

I've since been advised I could've used a paperclip and fed in plastic from a cable tie :) Next time.

I also fitted the OEM Honda petcock, fits like a glove and leak free...I washed out the inner and rinsed it with paraffin...no leaks overnight, so it's good to go, happy with that :)

Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: toffee on May 16, 2020, 06:25:05 PM
looking good!
the pipes are sitting quite wide, will you be able to access the side stand?
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 17, 2020, 05:18:58 PM
Thanx

The pipes will be fettled to sit as close as is practical....given they're for an RD350LC. The rear mount uses the pillion peg mount on the curved outriggers, which I had to bend outwards for the swingarm to clear. The brackets I'll make will be S shaped to allow the rear to sit tight to the outriggers....I don't want to alter the exhaust bracket if I can help.

The 400/4 side stand will need modifying, extending and the access peg extended to curve under the silencer.

Here's a recent shot.

(https://i.imgur.com/iWjVnBU.jpg)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 19, 2020, 01:02:26 PM
Update: Been trying to sort the wiring and fitting components in the Honda electrical area....doing OK I reckon, one small bracket away from everything mounted....wiring will be arranged to suit from an SB loom I have....defo needs a starter live from handlebar to solenoid as well as the run/kill switch too.

Battery, 12v AGM 9AH arrived and fits snugly, which was the plan ;)

(https://i.imgur.com/EzZQF1P.jpg)

My lad's popping in this Saturday to help connect it all up. Got this box of crimps and connectors which might help.

(https://i.imgur.com/dOBgl5e.jpg)

I also have a scrap loom that may provide colour coded wires. Wish me luck this weekend :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: sav0r on May 19, 2020, 04:06:29 PM
It’s all starting to come together! Great work!
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: m in sc on May 19, 2020, 05:06:14 PM
im liking it.

few comments:

i agree those pipes are out there, surprised you didnt tuck them in. think they will be an issue.

the headlight mounts: i did basically the exact same thing, except with TI sheet on my rd, it works a treat, and actually wished i had done it earlier on other projects from the past.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 20, 2020, 02:59:10 AM
It’s all starting to come together! Great work!

Yeah thnx, I feel like I've made some progress even though there's still a way to go :) keep on plugging away.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 20, 2020, 03:04:45 AM
im liking it.

few comments:

i agree those pipes are out there, surprised you didnt tuck them in. think they will be an issue.

the headlight mounts: i did basically the exact same thing, except with TI sheet on my rd, it works a treat, and actually wished i had done it earlier on other projects from the past.

The pipes are for an RD350LC I was told by the seller., so given the engine position I cannot get them to 'tuck' anymore that they are. Clearance is about 1/2" or less. The side stand will need extending and the foot tag thingy bending around the pipe.

The P clip headlight mount was the solution to overly expensive mounts that stuck the headlight out too far....see it quite often on other builds and as I'm using a cowl it had to sit tight as possible.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 20, 2020, 01:32:09 PM
I think I have everything for this weekend, ready for when my son does the wiring for me ;)

(https://i.imgur.com/ar1933h.jpg)

Battery on charge.

Clutch cable arrived.

Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 23, 2020, 04:02:06 PM
Today was a good day...my lad sorted the wiring so I now have working rear lights, indicators and the starter kicks over on the button...yay.

(https://i.imgur.com/yCkd1Xi.jpg)

(https://i.imgur.com/eB4F8pZ.jpg)

Just a headlight relay, indicators and an earth strap to sort.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 25, 2020, 03:58:11 PM
Any good reason why the coil can't be mounted in this position just above the carbs?

(https://i.imgur.com/XvoqFkc.jpg)

(https://i.imgur.com/weREzEF.jpg)

The bracket pops up through a hole on the tank mount and I'll fix it with a couple of Rivnuts.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on May 25, 2020, 06:33:00 PM
I think it's a fine location, functionally. Hopefully it'll be somewhat hidden by the fuel tank, 'cause it's none too pretty. Maybe you can conceal it with a repurposed airbox...?  ;)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 26, 2020, 05:12:31 AM
......conceal it with a repurposed airbox...?  ;)

...or a decal ;)

It'll be tucked under the tank...if anyone's nosing under there and dares to comment, a swift poke in the eye should have them see my point...haha!

I know coils get hot in use...wonder if a quick coat of VHT paint might work? Anyone done this?
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: RustyRD on May 26, 2020, 06:37:23 PM
Your chosen location looks like it will work fine. The coil may even see better cooling in this location. Be careful to maintain a good ground, does not take much resistance to start to lose current to the coil.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 27, 2020, 11:47:49 AM
Your chosen location looks like it will work fine. The coil may even see better cooling in this location. Be careful to maintain a good ground, does not take much resistance to start to lose current to the coil.

Thanx, thought it would but, better to check I've not made a rookie error.

I'll probably run a ground tail direct to the frame.


In other news....I've spotted a bijou problemo

(https://i.imgur.com/Qs6kjNp.jpg)

Hadn't given it a thought....then find the primary drive cover is 'kin miles out and requires some chopping...

(https://i.imgur.com/PNPdwWZ.jpg)

I thought to use/trial cut a crappy cover I had and glad I did......still working on it....this is a food break. I'm aiming for a straight (ish) fit as the clutch actuating rod has to align with the lever as well as the gear change shaft too....so any jiggery pokery must be kept to a minimum. Bugger.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 27, 2020, 11:54:39 AM
Don't you just love it when you deal with a good company, I needed to talk to someone in RamAir regarding my foam filter issue, called them and spoke to a helpful chap, we discussed my requirement and he suggested a couple of options, even recommending another company for the trumpets. We agreed, there would be a solution and I explored the trumpet options.

Trumpets and associated parts would cost loads and add time (delivery mid July/Aug for the adapter) so I ordered the single 34mm foam pod x2. Called the fella back to tell him what I'd decided to do and thank him for his time.....he promised my order will be dispatched that same day (yesterday 26/02/20) only for the parcel to arrive today...all present and correct.

(https://i.imgur.com/lbnJN4C.jpg)

The business is RamAir, they're UK based and worth a recommend IMO.

https://www.ramair-filters.co.uk/products/motorcycle/race-pod-air-filters-motorcycle/
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 27, 2020, 06:03:28 PM
Got the side cover issue sorted....shaped a good chunk off the top corner so the cover will jiggle in snugly and the clutch rod sits in the rubber bush.

Pleased I had the scrap/damaged cover to practice the shape on....learnt a lot and the final effort turned out OK I reckon.

Also, found a compression spring, but need to adjust the clutch actuation and cable adjustment to set the lever position.

 (https://i.imgur.com/HsLRU77.jpg)

Run the 1-3 throttle cable and fixed it with a P clip to the spine, cables run to the carbs nicely and between the carbs to the oil pump.....I'll need a longer one making up as I need another 3" as the bars are wider, I might have a go myself to be honest.
Unless anyone knows of a 1-3 for a twin trials bike that'd work with the GT200??
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: economan on May 28, 2020, 06:57:41 AM
I fell in to a burning ring of fire,
I went down down down, till the flames got higher
And it burns burns burns, the ring of fire,
The ring of fire.

Johnny & June would be proud. :celebrate:  Cant wait for the "Sunday Morning coming down", reveal.  :whistle:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 28, 2020, 07:20:48 AM
I fell in to a burning ring of fire,
I went down down down, till the flames got higher
And it burns burns burns, the ring of fire,
The ring of fire.

Johnny & June would be proud. :celebrate:  Cant wait for the "Sunday Morning coming down", reveal.  :whistle:

Haha...dont call us...well call you....next!!.

Controlled fire would be a good thing....reveal any time distant. :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: sav0r on May 28, 2020, 10:04:22 AM
The side cover is looking factory. Very nice!
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 28, 2020, 11:59:11 AM
The side cover is looking factory. Very nice!

Thanx...it'll look a bit better with a fresh coat of paint. Still a ways to go yet. :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: sav0r on May 28, 2020, 02:11:39 PM
Yeah, I can see it. The finished product is only going to be better.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: toffee on May 28, 2020, 05:12:22 PM
The side cover is looking factory. Very nice!

Thanx...it'll look a bit better with a fresh coat of paint. Still a ways to go yet. :)

That was some curve ball thrown at you with the side panel, nicely sorted though, looks good, good fix.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 28, 2020, 05:55:32 PM
The side cover is looking factory. Very nice!

Thanx...it'll look a bit better with a fresh coat of paint. Still a ways to go yet. :)

That was some curve ball thrown at you with the side panel, nicely sorted though, looks good, good fix.

Thnx Toffee....Even in a game of curveballs....I didn't expect or anticipate that one ;)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 29, 2020, 03:26:49 PM
While fiddling around in the clutch & oil pump area, I realised I didn't have a cable terminal for the oil pump lever.....so, I made one.

(https://i.imgur.com/d9jXE6h.jpg)

As you can see the top of a connector block fitted the bill.....drill one hole and slot.

Mind you, given it's importance I'd lost my bottle and ordered a genuine Suzuki part.

The bodywork, headlight cowl, tank and seat have been picked up by my painter/sprayer mate.....more anon.

One last job before it went to paint, position the ignition switch....it's not connected to the ignition but will switch a component earth...the run/kill switch is the live.

I like it in this position.....and, no I don't think I'll break the key. The switch is ex forktruck and the key is locked when in the live/on position, so it won't fall out while underway.

If I do break it, I'll replace it with a simple push on/off switch.

I've gone though the carbs again, the main jet looks to be 87.5 which isn't the stock size I think?...can anyone confirm?

Indicators arrived.....can you see them?

(https://i.imgur.com/cSTr2yS.jpg)

That's it for now....thanks for checking in - Colin
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 31, 2020, 04:23:23 AM
Any colour you like.... ;D
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: RustyRD on May 31, 2020, 08:21:19 AM
one vote for Guards Red, the build has been moving along.  :clap: :whoop: :whoop:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: economan on May 31, 2020, 12:25:11 PM
Tins, Miami blue & black
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 31, 2020, 12:46:28 PM
one vote for Guards Red, the build has been moving along.  :clap: :whoop: :whoop:

Ha...no not red. The build sure has been moving forward....just got to keep the momentum going now. :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on May 31, 2020, 12:48:13 PM
Tins, Miami blue & black

Blue is in there...;)

Think Suzuki GSXR triple blue/white colours in a retro 70s style.

(https://i.imgur.com/7xHRhMb.jpg)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on May 31, 2020, 05:01:47 PM
Yes! I like the blue scheme
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 02, 2020, 01:27:59 PM
Yes! I like the blue scheme

My favourite colour.

Did I say the wheels are done?

(https://i.imgur.com/jOm2I5E.jpg)

I'm very pleased :)

Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: Plasticman on June 02, 2020, 05:31:01 PM
The build looks great.  Can't wait to see the final product.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 03, 2020, 05:50:03 AM
The build looks great.  Can't wait to see the final product.

Thank you...I'm a kinda lookin' forward to it myself ;)

Throttle cable to be extended today by 3-4". Photos to follow...it's not done yet.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 03, 2020, 05:58:24 PM
Cables lengthened by 2" today

(https://i.imgur.com/CuVhLiX.jpg)

and working well with the Domino twister.

(https://i.imgur.com/5faWtpM.jpg)

I now have clutch, throttle and oil pump cables all adjusted.

(https://i.imgur.com/CoWz1rM.jpg)

Wheels are down the bike shop awaiting my ordered 130/70 tyre to match the front.

(https://i.imgur.com/5MNg8WB.jpg)

Should have rubber by mid next week.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on June 04, 2020, 01:31:11 AM
You're gonna be riding that thing this summer Colin! Getting super close.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 04, 2020, 06:03:20 AM
You're gonna be riding that thing this summer Colin! Getting super close.

Ha, you say that....the job list doesn't seem any shorter, but I hope to have it up the road at least, running, steering, changing gear and stopping.....then tear it all down to sort the frame....and then build it all back up again.

Did you mean this summer? :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 08, 2020, 06:05:17 PM
Well, quick update...I'm positive the powdercoated wheels and tank/bodywork paint don't match.....bugger. I'll be chcking them together tomorrow as the wheels are at the shop awaiting tyres...

In the meantime, I mounted the carbs and gave them a wet fuel test...came out dry.

(https://i.imgur.com/8IzB478.jpg)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: sav0r on June 08, 2020, 06:32:44 PM
You have a cable stretcher? I've always wanted one.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 08, 2020, 07:20:53 PM
You have a cable stretcher? I've always wanted one.

Ahh...get ya....wringing the arse off of it...haha!

We did make the single part of the 1-3 throttle cable...hope it holds. ;)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: sav0r on June 08, 2020, 08:10:40 PM
Good work, the build is shaping up nicely! I can already hear those fins sing!

Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 21, 2020, 02:53:43 PM
Fire in the hole.....first start up went well, first time ever  :celebrate:

https://youtu.be/RaX-dj8GzXM

The knocking is a leaking exhaust connection, nothing to worry about. Running it on 2stroke mix until I sort/prime the oil pump.

We had a couple of goes at it to be honest, but our makeshift tank had to fill the carbs and a teeny squirt of 'Start ya Bastard' did the trick. Long way to go but a fire up is a fire up and mo mistake guv'nor :)

This is all thanks to my son, who popped in for Father's Day to finalise some of the wiring.
I now have dip and main beam headlight, horn and of course a running engine...did I mention the engine runs? ;)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: SoCal250 on June 21, 2020, 03:02:00 PM
Congrats! :righteous:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: Czakky on June 21, 2020, 03:58:11 PM
Wow! You will turn some heads when they hear that electric starter and then it fires.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: RustyRD on June 22, 2020, 06:54:40 PM
 :whoop: :whoop:Great when they fire up and no parts fly off. Congrats :whoop: :whoop:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on June 22, 2020, 09:36:27 PM
Never any question of it starting up, it had no choice! Great work Colin, I assume the electric starter will only be used in emergencies?
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 23, 2020, 06:57:51 AM
:whoop: :whoop:Great when they fire up and no parts fly off. Congrats :whoop: :whoop:

Haha...no parts flew off.....but, don't speak too soon fella.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 23, 2020, 07:02:16 AM
Never any question of it starting up, it had no choice! Great work Colin, I assume the electric starter will only be used in emergencies?
Thanx...I turned 61 yesterday and the question of kicker or starter was given a lot of thunking time. My first engine, the SB200 had kicker only...and my ego was telling me "do it, it's cool as fuq"....then my head chipped in with "what da fuq are you thinkin' fool?" hence I have a kicker for show and a starter for go on the GT engine I found when lamely searching for a assisted starter mechanism ;)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 23, 2020, 07:02:58 AM
Congrats! :righteous:

Thank you, well pleased I have to say :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 23, 2020, 07:05:11 AM
Wow! You will turn some heads when they hear that electric starter and then it fires.

Haha...I hope so ;)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 23, 2020, 02:01:34 PM
Topped up the gearbox with oil.

Fitted the exhaust - may have to do it again to seal it, but it's only for a run up the road and back.

Making a pair of front upper engine mounts in 3mm steel, cut from box section...just need to drill the holes and paint.

Still need to sort the oil pump feed.....I'm trying to avoid stripping the battery/oil tank box out....hmmm?
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 26, 2020, 06:57:18 AM
Gez the trimmer delivered on the seat & tank pad.....awesome is not a word I bandy about, but I'm very pleased with the result.

(https://i.imgur.com/HDUn3Xu.jpg)

(https://i.imgur.com/tNnbrBp.jpg)

Ignore the gaps, it's just thrown together for now.....trims need to be fixed in place etc...still waiting for the bodywork to be repainted :(

I've given the suede a spray with protector to waterproof and stain guard too.

Front caliper is due shortly after it's refurbishment and rebuild.

Need to measure for a 520 chain.

Fashioning upper front engine mounts, then they'll need welding.

Thanks for checking in :)

Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: RustyRD on June 27, 2020, 08:59:56 AM
That bike is looking GREAT. The seat and trim look fantastic.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on June 27, 2020, 09:49:02 AM
 :agree: love the upholstery Colin; be careful filling that tank! Tell us about those suzonda tank badges, they look perfect  :thumbs:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 27, 2020, 05:05:03 PM
:agree: love the upholstery Colin; be careful filling that tank! Tell us about those suzonda tank badges, they look perfect  :thumbs:

Thanx I love it too.
I've used spray shoe protector on the entire set, the same stuff you use to waterproof new boots etc. I will be careful too.

Suzonda tank badge and side panel badges are 3D printed by a guy in the UK at a cost of £40 x4 ...not cheap, but he did exactly what I asked for and they came out great.

(https://i.imgur.com/KBoBdw4.jpg)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 27, 2020, 05:18:20 PM
That bike is looking GREAT. The seat and trim look fantastic.

Thank you. I knew the tank had the potential to stand out, the trimmer is 100% and I'm happy the seat pad turned out how I had tried to describe to him.
I've still got to have the tank n bodywork repainted in the matching white shade of the wheels RAL 9003. Then add the decals.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: RustyRD on June 27, 2020, 05:33:12 PM
I love the WTF 200/2 :bacon:  great idea on 3D printing. 
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 28, 2020, 08:05:50 AM
I love the WTF 200/2 :bacon:  great idea on 3D printing.

Yeah, when I saw them I knew they'd have a place on the bike. They will cover the original Honda CB200 tank badge which screws to a welded plate in a recess......the vinyl decal I had made wouldn't work correctly and I didn't want to fill the recess.

(https://i.imgur.com/Op1MVsO.jpg)
 
They are good and look the part, but they'll not pass for factory badges as the black background is a rough finish, not visible in the images.



WTF200/2 as the frame is a 400/4.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: 85RZwade on June 28, 2020, 08:47:18 AM
Such great details!
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 28, 2020, 01:29:04 PM
Such great details!

Well, thank you.....I spend a lot of time just sitting looking at it...then seeing something on another build or making it up as I go along. It's a fine line between details and too much I think...so mostly, I ponder the idea and see if I still think it's OK a few days later.

The side panel vents for example....thought that one through a good while, before I arrived at the end result....ie: fine stainless mesh formed from behind into the hole.....seen it on some great bikes and loved that the mesh formed into the hole, rather than just sit behind it. Considered punch stainless sheet which I used on the Honda, but preferred the old skool wire mesh in the end.

(https://i.imgur.com/4q2Yp33.jpg)

Did I mention I've mislaid the bloody ignition switch!! :/
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: SoCal250 on June 28, 2020, 08:34:00 PM
Those badges are awesome!  :clap:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 29, 2020, 11:41:46 AM
Those badges are awesome!  :clap:

Thankee SoCal :)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 29, 2020, 02:35:54 PM
Oil pump installed and primed. Using the factory feed pipes and will use my trusty syringe as a temp oil tank for the run around the block and then sort the proper oil tank when I rebuild it.

I've made sure the throttle slide and oil pump arm are sync'd as per the book. Fiddly, but it's all in place and working (as bench tested) :)

(https://i.imgur.com/Tb3XsuF.jpg)

I've made new front upper engine mounts out of 3mm steel, they need a return kink to allow access to the inner exhaust flange bolt....rather than me having to remove the mounts to access the bolt every time.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: dgorms on June 29, 2020, 11:24:20 PM
This is by far one of the coolest builds I've seen! Got me re-thinking a couple of mine................................D
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on June 30, 2020, 05:38:59 PM
This is by far one of the coolest builds I've seen! Got me re-thinking a couple of mine................................D

Gee thanx....what you got then?

Small, but important update:
Today, metal bashing. Andy,my neighbour, has acetylene so we heated and spent longer than I thought trying to figure how to shape the kink I needed to clear the exhaust flange bolt on both sides. I even made a buck but figuring the next bend was laughable tbh.
Got there in the end.

(https://i.imgur.com/cnMXrvq.jpg)

Two kinky upper front mounts in etch ready for a splash of satin black.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on July 03, 2020, 01:17:35 PM
Engine mounts, not an exciting area to report on...but, these upper front mounts needed to have a kinky offset to allow access to the exhaust inner flange bolt, without having to remove the mounts everytime.....plus it looked terrible.

So, the 3mm steel was heated n bashed into shape....took a bit longer than we thought as the bends (3 per bracket) had to be thought about..heheh!

Installed and I can access both inner flange bolts easily, fiddly but easily. :)

(https://i.imgur.com/dCqjM2v.jpg)

At least now they look like they've been made purposely.


Regina 520 gold chain arrived today.



I'm assured the bodywork will be painted over the weekend and I'm hopeful of the caliper returning too.



That'll mean I'm close to it's maiden run around the block.
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on July 20, 2020, 03:33:16 PM
Something has been happening at NoRiders towers...

Bodywork back from second painting...correct 9003 white now and it's certainly white :)

Chain fitted, exhaust sorted...just need 35mm springs. I'll probs wire it for the test ride.....yeah, I sadi test ride.

Front caliper/brakes are bled.

Tank fitted but need to check the petcock seal.

I'm close to the test ride around the block ;)

A few shots outside

(https://i.imgur.com/CI6wR9x.jpg)

(https://i.imgur.com/G22mcvh.jpg)

(https://i.imgur.com/qyhhb7K.jpg)
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: Czakky on July 20, 2020, 06:19:40 PM
 :clap:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: toffee on July 21, 2020, 07:21:15 AM
looking good overall!

the kinky brackets worked well  :whoop:
Title: Re: Johnny Cash Special - Suzonda 2smoker
Post by: NoRiders on July 23, 2020, 08:51:49 AM
Czakky & toffee - thank you gents. Sometimes a bit of kinkyness is just the ticket ;)

Might get the firing up and test ride done this weekend.