HONDA SUPER CAFE

HONDA S.S. TURNS INTO A SUPER CAFE

This is a 1978 SUPER SPORT that has been completly and utterly changed into a unique and cool Super Cafe that will soon be on the tarmac, and tearing up the road like Yellow Phantom.

Follow the complete build up as I go along.

This will be kinda long and drawn out, but this has taken me a year to get right, and now, I am getting near to completion, I thought that each day I would add some photo's and information.

Now, you people who do not like stock Super Sports, but love Cafe's, will get an instant pan handle when this is completed and it will be one of the best looking rides I have ever completed.

This ride started off as a Stock 1978F and it needed some serious attention in the style department,  I have seen better dressed salads than this bike.

I had an enquiry from a great bloke to commision me to build him a unique Cafe, something that would really turn a head and bounce a few chins too.

So, about a year ago I aquired this 1978 Super Sport, and whilst it had about as much charm as fart flavoured toothpaste, it had more potencial than an unemployed Bodybuilder looking to become a lumberjack.

Stick with me on this and you will see the complete build, so far I am about 80% done but soon she will be taking the curves like a go kart with no brakes.

I started taking the bike apart bit by bit and discovered more horrible sights than an inspector at a disfigured surgeons Court case.

The battery box area had more rust and crust on it than a parked  Delorian.

So, this had to be a bare to the bones build or nothing at all.

The Motor had low miles , but was Blacker than the inside of a Scotsmans wallet.

I polished up the stator cover to see what this would look like and polished looks far better than any other Motor in my department anyway.

The 78's are a stronger mill and this will be a tough nut to crack when she is on the road, I am going to be polishing by hand, as much as possible.

Every Cafe I build is built as if it were my own, and this is by far no exception.

With the bike torn aprt and in more pieces than a house built of Lego by Mount Fuji, I started the process of moulding this Machine into a Classic cafe, with more lines than a detention teacher.

With everything stripped to the bare bones, the frame was then at my mercy.

I removed any lugs or straps that I didnt like the lines of, I also smoothed out some of the factory welds, as they were rougher than the local shop keepers wifes legs.

Once that was sorted, I took the frame to Orange County Sand Blasters and took all the crap dull and flat black paint off, that 20 years ago was as shiney as polished boots.

Daytona Yellow was the choice of color and it was hit with a few coats of powder coating that was acheived through A&R powder Coaters up the road from me, Thank's Jack, ya done a cracking job.

I also stripped the shock absorbers and bead blasted the springs and had them powder coated Daytona Yellow too, the rest of the shocks I CHROMED.

Getting them bloody springs off was like pulling teeth, they were a bugger and i think i have at least 2 screw drivers embedded in the Garage ceiling.

Not from recoiling, but from slipping and almost cutting my knackers off.!!

Anyway, They look great Yellow, and whilst I was there I powder coated the engine brackets too.

This bike will really look awesome and am looking forward to finishing this ride.

The Yellow really does stand out and with a polished Motor, this will prove to be a great combination.

Now, whilct all the frame is sorted, I turn my hand to the inline four.

230 pounds of thumping aluminum and steel.

I removed all the Black paint using aircraft stripping Gel, that burns like a fire in a forrest of paper.

But, remember guys, when ya use this stuff and ya go and take a leak, wash ya hands first, I almost burnt my bell end off.

You could of heard me scream from Jupiter.

I spent alot of time getting that Black goop off the Motor, and even after 3 days of scraping and cleaning, it still looked like a turd.

There are many ways to polish a Motor and I am sure you prefer your way, I have seen people use steel wool to cocoa cola.

So long as you get the same result, it really does not matter.

but, I do this all myself at home, as it saves on paying some bugger else to do it.

Although the buffing wheel I use sometimes is in the garage on the bench and it vibrates so much, that nextdoors books jump off her shelves.

So I try to stick to using my own human power when I can.

It aint easy by a long shot and you will have more success cleaning the local crapper with a tooth brush and a bottle of Mr. clean than the first time you try on a SOHC motor.

Finally, after hours of cleaning and getting ready to buff, this engine starts to look like a pice of artwork.

This really does look nice and I still have to polish the valve cover and cases etc before the motor goes back ion the frame.

But all that hard work paid off and it looks completly different.

The Paint was all removed and I buffed this, then sanded and then buffed again, and I am finally happy to see this motor showing signs of shine.

I do not think I shall attemped to strip the Black off of a F2 Motor again, I had to rub harder than an impatient Alladin.

Check the pics and you can see how different it is, the most obvious is....its not Black.

When it comes to polishing, many people email me and ask how I do it, well it is just plain and simple really, hard work.

I don't want to pay chromers etc, so I bead blast the parts and then using sandpaper, i take all the imperfections out, looking for open pours etc and then grade up to about 1000 grit.

Then I buff the stuff on my buffing wheel and finally use my secret sauce to hand polish.

The valve cover was a total S.O.B. as I had to remove the paint with aircraft stripper and then hasnd sand etc, but it now looks so much cleaner and I am at last happy with the outlook.

Now, with the Motor all sorted, it was time to start putting the frame back together, I had put the frame on my bench and then began the assembly, and thats something thats always good when stuff is all painted and clean, but still have crappy problems on the way.

I attached rear swing arm etc and also I have this on a small pedastal to keep the frame in the air, then I used old Plumbers water pipe sponge to protect the bikes powder coating, as I do not want the 230 pound motor scratching the crap out of the frame.

A lot better than duct tape and the like too, so on that went, I then put the powder coated springs on the rechromed shocks and they look really cool.

I then grabbed the powder coated lower tree and bunged some lithium grease on the race and used new 1/4 ball bearings that i bought from a bolt shop.

Remember, 19 bottom and 18 top.

Now, I have not used a 78 triple tree, I have used a 75 CB750K as I want a different look, K tree's and F ones do differ believe me, so, once I had this figured out, I polished the upper tree, I slung the 18 ball bearings in the top and put her together like a kid with a new model kit.

Now this is starting to become the makings of a bike.

The foot peg holders on an F series are aluminum, but they had more oxidisation on them than a steel urinal in a local park full of beer bums.

So, off the the buffing wheel and shines this right up.

Staying with the forks etc, I had to strip some old K5 forks as they were totally buggered up from years of sitting in bad weather.

Most of the fork tubes on k model will have rust at the top of them, as the fork ears cover this area and weather will eventually work its way past the rubber seals and corrode the tube.

You will not notice it as the fork ears cover this area, Honda kinda skimmped on the chrome as they knew customers would not see it and save money on plating.

The fork legs were in much the same condition and i knw all of you can relate to this.

So I took all the clear coat of with a scotch pad and then hand sanded the lowers, until i was happy that all the dings and stuff were taken out.

The fork upper actually needed to be linish sanded and stripped of chrome, then copper coated and then re chromed, being careful not to over chrome.

As if the chrome is too thick (More than 3 thou) this forks will no longer fit in the fork lowers as the tube is to wide.

Well, this is alot of work and i am sure you have done all this before too.

Which is good, as you will know how long this takes.

But I have now polished the lowers, the fork tubes are at the chromers and I am about to pick them up.

So, the next thing is the springs.

I chose a set of progressive for tube springs, and these are a great item as the stock springs has soften and were in need of help.

So this will stiffen the thing up faster than Viagera on a old codger,.

I also bought new fork seals and had this all ready for assembly.

I now have the fork tubes back.

These have all been stripped and re chromed and now its the time to start to sling all these pieces back together.

I used 78F fork tubes as I am not using stock fork ears, I am using Race ones, and that will make the front of the bike look fast.

The forks were great and easily put together.

I liked the Proggresive springs and they seem to be alot stiffer than the stock ones, aslo to change the dampning, you can add washers etc as the preload will change,.

Finally I can install these forks and see what they look like.

I slapped a bit of duck shit on the forks, to make them slide in the tree's easier.

I then plopped them puppies in and also attached the racey fork ears too.

I added a old spoked rim for the time being, just to get the look, and later I shall replace these with a cool set of Excel rims from Japan.

I also fitted a set of my chrome 7/8 Clubman handle bars and now  the front end is looking sharp.

OK, the next bit is a long process and something kinda unique too, but this really will look cool once all is sorted out, as there are a heap of alterations to make on a K series gas tank to fit along this long CB750F frame.

The tank was cut in more places than a trainee surgeons first operation.

this tank will need to be then glassed, then sealed and then finally painted, but, you have to also move all sorts of things.

ie the petcock to mu dismay failed the carbs, so that had to be moved.

Then the factory indents had to be added, as the carbs would not open fully as the tops caught the underside of the tank.

This tank nearly went over next doors wall on more than one occasion .

but I stuck it out and my mate tom Jackson helped me alot with this.

I don't think i want to go this route with a gas tank anymore.

The tough part on this build, is to make the gas tank look like it was originally made to fit from the factory.

Then I also have the problem of making a Racing seat fit too.

All these parts have not been made for a CB750F and it is a challenege to say the least to get this right.

I had to then fit a snotty back wheel to be able to have the bike frame rolling, once that was achieved, i got my neighbour to help me unload the bike from the bench and bung it on the floor, now it really is starting to look like a Cafe Racer.

I then fitted the headlight and a set of cool turn signals, this is about the right length of turn signal i like, in California you have to have them if they were fitted factory, I nearly had a few tickets over this issue, so i try and make them as small as I can.

Many people do not notice them on my rides.

Next step for me was to mock the Gas tank up, this took some doing and had more modifications that the Discovery shuttle.

Although this will have many problems getting lift off, as its pretty darn heavy now as its a tank and a quarter , not stock.

OK, with the motor weighing in at 230 pounds, I dont want to be carrying the damn thing for too long, else my nuts will be hanging out of my arse.

So, I always stick the motor on a milk crate, this is the best height for taking the motor out and plonking back in.

Also you don't have to bend down so far to lift it up.

this is a toughy this time as I dont want to hurt the frame, so had a buddy help me, and with a grunt, and heave, the motor was in.

I then used a floor jack to position the motor in the frames mounting holes and Bobs ya uncle.  She was in, tighter than a frsh sock out of the drier.

With the motor in, I started to hook up all the bolts amd mounting hardware, this is the cool part slinging all the cleaned up and polished parts back on.

I grinded the holes in the frame incase there was any powder coating on it, as this will fail a good ground, but it really is taking shape now.

The Flying banana is getting there.

With the Motor now in place and Bolts tightened up etc, it was time to bring out and add the big guns, yep, you heard right, I had a Yoshimura exhaust system that i have had for a long time, and hanging on the wall makes no speed, so I thought this fitting, that a yoshi 4 into 1 would really trick this out.

I plopped her on and there, this thing is dressed to thrill.

This Cafe is sure gonna be a head turner.

The home page of this was of a cafe built in japan a few years ago and this is going to be simular, but not a replica.

Still have to sort out how to make a seat, as well as a rear fender, and a million other things too.

But so far she is really making headway.

I have a set of Tagasaki aluminum rims and they will be laced to new spokes and have new  TT100's on them, this will hold the road as good as any Cafe out there.

TT100's have been around for years, I used to buy them back in the late 70's when I lived in England.

The rear hub, sprocket carrier was as grungy as an MTV video, so, I cleaned it off with thinner, then sanded with the green scotch pad and then polish cream applied by hand and buffed with a cloth, this came out pretty good and took about an hour.

This will look pretty good against the hub itself and with the new aluminum shouldered excell rims etc, I am gonna be happy with this.

All takes time and I know loads of you build your bikes in your garage like me, so thats why i add as many photo's as I can, so you lot can visually have a gawp at what it starts off like and how they end up.

Now I guess it is time for the rims to be put together and then the new TT100 fitted and then, we can bung them on the Cafe and have a look what we have.

Always a cool time doing this.

Before I attached these I had to do a few other things.

Like I cleaned up the front disc rotor and painted the center.

In most cases, I usually remove the mainstand.

But to remove the rear wheel quickly, I took the yohimura muffler of and attached the mainstand to get her off the ground.

I needed to order a new rear sprocket for this Café, so I bought a 48 tooth model from parts unlimited.

The sprocket was then attached to the hub carrier and attached to the rear wheel.

Once I had the bike up in the air, I removed the old rusty spare wheel and made sure I put the brackets for the caliper on and the axle in the rim.

Gently I fitted the rear wheel, and she looked a million bucks.

I then jacked the bike up abit more, to get the front wheel off the ground, then I stuck a bottle jack under the oil pan and then I was able to drop the old rim out of the front forks.

This can be a royal pain in the poo hole sometimes, but it came out quicker than a rat in a drainpipe.

Previously I had a rotor all painted and ready to fit to the rim, with new bolts etc.

The rim was easy to fit, and was lucky not to have a problem with the new brake pads.

I had fitted a new rubber O-ring in the front caliper and that made moving the pads to allow the rotor to fit easy.

All my brakes have new o-rings and sometimes new pistons.

I always use new bleed nipples and hoses too.

So, with the front wheel in and the bike let down, lets have a look at how these cool rims are on the Cafe.

The wire harness was in pretty good condition, so I cleaned it all up with bumper cleaner and it looks as good as new.

Most wire harnesses are torn up, or burnt like toast in a cheap toaster.

So, I wired the super café up and then Started connecting everything else.

I don’t mind the rebuilds if its all clean.

But I still had a long way to go.

The rear master cylinder had to be totally rebuild, and genuine HONDA parts are expensive, but work great.

The rear caliper was totally torn apart, bead blasted and then cleaned out.

New seal fitted and the piston cleaned up.

New bleeder nipples and hoses were all bought and I fitted.

New cap and diaphram on the master cylinder was also installed, and then I bled the whole system with synthetic fluid.

I was going to use the stock carbs, but noticed how bad they were and they needed way toomuch work to get into a workable condition, so I used a set of 1976 carbs off a K model.

They too needed to be rebuilt, but were rebuildable, and as you can see in the pictures, they really do look good now.

I used more carb cleaner than Drag race Mechanic.

But all the hard work paid off and these are clean and crisp and will be very responsive.

I am still a long way off completion, but now this puppy runs and sounds awesome with the yoshimura exjhaust.

There are many things I have done on this ride, but would take way too long to tell you on here.

When I complete a Café now, I supply a photographic album of what I have done to it, then the owner has some idea of what is new or replaced on his or her ride.

Have a look at some of the things I have done in the thumbnails, and when you click on them you will notice the difference in the before and after shots.

You will see the front axle was in dire need of cleaning up, and I’d say 90% of people leave the axle alone, but, I could not have that, this will be a stunning bike and want everything to look cool.

I buffed the axle up and it looks great as you can see.

As well as the speedometer drive unit, as I buffed that too.

Also you will notice that I took the rear caliper and the bracket off and then I powder coated the bracket and I bead blasted the master cylinder.

The rear brake is now completed and I bled it today and works like a charm.

I also machined the rear rotor, so she stops safer.

The rear master cylinder hose is new, but, the clamps look terrible, so I am going to fit some stainless clamps some time today and shall add the picture later on.

This build up is updated fairly often, so check back.

Well, here are a few more updated photo's.

this build has at times been as demanding as a seperated angry wife after maintenance.

it has fought me tooth and nail at every step for some reason.

I have come across more problems here than a crossword book with bad printing.

But, she is taking shape now and soon to be completed.

if you look at the photo's you will have noticed that I have actually made changes to the seat unit, the rear cowl is molded and now painted Daytona yellow, I have also added some new LED 1939 Teardrop light assembly, so it has that old school look, but with a new age brightness that would dazzle like a braclet of Liberace.

I still have to connect the rear tirn signals and the tail light assembly.

Then I am painting the side covers daytona yellow with a cool 750 design with a black pin line.

Hopefully paint the headlight bucket yellow and then remove the rear caliper and powdercoat it Yellow, as the Customer has requested it.

But keep checking the updates as this CB-750 S.S. Special Cafe reaches its final guise.

Soon this will leave my stable and I am sure the new owner will be as happy as a fat man at Krispy Kreme Convention. 

BONE STOCK 1978-F SUPER SPORT-
 
Rear end is as appealing as Grandma's varacous Veins.
 
Tearing it down to its underpants.
 
WELCOME TO SNOTTSVILLE!!!
 
Blacker than the inside of a cows arse.
 
Everything was spread wider than a hooker practising gymnastics.
 
Frame ready for stripping to the bones.
 
Bolder than a Banana on steroids.
 
Smoother neck than a bald giraffe.
 
Motor now gets a cleaning of its life.
 
Took 3 days of hard graft removing that Black Factory paint.
 
Still looking as sad as a Jewish money lender.
 
Now the good bit, buffing it all up.
 
Cleaner than the nieghbours cats plums.
 
No More Black goop.
 
Sharper than a tack.
 
Getting frame together.
 
Springs put back together quicker than Michael Jackson with two 6 year olds.
 
Front fork leg was as Crusty as an uneaten steak and kidney pie.
 
More rust on this fork tube than the bottom of a lamp post in a dogs Kennels.
 
Get mums sink cleaning kit out.
 
Now, this is looking good.
 
More new parts than the Bionic Man.
 
Forks are now in place.
 
K series gas tank, cut, stretched to make this look longer than my write ups.
 
Bang, scrape, grind, weld, swear, weld, swear,grind and sob.
 
Now sat on the floor and ready to transform.
 
Headlight and turn signals sorted.
 
Here she is, all ready to have the Motor installed.
 
Fits like OJ'S GLOVE.
 
Tank on, to see how she looks.
 
3/4 shot shows how Racey this ride is looking.
 
Now to work how to make a seat.
 
Rear hub was crusty a 2 day old bread.
 
Polished by hand with scotch pad and polishing cream.
 
Rims and tires ready to roll onto the Cafe.
 
SWEEEET!!!!!!!!!!!!!!
 
Front speedometer hub painted.
 
YOWZA!!!!!!!!!!!!!!!!!!!!!!!! SWEET RIMS.
 
I used some earlier carbs, but they still needed rebuilding.
 
Now fully rebuilt and looking great.
 
Speedometer drive unit, looking dull.
 
Polished to hell and back.
 
Axle needed some TLC.
 
Polished axle ready to fit.
 
Rear caliper Bracket.
 
Black Powder coated.
 
Master Cylinder rebuilt.
 
Rear seat and fender combined and sporting a cool teardrop light.
 
Rear light is a LED system.
 
3/4 shot of SUPER CAFE.
 
Almost there, just a few more changes to complete this build.
 
Custom made Ignition Switch locator.
 
My own design on side covers.
 
Now all completed and looking Ready for LIFT off!!!
 
Yoshimura Exhausts sounds awesome.
 
L.E.D Tear drop Light is from a 1939 Ford. Real Hot Rod stuff.