A Wammo Update

Just thought I’d share what’s going on around the barn a little bit. Getting the fender, seat and battery box figured out now means that it is time for the real work to begin.

<custom Honda bobber>

A few days ago I dropped the engine out but since then most of my spare time has been spent elbows deep in the severely damaged engine of some guys atv. Today I caught a little break since I have to order more parts for the Brute Force, it gave me a chance to finish tearing this one down to a bare frame.

<bobbed honda 400 frame>

<CM400 rigid frame>

Now the previous owner of this fine mosheen was a true rat biker and whenever he felt the need to attach something else to it that could not be tied or glued on he resorted to that favorite motorcycling custom trick of using self drilling screws to tack shit to his motorcycle. So I spent a couple of hours brazing up small holes in the frame, before it was time to break out the angle grinder and safety glasses and remove all of the unwanted tabs from this frame.

Some of the tabs were saved and will be reused on this and other projects, but most of them were tossed into the scrap bin to be recycled. Now its time to soak it down with oven cleaner and get it completely clean so I can do a little more welding then clean it all up and prep for paint.

<oven cleaner motorcycle frame>

By the way, I have been documenting the crankshaft replacement of the Kawasaki Brute Force 750 and will be posting a ton of pictures in the days to come so stick around.

Peace Y’all

Custom ABS Plastic Battery Box

When I last posted the last picture was of sheet of plastic with my cardboard pattern lying on it. After tracing around it with a marker I used my bandsaw and a Dremel to cut it out to shape. Be certain when cutting plastic with any high speed rotary tool the you use either a saw blade or the router attachment. Do not under any circumstances try to use a metal cutoff wheel for plastic and of course always wear eye protection.

<custom abs plastic battery box>

This next step involves extremely high heat, possible hot metal & molten plastic. It is your responsibility to take all reasonable precautions to see that you don’t get hurt.

The first piece to get bent is the lower brace. It will get reshaped even more later but for now let’s just bend it to a nice 90 degree angle. First you clamp it into a vise sandwiched between a couple of metal angles and start heating it.

<heat forming abs plastic>

When it gets warm it will bend very easily. To get a really good square corner take a slab of wood or another piece of metal and press down on the corner and hold it for a minute as it cools.

<heat forming abs plastic>

<heat forming abs plastic>

<square corner abs plastic sheet>

After this I bent the tabs in for the sides. These tabs my not really be necessary but I like the security of having large bonding surfaces to hold parts like this together, especially in a high vibration environment like a motorcycle.

<build custom motorcycle battery box>

Bending the sides up to form the box takes a little more thought. If you have enough equipment and desire absolute perfection you should carefully clamp each corner to be folded and follow the procedures shown above. In the interest of time and since this motorcycle is going to be another deliberate neo-rat, I simply heated the plastic along the bend lines until it was bendable and then used two blocks of wood to form it to shape. Hey it works for me.

<custom chopper battery box>

<custom Honda chopper battery box>

Before moving on to the next step you will need to test the fit and make sure that your battery fits properly. At this point you can reheat the plastic and adjust things somewhat, once you glue everything together it’s not so easy

<custom chopper Shorai battery box>

When you glue it together be sure to use plenty of ABS cement. Do not use any other type of cement with ABS plastic.

<custom chopper plastic battery box>

One of the nicer things about working with ABS is that the cement is very thick and you can use it as a gap filler to seal off cracks and imperfections and then sand it down after it all dries.

<custom bobber plastic battery box>

<custom motorcycle plastic battery box>

Here is a quick shot of it in the frame with the bottom brace glued into place. At this point the battery box is pretty well done except for sanding and painting.

<custom rigid frame chopper,bobber,motorcycle abs battery box>

The next steps for Project Wammo is going to be a complete teardown to the bare frame to finish removing all the unwanted tabs & finish up the welding. Then it’ll go back together as a roller with new bearings, fork seals, brakes, tires, etc. Then it will be time to freshen up the engine & paint the sucker. Stick around & enjoy the fun.

 

 

 

 

 

 

Just a few more interesting things.

In my last post I showed you a nice old Harley service-car, now here’s the bones of one.

image

While we’re looking at basket cases check out this Mobylette.

image

image

There was actually a pretty good selection of offbeat European project bikes available.

image

image

image

And my personal favorite Harley Davidson model, the XLCR.

image

image

It is been a long day but we’ve had a really good time. Good night to all.

Gords Garage Blog The February 2014 Website Of The Month

Gords Garage Blog has one of the best subtitles I have ever read, “I am not a professional and I try things at home.” The is probably one of the most mechanically inspirational blogs I follow. If you are into metal working and motorcycles you need to go check this guy out. At the time of this writing he is just putting the finishing touches on a fantastic looking CB160 cafe racer. Gord has a well equipped home shop including machine tools and welding equipment along with a lot of talent & imagination so you are sure to find some good ideas for your next project if you look. Click here to visit Gord’s Garage.

 

 

 

Google+

The Old Biker Speaks. A Parable for the Modern Motorcycle Lover

Warning; When I wasn’t looking someone slipped a couple of naughty words into this one. No f-bombs, gratuitous sex, or boob pictures though, sorry.

 

Imagine that you are gathered with a group of your fellow motorcyclists, be you a group of yuppie cruisers, hipsters on retro style bobbers &café racers, hardcore chopperheads, or restoration junkies. Everyone is standing around, taking a breather, checking out each other’s bikes, telling interesting half-truths & just generally having a great time in the way that only a bunch of bikers can. The sun is bright; the beer is cold, and the ladies beautiful. It is truly a perfect day as long as no asshole decides to ruin it for you.

Somehow there is just one brief moment of silence and I heard it, far away in the distance the howl of an ancient four banger breathing out through a quartet of totally baffle free drag pipes. The exhaust note is raspy & uneven, and you catch the whirring sound of a loose cam chain, all obvious signs of deferred maintenance that would kill a lesser engine, but as we all know, some of these old SOHC 750’s will never die no matter how ratty they get.

By now the whole encampment has heard the sound and is looking up the winding road coming down the mountain to see what matter of machine is headed towards them. Some are commenting about how rough it sounds, others somehow seem to be watching in fear as if it may be some kind of hipster/yuppie/brand loyal purist eating dragon coming to consume them.

<old school Hipster eating Chopper>

It finally flashes into sight coming around the curve, a creature from another time, impossibly long, the rear wheel bouncing up & down in an ancient Amen Savior plunger frame. The front tire too bounces up, down, left and right as the rusty peeling girder front end rattles and shakes with each imperfection in the road surface. The bushings in the girder are shot & so are the steering head bearings. There is no way this thing should be moving so fast, especially on this twisty road, but it is.

As it approaches our group the rider lets off the throttle and downshifts, causing the engine to backfire on the overrun, blam! blam! blam! as flames pop out the ends of the exhaust pipes, that appear to have been fabricated from metal conduit 40 years ago. Small animals & nervous people immediately begin plotting escape routes, after all sensible people are afraid of folks who ride deathtraps like this.

The paint job was obviously gorgeous a long time ago, in a galaxy far, far, away but has now suffered several decades of weather beating and a million miles of hard riding. Every top surface was chalky, and crazed with cracks, looking as though hundreds of overlapping cobwebs had been deposited on the tops of the frame, tank, & rear fender.

On the sides you could still see the remains of a gold base coat topped with green & red kandy paints, sprayed through chicken wire to simulate scales. Back in the day a pretty good 70’s air brush artist had written the letters FYYFF on the sides of the tank in black and purple colors, tee shirt lettering style. Modern day neo rat riders immediately snapped pictures in hope of finding a way to re-create this patina on their next project. The engine side covers had been chromed at some point but had become sand blasted & peeling, as were the rims. Most of the spokes, bolt heads, & all four exhaust pipes where coated with rust. A fantastically ornate king and queen seat that is a work of art in its own right, despite being threadbare & worn reclined against a 3 foot high trident shaped sissy bar with 3 rusty spear points aimed at the sky.

Rattling to a complete stop and switching off the engine and the fuel tap, the grizzled old rider swung out the side stand and leaned the bike over to park it. Looking on as open mouthed & slack jawed as the rest of the crowd I couldn’t help but notice a tiny golden trickle of gasoline dribble down to the edge of the oxidized velocity stack on the number one carburetor forming just enough of a droplet to catch the sun’s rays like a tiny jewel in a rusty can, but not a big enough dribble to actually leak out onto the ground.

The rider himself, was a fascinating creature, he rode helmetless without gloves, with just a leather club vest covering his torso. Of course this caused a great murmur of disapproval amongst the safety nazis in the group. Although when astride his magnificent steed he seemed much larger than life, standing on the ground before me he was just man of just below average size. Bald on top with 2 foot of long grey hair on the sides, he sported the pointiest goatee I had ever seen and a finely waxed handlebar mustache. His bald spot was covered with a tattoo of a spider web, & a POW-MIA flag graced his right shoulder.  Despite his diminutive physical stature, he gives out the overwhelming sense of confidence that only a man on a mission that knows he’s doing the right thing can posses.

Next our mysterious stranger unstraps a wooden box from the sissy bar of his motorcycle, throws it on the ground in front of us, steps up on it, and in the most corn fed southern accent you ever heard in your life says, “Hey y’all we need to talk about some of the crazy shit going down in the motorcycle business sometimes.”

I’m sure that most of you younger folk have heard of this newfangled thing called the internet and that giant worldwide marketplace called ebay. It seems that a man can find almost anything he might need to survive, motorcycle parts, vinyl records, silver, gold, knives, heavy metal posters etc. In fact about the only necessities you can’t get there are guns and ammunition because the owners are a bunch of politically correct pussies that don’t see the necessity of such things like we do, but I digress let me get back on track here. Lately I’ve noticed an alarming tendency of people to put things up for sale at what is called a “no reserve auction.” But when the item sells for less than they expected they just don’t ship it, or if the item doesn’t get up to a certain price by the last day they cancel it. I’ve actually had both of these things happen to me lately and it left a very bad taste in my mouth. I was actually planning to bid on one original vintage European motorcycle but passed it by for a different motorcycle only to have the shop that was selling it cancel the auction in the last 5 hours. If I’d known the sum-bitches was lying about the no reserve auction I would be the proud owner of a 75 Jawa right now. Instead I got a pocket full of pissed off & another shop on my list of places not to buy anything from.

Now all of you know more about the workings of the internet than I do, but apparently not everyone understands how an auction works. First off if you have a certain dollar amount that you have to have for something, you should never ever use a low starting bid, no reserve auction to sell it, never. Either you pay the fee for a reserve auction or set your starting bid at your bottom dollar price & let it go up from there. If you do screw up, use a no reserve auction and sell something for far less than you thought, man up, take the beating, & learn from your mistake. I’ve done it a time or two before I learn’t better. Also all dealers selling bikes should disclose all fees & taxes up front in the auction listing. The same goes for dealers craigslist ads too.

Now let’s speak about selling motorcycles without titles. Decent honest people know that in most places you can’t register a bike without a title. Now if you live in a place where you can register an old bike without a title I am genuinely happy for you, but in all honesty the only way you can get any money for it will be to sell it locally. Even if I lived in one of these states, for any bike that was less than 25 years old and/or worth more than 3 or 4 thousand bucks you should still insist on enough paperwork to ensure that the current owner is the legal owner.

In the rest of the states stop trying to get full price for them, without the proper legal paperwork they are either just a pile of parts, or if dilapidated or unwanted enough just plain old scrap metal, and should be priced accordingly. People constantly say, “You can get a title.” Well that is an expensive maybe at best. In my home state of South Carolina there is a process you can go through for vehicles over 25 years old. You fill out forms, send in pictures & money including sales tax for the purchase price, then you take it to the DMV office where they inspect it to be sure the serial number matches what is on your paperwork. They then run it through the database and if there is no current title for it in existence & it has not been reported stolen, they will issue you a title. If the vehicle is not running at the time you will be given an off road use only title no matter what kind of bike it is. So once you get it restored you have to trailer it back to the DMV for a second inspection, and pay a second title fee to get the off road brand removed. When you count the time off from work this can run several hundred dollars. So to me, even a good running fair looking bike without a title is only worth ¼ to ½ as much as the same bike with a title. It’s gotta be cheap enough that I can take the chance. A rusty, locked up, old rice grinder that has no visible good parts on it or is of no collectible value should be weighed and sold by the pound at your local scrap yard. A number of you don’t even have the options that I have here in S.C. As for the title service companies there are many reputable ones out there, but even so you are still looking at hundreds of dollars in some cases to get paperwork. The last quote I got from one was ten or twelve years ago and it was nearly $300 then, and I am sure the price has not gone down any. Some states may have laws against using out of state title services so be careful and find out if yours is one of them.

The most dangerous thing I have ever seen in an ad is a seller whom actually said that he would not provide a bill of sale for a motorcycle he had with no title. His price was actually reasonable enough, that I might have bought it to part out, but there is no way I am ever going to bring home any motorcycle frame of any kind without either a title or a bill of sale to prove that it was purchased legally. The same goes for a Harley engine because some states will issue a title on the engine. If you won’t give me any paperwork to prove I bought it, well FYYFF I’m not going to buy it. Big Bubba down at the grey bar hotel ain’t near as fun to snuggle with as my old lady. Remember kiddos if you can’t at least get a bill of sale or receipt to show the man if he asks for it, walk away.

And finally, I guess we (myself included) should quit picking on the hipsters so much. Yes I know with their funky brakeless one speed bicycles & queer eye for the straight lumberjack style of clothing, they do make easy targets. But come on; give them some credit for their role in the current café racer, old school skinny tire chopper & bobber revival. They have dusted off a bunch of cool stuff from the past & are helping to insure its future. Plus without them, Pabst Blue Ribbon beer might have disappeared for good.

<bikers and hipsters too>

Then the old timer stepped down off of his soap box and the crowd cheered, although I don’t know if it’s because they enjoyed the lesson or just because the old man finally shut up. After he strapped the box back to his sissy bar, a rosy cheeked young man, with a long beard, in a flannel shirt handed him a cold PBR that he sipped on while chatting with the curious bikers who wanted to take a look at his ancient steed. When he had polished off the brew he crushed the can between his hand and his forehead and tossed it in the general direction of the nearest trash can, straddled his old chopper, twisted the grip three times and with a mighty heave on the kick starter fired it up. Once again the crowd turned to see and just as he rolled out of the exit, they all raised a cold one in a salute as the prophet sped away to the next gathering to preach his message of honesty, fair dealing, staying out of jail & caring for your fellow man.

 

Happy Trails Y’all

 

Happy New Year & A Quick Update

Just a couple of quick updates, I am still working on Project wAMMO but have been slowed down a little bit by life getting in the way, but tonight my favorite big brown van dropped off a nice little box from Dime City Cycles.

<Bates headlight & limp dick tail light>

Bates headlight & Sparto taillight

Hopefully I can get back to the shop this weekend.

Also over the next couple of weeks I’ll be adding a store page with some new & used parts & supplies for motorcycles. There may be some glitches at first so bear with me and give me a chance to get things sorted.

UPDATE; 1/1/17 store page removed

Peace Y’all

Introducing Project wAMMO!

Perhaps I should just write all of this down and wait til I finish to start posting. Nothing like laying everything bare for the public eye to put the pressure on a man, but that’s okay it’s under control and everything’s gonna be alright. Before I started the teardown I just had to hear it run one more time, click here to have a listen for yourself. At the end it started to act like a runaway but settled back down a second or so after I let off the throttle, definitely a sign that it is running a bit lean. All the necessary bits to fix that are already en-route to my secret workshop as we speak.

CM400 chopper

Let’s get started

The seat just hit the scrap pile, notice that in a pinch you can substitute bandage tape & scotch tape for electrical tape, zip ties, & proper brackets.

<1981 CM400E>

I’m digging the old rhinestones glued to the rear fender aren’t you?

Here was the ingenious repair repair to the broken carb boot. McGyver would be proud. I must confess that if I were broke and/or stuck in the middle of nowhere I would do something like this to get home. New carb insulators inbound as I type this.

Honda CM400E Carb insulator

Hey it runs just like this.

And there were a large number of auxiliary fuses embedded all through the tape, of course all of them except for one had been bypassed….

<murdercycle kustomizing>

<kustom ratrod motorsickle>

<hellbilly special murdersickle>

This one has got me feeling more like a motor archeologist than a mechanic. Speaking of which if any of my readers can identify the object in the next two pictures would you please be so kind as to let me know. Thank you in advance for for being such fantastic and intelligent people.

<strange doohickey>

<if u no tel me>

if you know what it is please tell me

I was able to get the fender off without needing a tetanus shot.

<a real ratbike fender>

a real rat bike fender

Looking a little bit cleaner…

<backyard built rat chopper>

The original shock mounts were used for the fender struts and the side mount license plate holder.

<side mount plate holder>

Fortunately the frame modifications all appear to be well done by someone that had a clue about welding. Can’t say the same about the decades of accumulated stuff that got put on it afterwards.

<dangerous repair>

At least this is safer than no cotter pin at all.

I did a little more but will show you later as the UPS man just dropped off my new riding suit & I want to go try it on!

Peace Y’all

The Organic Rat! Honda CM400 Junkyard Dog!

This one has a kind of an interesting story to it. I had stopped at lunchtime a couple of weeks ago to fill the Suburban Assault Scrambler up up with ethanol free premium at my favorite gas station, when a local folk artist named Frank Cooper rolled up next to me in his mural covered Roadmaster. He comes over & tells me that he has an old Honda 400 in a storage unit that he might like to sell.

art car

super cool acrylic painted sled

I really didn’t think anything more of it for a week or two and then this morning  I gave him a call and met him at the rented storage unit where he stored this bike & apparently the rest of his worldly possessions also. After moving piles of junk (aka art supplies) this little bobber came into view. My immediate reaction was oh no I don’t want anything to do with that one. but after we got it outside he hooked up a battery & poured some gas in the tank and within a minute or so it fired right up and the engine sounded pretty good.

<ratty old cm400 motorcycle>

After negotiating a price I loaded it into my van & let it ride along to lunch with my beautiful wife & I. She didn’t even roll her eyes at me for buying it, I wish every man were as lucky as me. Here it is tucked into the back of my old Astro van. A normal sized motorcycle will not fit without removing the mirrors & maybe folding down the handlebars, but this one is so low it fits with plenty of headroom to spare.

<rat bobber chevy van>

loaded up and ready to haul

After getting it home I snapped a few pics of it to share with you. Lets start with the details first. I have no idea where this hardtail came from or what that silver thing is that is hose clamped to the frame.

<honda twinhard tail>

It kind of sketchy and dangerous looking….

The bottle opener is a nice touch.

<crazy dangerous motorcycle>

I might trade the bottle opener for one that says Guinness

I have no doubt this was the license plate he rode around with. 😉

<folk art license plate>

The seat is literally a junkyard dog.

<junkyard dog motorcycle seat>

woof woof!

How ’bout a top view?

<bobbed Honda CM400>

I hope any passengers don’t mind the comfy looking rear fender.

Come on you have to admit it has a mean looking stance!

<bobbed honda chopper 400>

“The Gunn”

The design and fabrication look as dangerous as a gunfight but all I plan to do to this one is to get it as functional & dependable as possible without changing anything about the way it looks or worrying about safety beyond making sure that it is not too likely to break in half if it hits a bump in the road. All motorcycles are dangerous, but some are more dangerous than others.

<wicked evil dangerous chopper motorcycle>

“The Bullet”

I am more than willing to entertain reasonable offers on this machine, as long as you understand that it is being sold as folk art with no warranty that you would ever be able to ride it at all and that it was fabricated by an unknown amateur of questionable talent & that I am not responsible for anything that happens to you as a result of attempting to ride this motorcycle. Of course the longer I keep it & the more I do to it, the better your offers must be.

Peace Y’all

Motopsyco.

QUICK UPDATE! A friend of mine saw this bike on Facebook & has purchased it from me. It is still parked in my shop because I have been commissioned to rebuild it to his specifications. Though I hate to see a real vintage rat disappear it will be a gritty down & dirty bobber, just right for him to tool around on down here in the dirty south! STAY TUNED!

Various Motorcycle Sounds

I have made a few video clips of various motorcycles, and how they sound that are posted over on the Motopsyco.com Facebook page just in case you are interested. While there are not many now I will be adding more as time goes by. The first 3 vids I link to will be 3 different exhaust systems on 250 Ninjas.

The first video up is an older one of an EX250 with a mean sounding Yoshimura System on it. Click here to go directly to the video!

In the second video the bike has a pair of Emgo Dunstall Replica mufflers on it. This was shot as the owner was leaving work one day when the temperature was about 40 degrees Fahrenheit. Click here to go directly to the video!

The third video features one of the most earsplitting loud motorcycles I have ever heard. If I had not heard it with my own ears I would never have believed that 250cc could make that much noise. Thankfully it is done & I never have to hear it run again! Click here to go check it out. It does have a severe case of “megaphonitis” at low speed but once it gets “on the pipe” it pulls alright.

And just in case you were wondering how that Mac System on the Suburban Assault Scrambler sounded you can listen to it by clicking here.

There is also a video with the sound of a totally stock Honda CRF150 posted, just click here.

I’ll continue to add to this library of short clips as I get the chance so check back often, sign up for notifications on the right side of the page, like the Facebook page.

Revenge of a Junkyard Dog! (Suburban Assault Scrambler Finished!)

It seems hard to believe that it has already been six months since I dragged home a rusty non running 1980 Honda CB650 Custom that I bought sight unseen at a local junk auction for the princely sum of 150 bucks.  If you didn’t see it back then click on this link to see the before pictures. Of course along the way there were various challenges & fun but I had a blast getting this one going and as unlikely a candidate as it was for a scrambler conversion it really did turn out that the whole was greater than the sum of its parts!

Normally I am a man of way too many words so how about if this time I just show you some pictures interspersed with a few tidbits of technical information?

<next to the old yard truck>

1980 Honda CB650 with 1974 Honda CB750 gas tank & a set of 1979 CB650 standard wheels.

<1980 Honda CB650 Scrambler>

1980 Honda CB650 Custom Scrambler

The handlebars are courtesy of a 1970 Honda CL450 I just happen to have lying around. The tires are Shinko 705 adventure touring tires.

<Vintage Honda with vintage plasma cutter>

I wish I had a plasma cutter like this at home!

The green paint is a mixture of gloss green & flat black tractor enamel, & the exhaust is from Mac.

<custom Honda vintage Lincoln welder>

they don’t make machines like this vintage Lincoln welder anymore.

<custom scrambler front forks>

Don’t let the nasty looking lowers fool you, the forks have new seals, Progressive Suspension springs & fresh 10w fork oil. I decided to keep the 650 Custom fork legs for the scrambler conversion since they are longer than the 650 standard forks. When I raised the rear by switching to the 17 inch wheel & taller tire it helped to compensate for the extra rake of the custom and gave more ground clearance.

<kustom 1980 Honda CB650C>

<old Honda with giant press brake>

At this time I would like to give thanks to the wonderful folks who provide me with my day job that makes all of this possible.

Safe Harbor Access Systems for allowing me use of the old warehouse and some production areas for this photo shoot. Click here to see the stuff I spend all day drawing blueprints for! And if you see anything you need let them know where you got the information.

<a green scrambler>

Here’s some more of that headlight bracket drillium that I showed you in my last post.

<1980 CB650C headlight>

speed holes make it faster right?

I couldn’t stand the 85 m.p.h. speedometer that came on this bike, plus it was making a horrible squeaking sound, so on went the 140 m.p.h. speedo & tach from a 1976 CB750F, with green faces of course.

<cb650 engine>

Do you have any idea how hard it was for me not to attack this with the polisher?

K&N air filters hang off the back of the original carburetors, to learn what I did to them just click here. Other than a re-jetting

& a Mac pipe the engine is bone stock in all of it’s 11,000 original mile glory.

<scrambler baby!>

Slug & liquids? Sounds like the results of cheap beer & too many hot wings…

<80 Honda 650 chain guard>

I put a lot of speed holes in this one ’cause I wanted it to be really fast 🙂

Holding up the rear is a set of Progressive Suspension 412 shocks with the heavy duty springs. I have been very pleased with this suspension, it gives a nice cushy ride over some pretty rough bumps but is still firm enough to rock out on a set of curves. Well at least as much as you can with a bike like this.

<honda cb650 with flatbed>

Sometimes you just find the perfect graffiti to really set a picture off.

<Suburban Assaullt Scrambler CB650>

Beware of the Dog

Peace Y’all

‘Psyco