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Thread: Cx-500 From scrapyard

  1. #11
    Senior Member big1000's Avatar
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    Quote Originally Posted by eetu höyden View Post
    hello,

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    Eetu höyden
    soooo shiny omg
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    Did you polish it, how is it that shiny!!?
    Last edited by big1000; 10-22-2016 at 10:05 AM.

  2. #12
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    big 1000, Yes i finished the surface with 000 steel wool.

    The heads are now done, ( Actually the engine is almost done by now ) I will update in rapid succession.


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    The heads were not that complicated, i sent the head to be re machined, and lapped the old valves back in. I was how ever temped to buy / make new valves, but decided that the old ones were in good enough condition to re install. They seem to have some heavy pitting never the less.

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    Baked the new paint job on, My Wife loved me for it. She told that i will need to go and buy a new oven. I got to admit smoke was pretty thick. But what matters is the end result and i could not be happier with this kind of paint adhesion. Had to break the old guide pins, quickly machined a set of new ones for the heads.

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    Starter Motor was done, it was filled with some random universal lubricant...
    Sodablasted everything washed, degreased and re soldered missing pieces, Now i need to just go and find me a brass nuts for electric connector.
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    And While i was at it, I made a new set of motor screws, bought this 5mm threaded A2 rod, And machined heads of from few allen key bolts. Soldered everything back with silver solder. Works like a charm.

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    Copper paste might be a little overkill for this, but hey at least i won't be fighting with stuck bolts again.

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    Last and the first pictures are taken with cellphone camera i accidentally dropped my good camera and now its toast. I will get a new one asap. Sorry for the inconvenience.

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  3. #13
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    Engine breakdown was smooth few tight nuts and one Major setback, In the next update.

    Beginning,
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    Engine sides were easily dislocated and Degreased, soda blasted and painted + baked. I will send you guys new pictures once i have the new camera shitty pictures are not fun to watch.

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    The engine oil was pretty saturated with carbon, Degreasing agent took care of most. and soda blasting dealt with the rest of the oil residue.

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    Ready for my little blasting cabinet. I wish i had bought a bigger one.

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    Piston rods were rusted. i don't even know what to say.

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    Sodablasted these too and the end result is a clean piston and a rod.

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    I will update next with the sad story of my camshaft. This update will most probably take 1-2 days. Don't worry its worth it.
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  5. #14
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    This is what happens when you do things without enough sleep.

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    I felt like Chef Ramsey himself Was shouting at me.Name:  Näyttökuva 2016-10-22 kello 10.51.49.png
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    I even went the trouble to machine the bolt socket properly and in to proper size in order to fit perfectly for removal of this infamous 27mm devil.
    I was pulling it out with sleepy eyes socket slipped or it wasn't perfectly seated in the first place and the disaster was ready.

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    Stormed out from the shop, went to eat something and came back with a plan.

    I decided That i would drill out the old remnants of the cast iron core, Insert new core made from Fe-52 Mainly thanks to the generic properties of Fe-52 It acts quite similar to cast iron but it still needs to act as a connection point to the water impeller "axle" and the cast iron camshaft. The heat shrinkage and the Quench properties were something i wanted to use.

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    Sleeve was now measured to be in 0.05 of the wanted dimension Next course of action was to Get it all the way to shrink fitting dimensions, they were not easily achieved, took me 1 hour to make the 0.02 fitting difference to the internal "slug" and The impeller Shaft Since i did not really have the option of changing the impeller shaft dimensions i had to tweak with the axle

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    The piece was polished and Wife was lured to the shop with promises of back massage. And new oven after the ordeal was finally done. Oven might need to wait a bit longer than expected..

    She provided the gentle heat and guidance, i was the one to do the hard labour of pushing it in. ( you little perverts )

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    Piece was then re machined to make new connecting axle sleeker, The new dimension was not more than a 8,5 mm, and thats determined by the locking pin in the camshaft. i did not want to drill the locking pin or i did want to re drill the locking pin hole ( just to make sure i don't fuck anything else while I'm on it )

    Next phase is pretty self explanatory, make exact hole to the camshaft you have 1 try. If you Fail the hole drilling thrash that cam, Thanks to the spent time in this procedure i did not fail.

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  6. #15
    Senior Member fogelsvillejoe's Avatar
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    Very nice, detailed work. Thank you for the photos. Can't wait for the finished product, but do get some sleep.
    cx650c/cx500/gl500/gl650
    gearshift spring #4 on microfiche:http://www.ebay.com/itm/141622820137...84.m1555.l2649

  7. #16
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    The piece was finally installed co centric accuracy of the installation is 0.03 and thats the best i was able to achieve. And still i see that as a remarkable achievement with home shop tools. It will serve better than well with that accuracy.

    Cam lobes were shit to be honest. I had to to do something about it. I opted the old machinist way Excruciating amount of work but it had to be done.

    Cam lobes were soldered with high grade silver. In the mosh's scale i know that this silver reaches up to 3,8-4,2 When cast iron rolls in the ballpark of 4-5. This shaft is definitely in the top part of its scale, thanks to huge amounts of carbon in it, thats whats making this piece is so brittle. Anyways Cam was placed in oven 300 celsius for 3 hours, Taken from there and placed to lathe chucks for convenience. Heat treatment was to remove all old oil residue and most importantly to stop piece from cracking when applying spot heat with the gas torch to reach silver soldering temperature of 700 celsius. ( Also cam was soda blasted before operation )

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    Then i used un hardened iron file to take of exes silver. Im sorry i don't have pictures of the result ( i will go and try to take some pictures of it ) Since my camera broke i have not been able to provide you with good pictures from the current stages. ( to be continued part 1 )


    Then The other troubles.

    The culprit who started this engine rebuild is now found.

    Seised bearing surface. There was no way any amount of polishing or reaming was ever gonna make this a working piece, so i opted another way of doing it. In The process i tried to remove meter spinner bolt. It fell to my concrete floor with expected results. A dab of cleaning and a sliver solder just like a new one.

    Anyways i decided that i would machine all the damage out from the aluminum slide bearing surface, and i decided to use 22x26x20 Needle bearing in its place. I know that this is not the original way of doing it, but i founded that this will most likely outlast the camshaft anyways. and by this way i don't need to machine the other end of the camshaft or i need to spent any more time in the search of new piece like this. Let see when the installation is done what i will look like. Updating later on today / tomorrow.

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  8. #17
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    Litle things when waiting for the custom bearing to arrive. Changed the original iron screws to A4 screws, and painted the engine "brand label " like this. I remember seeing engine in a stand with this painted as i have now done. I liked it so thats the reason.

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    Thanks for reading I really appreciate it.
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  9. #18
    Member Balsawings's Avatar
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    You're doing some amazing work for a home shop. Wish I had a shop like that. I will watch this resurrection with interest.

    Bob C.
    1982 GL 500 Silverwing Interstate, 1981 GL 1100 Goldwing Interstate

  10. #19
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    Bob C.

    Appreciate it, I really do.

    I Drove to the shop and snapped few pictures of the silver soldered camshaft. I'm Really sorry about the picture quality i will go buy new camera probably tomorrow.

    But what you see is silver that has filled Pits and cavities in the camshaft. Also in the earlier pictures you might be able to see deformation in cam And that is now fixed by applying silver to it and reshaping it with iron file and loads of lubricant. Silver is the perfect for fixing these parts too. I don't Know if any of you guys have ever fixed these with silver but to my understanding this method of repairing dates somewhere 1800 - 1950 I can't remember where i learned to do this. I Can Make a how to Miniseries if someone is interested in this kind of repair method/stuff.

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    Cams are already inside the engine. And i could not dear to take them out ( remember that 27mm Devil )

    Silver is placed in locations of wear, You don't generally apply the silver to such areas where its not needed Silver is expensive and coating the entire thing with it is useless. Its used merely to keep everything in the right shape. There is a limit to a what the silver can fix and what it can't small pitting and shape errors is a easy repair. But if you need to reshape entire sections o would not use silver i would rather turn to aluminum bronze alloys. ( or buy a new one ) ( and one last note Don't be afraid of "filing" too much of the silver you can always place new silver back )
    + Never use sand paper with preparation work or smoothing the final result, little particles might get in there and all hell breaks loose.

    Thanks for reading i will try to update as the process continues.

    Eetu
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  11. #20
    Senior Member MobileAZN's Avatar
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    Amazing. A truly lost art. I wish it were easier to get into learning these kinds of fixes around here in the states.
    1980 Honda CX500 Custom (In a pile of parts, current project)
    1981 Suzuki GN400CR (Cafe Racer, current ride)
    1976 Honda CB125S1 (Full original restoration. Sold her and miss it. Every. Single. Day.)

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