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Thread: 1980 CX500D conversion using CRK Cafe Racer Kit

  1. #1
    Senior Member Flipper's Avatar
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    1980 CX500D conversion using CRK Cafe Racer Kit

    Have a 1980 CX500 Deluxe which needs a triple bypass and the usual work on brakes, forks etc. Decided to convert it to a café using a CRK Café Racer Kit from Great Britain. The kit doesn't add too much to the cost of the project, considering what I would have to pay for some of the required fabrication. Having the kit is a good way for me to start and hopefully finish the project in a timely manner.
    The kit was ordered, received well packaged and complete. There was a very well made instruction booklet included. Communications with the maker in GB were excellent. Everything was as advertised with no disappointments!

    I will try to document progress on the project as I go.
    The bike is currently in pieces on the garage floor. The engine is open and I am prepping engine case parts and cooling system components for paint.

    Name:  001.JPG
Views: 1695
Size:  1.91 MB
    Before...
    [IMG][/IMG]
    Ready for primer and paint
    Last edited by Flipper; 09-15-2013 at 11:14 AM.
    1979 Honda CX500 Deluxe,12800 miles; 1980 Honda CX500 Deluxe,14500 miles in conversion to a café ; 1972 Honda CB450 K5 in pieces; 2014 Honda CB1100 Deluxe

  2. #2
    Senior Member Tallpaul's Avatar
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    I will follow this with interest, Flipper. I am just trying to persuade SWMBO that the CRK Roadster is a good idea....................
    1981 CX500A

    2013 Triumph Tiger Sport 1050



    Being British is about driving a German car to an Irish pub for a Belgian beer, then travelling home, grabbing an Indian curry or a Turkish kebab on the way, to sit on Swedish furniture and watch American shows on a Japanese TV.

  3. #3
    Senior Member Flipper's Avatar
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    Tallpaul,
    love that Roadster - wasn't available as I ordered my kit.
    Go for it!
    1979 Honda CX500 Deluxe,12800 miles; 1980 Honda CX500 Deluxe,14500 miles in conversion to a café ; 1972 Honda CB450 K5 in pieces; 2014 Honda CB1100 Deluxe

  4. #4
    Senior Member Flipper's Avatar
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    Surprise, somebody had already changed the mechanical seal at one point. The tool of choice was apparently a hammer. The seat of the water pump impeller and the seat of the mechanical seal (machined flanges in the case) had deep "tool marks" left behind . Ordered a new - used rear case from ebay and plan un using that one. The new case had a bit corrosion and required stripping of paint and lots of sanding in preparation for paint.

    rear case before...

    clutch cover before...

    after priming and painting with Dupli-color Engine Enamel in Aluminum
    Last edited by Flipper; 09-17-2013 at 09:03 AM.
    1979 Honda CX500 Deluxe,12800 miles; 1980 Honda CX500 Deluxe,14500 miles in conversion to a café ; 1972 Honda CB450 K5 in pieces; 2014 Honda CB1100 Deluxe

  5. #5
    Senior Member Flipper's Avatar
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    Worked on painting and polishing of small engine parts.
    Trying to do at least one part a day. That's what I got done so far.
    The valve covers need a little more polishing.

    .Name:  003.JPG
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    CXPHREAK likes this.
    1979 Honda CX500 Deluxe,12800 miles; 1980 Honda CX500 Deluxe,14500 miles in conversion to a café ; 1972 Honda CB450 K5 in pieces; 2014 Honda CB1100 Deluxe

  6. #6
    Super Moderator CXPHREAK's Avatar
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    Nice work mate.
    Help with handlebar and ignition switches.

    http://cxgl.wikispaces.com/Rebuildin...lebar+switches

    Rider 81 500C, Thingy Born a 78Z. Ozdeluxe born an 80 shadow.

    RTFM

  7. #7
    Senior Member Flipper's Avatar
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    CXPHREAK.... I like that Remington
    1979 Honda CX500 Deluxe,12800 miles; 1980 Honda CX500 Deluxe,14500 miles in conversion to a café ; 1972 Honda CB450 K5 in pieces; 2014 Honda CB1100 Deluxe

  8. #8
    Super Moderator CXPHREAK's Avatar
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    It's a plastic replica.... the gubment took my guns.

    I'm probably not even allowed to have that... in my own home.

    It's a colt navy 36.
    Help with handlebar and ignition switches.

    http://cxgl.wikispaces.com/Rebuildin...lebar+switches

    Rider 81 500C, Thingy Born a 78Z. Ozdeluxe born an 80 shadow.

    RTFM

  9. #9
    Senior Member Flipper's Avatar
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    Sorry, had no idea. Mine is a 44 genuine lead ball .
    1979 Honda CX500 Deluxe,12800 miles; 1980 Honda CX500 Deluxe,14500 miles in conversion to a café ; 1972 Honda CB450 K5 in pieces; 2014 Honda CB1100 Deluxe

  10. #10
    Senior Member Solace's Avatar
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    I have just made my mind up to build a CRK Roadster - so I'm anxious to see how your build goes.

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