Chinese, Japanese, Dirty Knees, Look at Theese...

Discussion in 'Some Assembly Required' started by Dirt Road Cowboy, Aug 4, 2013.

  1. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    Yesterday was a little strange here.

    Our regular USPS letter carrier was off, so we get a new guy/substitute.
    Anyway, he drove around the neighborhood, and checked each house for outgoing mail. Then, he drove around again to deliver the mail. He delivered 1 piece of junk mail, and drove off. A little while later, he drives back, and delivers an identical piece of junk mail! On his 4th trip around the neighborhood, he delivered a package I was waiting for! :clap

    4 trips to deliver the mail, one thing per trip! I'm glad I didn't have 100 pieces of mail, or the poor guy would still be driving around the neighborhood today! God forbid that he would have to walk the route instead of driving that little truck! :huh

    The US tax dollar at work! :lol3

    Our regular carrier is pretty cool though. He always takes time to say hi, or pet my dogs. He'll even ask how "his girls" are doing if they aren't out when he comes by.

    So, what does this have to do with the CT build? I was getting to that, just sit back and wait! :lol3

    The package that the postman brought on the 4th trip was the stop/tail/turn signal/license holder that I bought for the CT.
    I wanted a compact unit, rather than turn signals sticking out where they could get broken if the bike fell, so I found an all-in-one unit with LED lights for about $21 on ebay:

    [​IMG]



    This is the stock CT tail light bracket:

    [​IMG]


    (It has some cracks in the license bracket that I would have to weld up if I wanted to use it.)

    I was just going to use the stock one, and find somewhere for the signal lights, but I like the all-in-one setup, plus, it's cheaper. :deal

    Then I got to looking at them, and saw something… The new unit has 2 sets of wires…

    [​IMG]


    And I started thinking (I know, it's dangerous!), maybe…

    [​IMG]


    Almost perfect! :clap

    [​IMG]


    There's a bit of a gap that I'll have to try to work with, but I think this might just be the ticket:

    [​IMG]


    So, I'm thinking that I can bend the stock bracket, where the license plate bolts to, up and over to bolt to the new bracket, and drill a couple of holes to mount the top together. :deal

    If that doesn't work, I can just bolt the new set-up to the fender.

    :freaky

    .
    #21
  2. 4play

    4play Next?

    Joined:
    Feb 28, 2008
    Oddometer:
    2,609
    Location:
    Avondale, AZ
    I bought the same tail light & ithe tail light & stop light are not brite enough to use safely. Since it was already wired in & had my turnsignals & license plate light, I made a bracket from some ABS plastic & added a LED stop tail that is very bright. The turn signals are so so, but legal.

    [​IMG]

    [​IMG]
    #22
  3. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    Thanks for the warning. I'll have to hook them up to a 12v battery and check them out.

    Were you running yours with a battery, or just off the engine?
    #23
  4. 4play

    4play Next?

    Joined:
    Feb 28, 2008
    Oddometer:
    2,609
    Location:
    Avondale, AZ
    They were/are installed on my bike. Intitially just the cat eyes & my riding buddies let me know I wasn't very visible on the road. That cheap LED stop tail in the center is extremly bright.
    #24
  5. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    Thanks 4play. It's always good to hear from people with experience. Where did you get the brighter stop light?

    #25
  6. slowpoke69

    slowpoke69 Been here awhile

    Joined:
    Feb 2, 2010
    Oddometer:
    600
    Location:
    So. Jersey
    It looks like the lights we use on our trailers, check a parts house for big trucks.
    I don't think they're expensive, very bright too. Good luck, more pix please.
    #26
  7. Curtis in Texas

    Curtis in Texas Been here awhile

    Joined:
    Jan 15, 2006
    Oddometer:
    207
    Location:
    Rhome Texas
    Subscribed!

    I'm on the other side of the Metromess from you so I probably won't be running out to give you an hand, but I have been wanting to get one of the CT's for my wife to ride. So I"m going to watch your build
    And that Lifan looks to be just the ticket for her.

    I've got several 70's XL 125's in the bowels of my shop and when the Grandsons get bigger I may dig them out and put them back together for them to tear up.

    Should you decide you have to have something powder coated let me know. My oven is 32" x 32" x 60"'s so I can PC and bake anything up to a bike frame. As long as it fits! Just one of those tools I always wanted and it fell in my lap one day.
    #27
  8. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    Sorry for being so slow at doing the bike work. Life has been getting in the way.

    Yeah, I know, stop the excuses, and get your priorities straight…Bike work and build report before the brakes on the wife's truck!

    If only it worked that way… :lol3

    I found a spot where the frame still hit the engine, and made it a tight fit, so I ground it down a little more, and now it's all good.
    Then a little paint touch up, and the frame is done.

    <a target='_blank' title='ImageShack - Image And Video Hosting' href='http://imageshack.us/photo/my-images/854/vdwr.jpg/'><img src='http://img854.imageshack.us/img854/9012/vdwr.jpg' border='0'/></a><br>

    Finished:

    <a target='_blank' title='ImageShack - Image And Video Hosting' href='http://imageshack.us/photo/my-images/17/vq51.jpg/'><img src='http://img17.imageshack.us/img17/659/vq51.jpg' border='0'/></a><br>

    And, I got a little more sanding and painting done on a few other parts.

    Under seat gas tank:

    <a target='_blank' title='ImageShack - Image And Video Hosting' href='http://imageshack.us/photo/my-images/856/coxy.jpg/'><img src='http://img856.imageshack.us/img856/3483/coxy.jpg' border='0'/></a><br>

    <a target='_blank' title='ImageShack - Image And Video Hosting' href='http://imageshack.us/photo/my-images/23/vq48.jpg/'><img src='http://img23.imageshack.us/img23/8235/vq48.jpg' border='0'/></a><br>

    <a target='_blank' title='ImageShack - Image And Video Hosting' href='http://imageshack.us/photo/my-images/844/bpjz.jpg/'><img src='http://img844.imageshack.us/img844/9537/bpjz.jpg' border='0'/></a><br>

    Luggage rack:

    <a target='_blank' title='ImageShack - Image And Video Hosting' href='http://imageshack.us/photo/my-images/841/yrqx.jpg/'><img src='http://img841.imageshack.us/img841/5923/yrqx.jpg' border='0'/></a><br>

    <a target='_blank' title='ImageShack - Image And Video Hosting' href='http://imageshack.us/photo/my-images/22/twda.jpg/'><img src='http://img22.imageshack.us/img22/1986/twda.jpg' border='0'/></a><br>

    Swing arm:

    <a target='_blank' title='ImageShack - Image And Video Hosting' href='http://imageshack.us/photo/my-images/856/bqvl.jpg/'><img src='http://img856.imageshack.us/img856/4308/bqvl.jpg' border='0'/></a><br>

    I don't know why the pictures look orange, but the parts really are very red!

    Hopefully, I'll be able to start putting some of the pieces together tomorrow.

    :D

    .
    #28
  9. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    Finally - visible progress! :clap


    I did a bit of rough assembly today just to see how things will look, and to give myself some motivation! :wink:

    This will be about the actual height, as you can tell from the low tires (I don't have the tubes in them yet).

    Rear High:

    [​IMG]


    Rear Low:

    [​IMG]


    The rear shocks are from a Honda 500. I don't remember the exact model right off hand though. It looks like they will give me about 4" over stock height, keeping the 17" CT wheel.

    Front High:

    [​IMG]


    Front Low:

    [​IMG]


    The front forks are from a Honda 125, either an XT or XR. I'm not sure. The front fender definitely needs some alterations, since it is hitting the engine right now!
    The ball bearings were easy to get in, just glue them in with lots of grease!

    I have a few different handlebars, some lower, some higher, but I think I like the height of these.

    The plastic top gas tank will still need to have some brackets made to hold it, and the seat will have to go back 2" - 3" to fit comfortably. I'll make a steel plate with some adjustable mounting holes to get a perfect fit, and I will need to make some brackets to move the rack back a little, too.

    Anyway, that's roughly how Linda is going to look. I think she's looking nice, but I may be a bit biased! :D

    .
    #29
  10. ben2go

    ben2go Moto Flunky

    Joined:
    Jun 23, 2011
    Oddometer:
    3,994
    Location:
    Upstate SC USA
    You know we love dirt bike pics.you delivered.The frame is humping it's own power plant. :clap

    [​IMG]
    #30
  11. Te Hopo

    Te Hopo AKA Deanohit

    Joined:
    Sep 25, 2007
    Oddometer:
    1,759
    Location:
    Either Picton or Kokatahi, New Zealand
    I love it, this bike looks like it's gonna be a great backwoods explorer and it should get great grins per mile. :clap
    #31
  12. Dungeyfan5

    Dungeyfan5 MXnut

    Joined:
    Sep 16, 2013
    Oddometer:
    2
    Location:
    MN
    i have to say thanks for at least showing the clip of sherry moon zombie. I think it is one of my favorite movies and the title is the only reason i stopped in. I do like what you have cooking though. Looks sweet!
    #32
  13. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    :lol3

    I thought someone would like that!

    Thanks for checking out the report. I'll try to get more done on the bike this week. Seeing it together does give me some additional motivation to get it finished for the fall riding season. :evil
    #33
  14. JerryH

    JerryH Banned

    Joined:
    Jul 4, 2009
    Oddometer:
    5,069
    Location:
    Chandler, AZ
    Great build. That engine sure is a tight fit. The more of these CT-90 projects I see, the more I want one. I love small bikes, but my smallest manual transmission bike is a Yamaha XT225. I have a couple of 125cc Yamaha scooters, but they have CVTs, and are no good for climbing due to the too high gearing. I am not a purist in the usual sense, and have also built several cars and bikes. I have a '64 Fairlane that was in about the same condition as your Cougar when I bought it. It has a 200ci straight six right now, but I am building a 302 for it. I built the XT225 out of 3 different bikes, lots of aftermarket parts, and some fabricated and modified parts. The only way I consider myself a purest is I am totally against any kind of computerized electronics on bikes and cars. To me they are supposed to be purely mechanical machines with a basic electrical system. No FI or ABS
    #34
  15. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    Good to see you stop by Jerry. You should get one of these to build up. These CT's are definitely easier to work on than the Gold Wings! :lol3

    Did you ever get all the electronic bugs worked out on your 1200?

    This definitely won't be a long distance, 2-up touring bike, but it will be great for my needs. It will be a great lane-splitter too! It's so much narrower than the full-dressed Wing! :evil

    My next project, the XR, will be even smaller and lighter.

    Anyway, thanks to everyone for following along! I'll try to get more done in the next couple of days. I think I'll be tackling the electrical system next.
    #35
  16. PNWRR

    PNWRR not fragile

    Joined:
    Apr 29, 2011
    Oddometer:
    955
    Do I stutter, Bitch?

    [​IMG]
    Working on a 1970 CT 90 right now, got some engine seals to replace then it should be ready for me to start up and see if it runs right, then I'll do more to it if everything is correct. Nice job so far.

    :freaky
    #36
  17. jese

    jese Adventurer

    Joined:
    Feb 26, 2013
    Oddometer:
    12
    I love these little honda builds
    #37
  18. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    Sorry for the lack of progress here. I had a lot of crap come up, but I'll try to get the bike finished soon.
    #38
  19. WECSOG

    WECSOG Been here awhile

    Joined:
    Mar 30, 2013
    Oddometer:
    431
    Location:
    Just past the pavement's end in North Alabama
    Is a build ever really finished?
    My builds just reach temporary stopping points. Hopefully at a stage where it at least kinda' works!:rofl
    #39
  20. RVeenster

    RVeenster Adventurer

    Joined:
    Feb 15, 2014
    Oddometer:
    15
    This is good stuff. The cherry red is a nice touch. Looks like a run rider once it's all ready to go! I know you started this project a while back, but where did you get all of your non-engine parts (chassis, wheels, shocks, etc)? I'm starting up a CT90 build and all I have is the engine and transmission--looking for pretty much everything else!
    #40