Resurrecting a vintage Honda
We received this bike as part of a trailer full of parts, frames and motors. When we saw the frame cut up, we knew we had to customize it and make it something special.
Tearing it down
Everything was torn apart, including the engine, to see what we were working with. We really had no clue as to the condition of the motor. As we moved through it, we found the usual issues like stuck head bolt number seven and leaky seals but most everything mic’ed in within spec.
You need to bathe
As with any tear down, once you have the parts disassembled and noted, everything goes into the parts bath to see what we see. Its easy for everything from chips in head fins to cracks in the case to hide in the gunk that 40 years of driving will put on a bike.
Spend the money to get what you want
A lot of people don’t want to tinker with electrical, but we have to. This bike has all new electrical because much of the stock electrical wasn’t even that good in the 80’s. To that point, we sent the stator out to have it respun with new copper wire. When we build a bike, it should run another 40 years, in our opinion.
Foam is fun
One of the habits I bring over from off-road truck builds is the use of pipe insulation foam to help visualize the build. Since the previous owner sawed off half the back frame, we opted to redesign the new back end to be more supportive of a straight line cafe racer.
Weld away the ugly
Once we have the form figured out, its time to make final cuts and begin tube bending and welding. All tube is DOM for the best combination of weight and strength. We also factor in elements that will need tabbing for mounts (like fenders, seat base, etc.)
Once the initial weld work is complete, its bench checked for bead quality, burr grinding and initial fit up for a tank, seat and electrical box.
I got big ass
I don’t care what I’m building or designing. If the seat isn’t right, I still won’t want to ride it for long. As a result, I may go through four or five seat designs until the height, width and depth feel AND look right. If its beautiful and not functional you don’t have a bike, you have a paperweight.
Wiring fit up
Before paint, I like to mock up the custom electrical box, major electrical components and have a general idea of how I’ll need to route things. In this bike, we’re using a solid state controller that eliminates all circuit fuses and allows us to manage maintenance from a phone.
Final comp
With a seat idea complete, I can now add other elements like light choice, handlebar options and take configurations where I need the look to go. Once I’m digging what I see, it gets blown apart for paint and final assembly.
Beginning to look like a bike
Once the frame is painted, I also begin building the final electrical box, bolting in starter components and sheathing wire harnesses. When you build a bike of this nature you’re better off wiring your own harness and looms. You can route them more precisely and customize them as you go.
The fog clears
I love this stage: Rims back from powder coat, tires mounted, shocks are in, engine fit up and final wiring. You want to go at it hard until its ready, but truthfully, this bike has a another 150 hours left to go before its up and running for the first time since it left the road.
You can’t replace the feeling of first start up. There’s a certain smell of assembly lube, new piston ring break in and more that just leaves you shaking in your boots just hoping there isn’t something you overlooked, like torquing every bolt to spec.
Check out the Track Starr build. A 1982 Honda CM450 and sister bike to Bullitt Boy
Chicken Creek Customs 
Nice build. What did you do about the air assist forks? Did you keep them or change out the suspension and fork caps?
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I like the air-assist forks, so we kept them. I rarely run the full pressure, since I want a little more feel in the fork. I keep it around 10 PSI.
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Hi – does this bike have the automatic transmission, like a twist and go? Or is it the dual clutch transmission? Thanks
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Hi Christopher, It’s a two speed automatic. So, no clutch. Click it into 1st and you can run up to about 40MPH then up to 2nd gear which can take you up to around 75MPH. These were popular because of their ease of riding around town. Less for the rider to focus on, but plenty of power to run you where you needed to go.
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Hey Dan – are you around this Saturday 8/16? I would love to come look at the bike if its still available. Morning would be ideal. I know this is late notice. Heres my cell 404-226-9821. Thanks
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