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Project Brutus - 1966 CB600 K0 Black Bomber

43K views 134 replies 30 participants last post by  subaruski  
#1 ·
This will be my project for next winter but as I seams to have started gathering parts and do some work on it already I thought I should present it. I bought the 1966 CB450 K0 Black Bomber frame and a box of parts a couple of months ago and since Bomber parts is both rare and quite expensive I'm going to build the first version as a period café racer mostly with left over parts from other projects and get a built in patina in the process.
There are some Bomber features I want on the bike from the beginning though. The correct side covers, the characteristic headlight combo with built in speedo/tacho and the stock rear fender as almost nothing else will fit.

You might have noticed that I've written CB600 in the title. I haven't found an engine for the project yet but it will be a 500T engine bored out to maximum. I figure if I can get the engine over 550 cc I've earned the right to call it a 600. Ideally the engine will be mildly tuned too but getting the bike up and running is the first priority. :D

I've been offered workspace among a group of friends that, like me, are motorcycle enthusiasts so if everything goes to plan I will have a complete machine shop to my disposal in the fall which will give me the possibility to build motorcycles on a whole new level. The bike will be a rolling restoration and over time my goal is to get the bike looking like the Bomber in my daughters drawing as I really like the look of it.
http://www.hondatwins.net/forums/8-...ideos/27543-looks-like-there-s-bomber-ink-illustration-making-2.html#post222613


 
Discussion starter · #132 ·
Can have been previously in this thread, as I mentioned I haven't visited HT for for a long time. Information I got might identify the meter as possibly a CR93, early CB125 and CB160.

That unit came up in a prior Bomber build thread. Maybe it was maduncle's build? I can't remember what bike it was from, but it was small displacement.
 
Discussion starter · #129 ·
Ronny,
Did the Swedish Honda CB160 models come with the speedo & tach. all in the same meter similar to the CB77 Superhawk ? I have only seen the speedo meter in the USA CB160 models.
I'm actually not totally sure what model the headlight bucket and speedo/tacho unit are from. I'll snap a photo of the speedo/tacho tomorrow and see if anybody recognise it. Very similar to the 450 K0 unit, might be CB77/72.
 
Discussion starter · #126 · (Edited)
Seems like there are circa 10 mm difference between the older drum brake forks and the newer disc brake ones. Nothing some distances and a slight adjustment with a hammer couldn't overcome. :D


Mock up of '66 BB front end. Version 1.0 is going to be a real bitsa. Front forks are CB450 K5, fork ears (probably) early CL450, headlight bucket CB125 and Speedo/tacho unit CB160 (?). Since the '66 CB450D purchase went south I have to work with what I have to get this Bomber on the road.

 
Discussion starter · #118 · (Edited)
No, I have not fallen off the face of the earth. It's just that life sometimes throws you a curved ball that you have to go out in the woods to find. ;)

Not much have happened with the Bomber since I last wrote. I bought a complete '66 450D, yes 450D, this spring with only engine and exhausts missing. Frame number was very close to mine so I told the seller in Jersey Shore to sell his frame on Ebay. That way he would earn an extra buck and I wouldn't have all the hassle with importing and registering a complete bike. I was so happy as I now had most of the Bomber parts I was missing. Five months later there was still no parts on their way so I had to contact Paypals legal department and luckily got my money back.


First things to fix is the sawed off rear frame loop and steering bearing seats.



My welding skills are not great but I think the replica rear frame loop I made turned out quite well. Not very easy to fabric as the profile is oval (think Milwaukee Mile) but the ends are tri ovals (think Daytona).



I scavenged the steering bearing seats from an old K5 frame I had. It was already modified so I let it donate some parts before it went to the scrap yard (frame tubes was for example used to elongate a friends old 50's Triumph swing arm but that's another story). My friend and garage buddy Jorgen (master welder for over 30 years and magic metal worker) helped me welding the bearing seats as I didn't want them to come loose after a hard bump or heavy brake.



So now, when the frame, is finished it's time to start looking at the 500T engine. I stated in the beginning that it'll be a 600 cc monster but since I don't know anything about the engine I thought it would be wise to assemble it in stock configuration the first season to verify that it's healthy. That way I will also be able to notice the difference between stock pistons and THR 74mm high compression ones.



First test ride on the Bomber.
Image






Is it only me that can't see the photos above?
EDIT: They seems to be visible now.
 
Discussion starter · #115 ·
Bilbikek411, it will hopefully be a low revving engine with good torque on low revs.

Rod, good to hear from you my friend! Very kind of you to offer me a K2 frame loop but unfortunately the Bomber loop is not similar to any other 450 model. It's more like a tube pressed into an oval shape and then turned into a loop. Very strange design. I will have to try to make one by hand. Regarding pistons I'm going to use 74mm over size ones but again, thanks for your kind offer.
 
Discussion starter · #99 · (Edited)
I'm pretty sure the CB500T will go way bigger than 74mm.
I usually measure the narrowest diagonal between studs, 10mm smaller is max bore size (allows boring block and fitting new liners)
You can fit 74mm pistons into CB360, (2mm over is kinda a 'stock' fitting for extra 22cc, I've done 70mm, load more work)
I would think 500T will go to ~80+mm but it's a long time since I've had 450/500 in pieces Use Kawasaki KZ1000 drag race pistons (they go all the way to 82mm and have a high dome)
I also think it's possible to go much bigger than 74 mm with other sleeves as THR f.ex. sell 75.5 mm pistons. I'm determined though to bore out stock barrels.



Started work on the Bomber today by mounting a CB450 K5 centre stand and trying out Raask rearsets. As I've mentioned before I am missing many Bomber parts so I'm going to use what I have to get the bike rolling. It will in it's first version be a real bitsa but if I know myself correctly it will be a proper Bomber in a couple of years.

 
Discussion starter · #95 ·
After acquiring a 1975 CB500T recently I found that my newly built workshop suddenly not is as big as it seamed so I decided to disassemble the 500T. Several parts will be used for the Bomber build but I have to get rid of a lot of parts too.

Before.


After.




Oh, since this Bomber frame has seen the hack saw can somebody please help me with measurements or a drawing of what the rear frame hoop is supposed to look like?
Is anything attached to the rear frame hoop on a Bomber?
 
Discussion starter · #90 ·
Jim, the THR forged pistons are high compression (11.5:1) 450 racing pistons so the end result on a 500T without shaving the head or cylinders will probably still be higher compression than a stock 450. Since I'm not shaving the head or cylinders the cam chain, and thereby the cam timing, will not be altered from stock specifications.
 
Discussion starter · #88 ·
Jim. as I understand the (stock) Z1100 piston must be slightly modified at the edge of the piston crown and also at the valve outtakes so THR's kit seam to be the easier route. THR's 450 pistons will sit about 2 mm under the top of the cylinder wall in a 500T engine hence making the compression slightly lower than on a 450. This will suit my project well as I'm more after low and mid range torque than a lot of HP at high revs. I might also try an intake cam with a little longer duration and avoid higher lift as I think it's not a good idea to put even more strain on the cam followers.