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Spokes
03-30-2010, 04:23 PM
Delivered today is my 1968 CA160. No rust, no engine work needed, low mileage old parade bike.

It needs some body work and tires. Other than tires it is sweet. The bike will be carefully taken down and cleaned, inspected, body repaired and repainted. This is the first project bike I ever had that is 100% original and complete. I will loose sleep thinking about what color to paint it.
(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=120

Smithers
03-30-2010, 08:56 PM
Very nice. Just like my black one. :) Need to move this over to the CA160 section later. Now these are much more refined, less vibration etc etc.

phoenix216
03-30-2010, 09:02 PM
I will loose sleep thinking about what color to paint it.


Purple! I haven't seen a purple Dream or Benly yet.

Smithers
03-30-2010, 09:11 PM
I can't decide what color I would like to see it either. Tough decision on this model.

Sam Green
03-31-2010, 12:24 AM
I'm begining to think, I don't like you:D the bike is a load of crap, I think you should send it to me for humane dissposal.
Why not leave it white, looks great, wish I could find a 95 as nice as that.

Sam.;)

aaron7
03-31-2010, 03:40 AM
White is nice but over played on these old bikes.

I say gloss black, but then I paint everything black!

Brewster
04-01-2010, 07:36 PM
Spokes you DOG ! That bike is sweet!! Very clean,nice nice nice.
I have seen a few dreams in a medium blue metallic. I question why Honda didnt paint the bikes that color as it looks so good. Color is the hardest decision. Congrads on the CA160.

Spokes
04-02-2010, 08:01 AM
Sorry all..I miss represented the bike. It has after market tank emblems and a new MPH speedometer and a new bulb replaceable headlight. I was depressed for over 10 seconds, but I got over it...LOL

Thanks for the color idea's.. Purple....hmmm, stay white...gotta go pearl if white, metallic blue, gotta go with crushed glass rather than metallic with pearl added. If Red..Candy with pearl and maybe just maybe Pearl Candy Green.

When the stage is set, I will take pics. The CA95 is going to be a Cafe' style custom. It may be wild and it may be Orange. 55 Ford Crown Vic Orange with a touch of pearl. So one decision made. The color will have a pearl additive.

Spokes
04-05-2010, 03:18 PM
Started today to break down the CA160. It is interesting having both the CA95 build and the CA160 rebuild at the same time. I will try to list what is interchangable and what is not. This should be interesting.

Spokes
04-05-2010, 09:23 PM
The first thing I have to note is the exaust system. This bike has the original mufflers. Wtth the exception of some dents from an incorrect kickstart arm on one side and some slight rust through at the back bottom seam (epoxy repairable) on the other they would be perfect. They still have the baffles in them!

My point is that I see lots of ebay offers for aftermarket mufflers for the CA95 and they include the CA160.

Bottom line: The mounts for the CA95 are not the same for the CA160. The mufflers look the same, but not the mounts.

More to come.

Spokes
04-13-2010, 07:15 PM
I had to name my CA160 since it is a 1968, a good year for me, a bad year for the Viet Nam, so I decided to name it " The Sixty Eight"

One more day and the Sixty Eight will be completely dismantled. The engine is sound so it rests for a while in storage. I have a nasty hole in the rear fender from a rack, so I will cut out the damage and make a metal patch to be welded in. The front fender bottom flair needs to be corrected and some screw holes welded closed.

Then along with its partner project the CA95 will be sandblasted and primed. Once a color is chosen it will be painted in small jobs until all body parts are the same color. Then it is reassembly time. Which will be slow as all things will be checked for safety and as much aluminum polishing as possible. Pics soon.

Spokes
04-19-2010, 03:23 PM
Well the bike in the pic is now down to individual parts. The engine is in storage and the slow reassemble begins soon. I will be posting some pics of the before and after body work and of course the final product. A close inspection shows the bike was repainted and some engine screws were damaged. I was happy to see that the rims and hardware are clean. The clutch handle does not match the brake handle and one is bent. I guess this bike took a spill at one time or another. I had sold the original crashbars for it in Feb., the bars had some serious road rash.

The mufflers still have the original exaust defusers. They were rusted in pretty bad but I got them loose. One muffler has rot along the bottom. I made a sneeky repair so that only if your on your back looking up, you will see it. When I test rode the bike it was whisper quiet, so it should remain so after it's back together, unless I make straight pipes for it. I might have my fab guy match the muffler hangers and just weld the straight pipes to the new hangers.

All the body parts will be sandblasted and in primer within a couple of weeks along with the CA95. I will post some pics to show little difference between the two bikes.

Color yet to be determined, but most likely Orange Pearl for one and Possible Pearl Blue for the other.

Spokes
05-05-2010, 05:50 PM
Time Stamp 5-5-10
The pics below show where the CA160 is today. I got the frame back from the blasters. The rear of the frame had a huge ruptured hole in it. The sides of the frame were distorted as well. The bad metal was cut out. Then the frame sandblasted where the welded patch was to be. After the welding the frame sides were metal formed back into place. Below are a few pics of the reblasted frame and the start of body work.

The bare frame
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=175(picture here)

The welded patch, ground then reblasted
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=177(picture here)

I mix fiberglass resin and a small amount of polyester body filler and sealed the bottom of the weld.
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=176(picture here)

The first body filler application
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=178(picture here)

More to come.

Spokes
05-08-2010, 10:21 AM
5-8-10
Ordered the paint today.
Acrylic Enamel Metallic Candy Apple Red.
Body work 50% done.
Painting starts in two weeks.

Spokes
05-13-2010, 06:47 PM
5-13-10
Pics of the paint color on a sample part
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=183(picture here)

The repaired fender in primer
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=182(picture here)

The nearly done front fender flare repair
(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=184

Spokes
05-18-2010, 03:48 AM
5-18-10

I have ordered all of the componants for my custom turn signals. Looking forward, it's always good to do any custom wiring during re-assembly.

We have had rain the last few days, so too wet for painting. I took the front fender to my fab guy to weld shut some poorly drilled holes in the front fender.

I also coated the inside of the rear fender with a high zinc content primer. It will be reprimed with standard primer before a top coat of acrylic enamel. The underside of the frame and fenders will be painted first along with the battery holder and air filter/tool tray.

Spokes
05-23-2010, 08:22 PM
Drilled holes and temp. mounted the rear turn signals. I might mount them to the fender or install a fender trim from a CA95 and mount the lights to the trim. I don't know yet.
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=189(picture here)

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=190

Smithers
05-24-2010, 07:21 PM
Looking good! One thing I would do if I restored one of these frames is plate the underside of the fender with an inner liner of sheet metal. This would help immensely with frame fatigue in the rear section. You know... for hauling around your old lady or something. :D

Spokes
05-29-2010, 08:42 AM
Time Stamp 5-29-10

Today is woodworking day, building paint stands. 99% of all of the prep has been done. Once stands are complete a second coat of 2 part primer will be sprayed. Also there are a couple of extra parts being finished.

1.) An extra front fender.
2.) An extra front fork

They will be primed but not painted the Candy color
(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=192

Spokes
05-30-2010, 07:54 AM
Time Stamp 5-30-10

2 months from the start of the Sixty Eight Project.

All repairs made. All metal returned back to clean and rust free.

It is hard to imagine all of the fine detail work that goes into a complete restoration. Much labor & small cost in the home shop.

This pic represents the all of the parts for a CA160 together. Primed and wet sanded once. The second prime coat will be applied and the wet sand step repeated. Then Color.

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=193

Smithers
06-01-2010, 08:52 AM
Yes it takes up a lot of space. We all love to work out those details and body work though. I got a dose of that over the weekend doing plastic repair for my Aprilia. It's cool to see all the work come together as it actually goes quite quickly compared to a car or a truck restoration, that's for sure. Plus we get to see all the mechanics of the bike working properly together when we're done. Fun stuff!

Spokes
06-02-2010, 04:30 PM
I have decided to take a break from painting and concentrate on rebuilding parts and preparing for assembly later this month. Below is a pic of the handlebars, controls, levers and front turn signals. The signals are just mounted and will be further custom installed once on the bike.

Both controls have been cleaned and lubricated with dielectric grease. The brake and clutch levers were sourced and slightly modified to fit. All of the aluminum casings have been polished. Footpeg clamps have been modified to become turn signal mounts and installed ready to go.

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=194

aaron7
06-02-2010, 04:32 PM
Looks awesome!

Smithers
06-04-2010, 09:07 AM
Yeah painting is a lot of work. You have to have your head clear to really take your time with all that prep work and to concentrate on all those curved surfaces when you are spraying.

Spokes
06-05-2010, 05:09 PM
Time Stamp 6-5-10

Finished with the 2nd coat of primer and masked off the outside of the parts.
The pic below, while a bit dark, shows basically the color of the bike. The parts will remain the my dock box for a few days to cure. Then the rest of the bike will be painted and wet sanded several times to bring out a deep candy color.

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=195

joeficsit
06-05-2010, 07:22 PM
Looking great! Keep us updated as you know how we long for pictures!

Spokes
06-06-2010, 05:13 PM
Time Stamp 6-6-10

The first coat of candy metallic red has been applied. This coat will be sanded to remove any defects. I expect to repaint at least two more times. The last coat will be the mac daddy coat.

Also included is a shot of the repaired front fender flare and a close up of the color.

Reassembly should start in two weeks.
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=196(picture here)

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=197

gbaumgratz
06-07-2010, 05:22 PM
Are the previous pictures of the underside a darker shade or just in different lighting?

Spokes
06-07-2010, 06:03 PM
Lighting for sure. The color will darken a bit overall by the 3rd coat. But the final finish will be deep and metallic. Next coat in 5 days. Then again after another 5 days. I let the finish cure completely between coats, wet sand and shoot again. It is ok to reshoot after 24 hrs but I like the results of slow and methodic paint job.

Red Candy Metallic is hard to paint. If I was a beginner or novice I would stick to solid colors and base coat clear coat systems.

This paint is old fashion acrylic enamel with a hardner package. The reducer is matched to the ambient temperature. This color on the 160 screams Sixties. It will be max retro.

Spokes
06-12-2010, 10:02 AM
Here is a shot after the second heavy coat of candy apple red. Usually I do a third coat but this coat should be it. The pic does no justice to the color depth and metallic content.

Now to let the paint cure and work on the wiring and wait for tires....another story...phoey!

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=203

Smithers
06-12-2010, 11:23 AM
Ok you passed the test. You are now invited to come over and paint my truck. :D Looks great! I'm getting inspired to do some new motorcycle paint myself soon.


p.s. sorry about the server reboot yesterday. this forum isn't going anywhere so don't worry! :->

Spokes
06-12-2010, 12:59 PM
Man that would be sweet. Come to San Luis Obispo to do a paint job. Lets see... 1 month prep...1 month to prep the prep...1 month to prime..wait a month to prime again.. 3 coats base..1 month to sand..2 coats again..1 month to sand...clear coat wait, clear coat, wait..1 month to hand polish.

OK 7 months in San Luis Obismo...Every Thursday evening at the street fair.....

I could see it now......

Brewster
06-13-2010, 05:29 AM
Hey can I get in on that paint work? Start in November and work on it for ???
Your paint work looks great Spokes. Do you paint outside or put together a spray booth? I paint outside, todays paint drys fast.

Spokes
06-13-2010, 07:42 AM
I will share my technique. Real easy.

$15.00 Touch up spray gun from Harbor Freight. I buy several.
$5.00 in line air dryer. Good for one complete job
$99.00 Craftsman Compressor
2 part primer- low VOC
2 part acrylic enamel-low VOC
Face mask designed for Acrylic enamel & solvents. 3M
30 lb spray pressure
$15.00 Box Fan
2 tack rags
1 package of alcohol prep sheets
Disposable gloves-NO POWDER

I have a body shop supply house that provides me with PPG paints and all of the goods.

I spray in my garage near the door with good light. The box fan mover the air. I wet sand between coats. I clean the shop after every step

Never a problem with dust or smell.

Because this is a hobby (trying to be a business) it takes upward of 3 months to complete one of my bag restorations or cycle paint jobs.

I quoted several months Smithers, because once out in California..I would never come back!

Smithers
06-14-2010, 08:04 PM
Yeah we sure pay the tourist prices for fuel and food though. Kinda sucks but other than that if you can put up with a couple months of intense heat then it's a great place. The airport is AWESOME in Paso Robles. It's seriously the best private airport for all the retired airmen and airplane enthusiasts. I have a couple friends I catch rides with sometimes. Motorcycles are plenty of fun and I like keeping my feet on the ground just fine.

I need a big ol airplane hanger for all my projects and you guys could come hang out. Need to play more Lotto!

Spokes
06-17-2010, 08:04 AM
Time Stamp 6-16-10

It's time for wiring. 1st thing was to rewire the original tail light with correct color coded wire.

Next was to build and install the custom bullet light rear turn signals. The fender brackets are from a 1964-1966 Honda CA95. I like the look better than the fender trim on the CA160. Before the final paint job I used the CA95 fender trim as a fixture to drill the hole for the rear signal wiring. The CA95 has the hole already in the frame, the CA160 does not.

I modified the fender trim to fit the bullet lights, rewired the bullet lights to color coded wires (yellow for running lights, red for right turn signal and green for left turn signal).

The fender mounts were polished and the lights installed. The signal lights and the fender trim was built as a module. The access hole in the fender was grommeted and the unit mounted. Later the wires will be run through the under fender conduit. Those pics will follow.
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=205
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=206(picture here)

(picture here)

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=207

Spokes
06-20-2010, 02:22 PM
Time Stamp 6-20-10

When I do a restore job, I clean and prepare all of the parts to absolute clean. After painting I allow the paint to cure to fume free. Don't be freaked out that the bike sits in my air conditioned office. For the detail work of wiring and initial assembly, I like to take my time and be comfortable.

In the last few days I have been concentrating on detail. Installing the rubber wire grommets, cleaning rubber bushings and boots and soon I will install the wire harness. The harness will be cleaned as well as all of the connections. Once this is done then back to the shop for the final assembly.
Here is today's pic.

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=211

Spokes
06-21-2010, 12:30 PM
Today 6-21-10
The shocks have been rebuilt. The tops were painted with the bike.

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=212

Spokes
06-25-2010, 02:59 PM
6-25-10
While waiting on tires again I have been focusing on wiring and polishing.
The two pics below show that you can find matching gray tape to reinsulate and dress up the wiring (3M Scotch 35 Gray Vinyl Electrical Tape Part# 054007-00072) and I decided to wire the turn signal "winker" in the body of the bike rather than in the headlight bucket. The fuse to the signals is also tucked away in the frame and will be easy to get to. For those of you following this thread, I use red wire for the right signal, green for the left and yellow for power (after the winker). I wired the rear blinkers and brought them into the bike frame with the tail light wiring. I taped the 3 colors to the harness leading up to the front of the bike and used plug in connectors to connect the rear signal wiring. I will follow up soon with the front signal connections.
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=216
(picture here)

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=217

Spokes
06-26-2010, 10:02 AM
Detail Detail Detail. Here is a pic of the polished handlebar clamp.

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=218

Spokes
06-30-2010, 01:59 AM
Time Stamp 6-30-10

Although it is completely insane to have a bike in a nice house, remember it is absolutly clean in all respects. Here is a pic of how she stands today. Hopefully in the next two weeks she will be up on wheels.

In the meantime, the turn signals and tail light will be converted to L.E.D. The parts have been ordered. The project slowed a bit due to finances but brighter days ahead.

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=219

Brewster
07-01-2010, 04:37 AM
I would never call that insane! The bike is looking really nice Chip. I wish you were closer so I could stop by and help out. Maybe get a ride when its driveable, LOL.

Spokes
07-04-2010, 04:56 PM
My welcome mat is out should you be in the area.
Today 7-4-10 is wheel and polish day. I pulled the bearings out of both the front and rear wheels. Being that the bike has less than 7K and it was never stored in poor conditions, the bearings are fine. The rims were polished and the insides of the rim (tube side)were cleaned and painted. I have found tires again....3.50 x 16 and they should be here by weeks end. They are closeouts chin-shen c155 (i think) normally $49.00 ea. I got them for $6.and change each off of eBay. I know the 3.50 x 16 should work as I had that size on my 65 CA95. If all goes well by 7-10 or 11 the bike will be on wheels and soon after to be completed. No pics yet, just a pile of shiney parts ready to go.

I have a pair of CA160 fender trim that has been polished like chrome and a real clean swing arm bolt, washers & nut. If anyone is interested let me know. They will be listed on ebay soon.

Spokes
07-05-2010, 09:26 AM
7-5-10
Today the bike goes back into the shop and rests upside down to install the polished front suspension and to continue to connect the coil, starting solenoid and make a custom mount for a custom chrome horn. As much wiring will be done at this point and the front fender will be attached.

When it is time my backdoor neighbor, Berry, will help turn her rightside up.
This is a great time to take a couple of pics for reference. It is rare to get a birdseye view from this angle.

(picture here)

(picture here)

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=233
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=234
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=235

The primer you see is a 2 part system. 99.99% of the bike is painted. There are a few spots as you can see that i missed. The 2 part primer system will protect those areas. Some of the primer you see will be covered by parts.

Spokes
07-09-2010, 06:04 PM
Time Stamp 7-9-10

This is the last pic upside down. Tomorrow she will be on her wheels. By next week perhaps complete. Once completed the Sixty Eight may be up for sale. One individual has the first right of refusal. If said refusal is forgiven then it may be offered to the public. If sold, another will be started. Maybe back to the CA95 that was put on hold. For me it's the journey more than the destination.

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=236

Spokes
07-10-2010, 10:20 AM
7-10-10

Finally up and waiting for the wheels.
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=237
(picture here)

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=238

joeficsit
07-10-2010, 01:46 PM
WOW! Spokes, you are an inspiration for us all. I'm logging off and going outside to work on my bike.

Spokes
07-10-2010, 05:33 PM
Thanks Chris I am humbled.

Below is the Sixty Eight up on her wheels. The tires are 3.50 x 16. I got them for under $7.00 ea off of eBay. Close outs.

Time Stamp 7-10-10
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=241
(picture here)

(picture here)
http://fourwheelforum.com/picture.php?albumid=15&pictureid=240

Brewster
07-11-2010, 05:00 AM
Spokes that is looking good ! You do some great work.

Spokes
07-11-2010, 02:50 PM
Time Stamp 7-11-10

Finished the L.E.D. turn signals. Here is a preview of the bike with the tank and seat. Note the one shock missing. You only need one to keep the bike up while building.
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=242
(picture here)

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=243

Spokes
07-12-2010, 07:20 PM
After looking at the bike with the solo seat, I have decided against using it. I may have to build a seat or use the original.

Time stamp 7-12-10

I pulled the side covers off the engine today. I will replace the seals then clean the engine up and install it. I am not sure at this point how much of the engine will be polished.

Smithers
07-12-2010, 08:09 PM
Looks like candy. I would prefer to see the traditional seat on the old girl.

Spokes
07-14-2010, 09:02 PM
Time Stamp 7-14-10

Wiring complete. L.E.D. signals installed and operational. L.E.D tail light installed as well, looks very cool. Headlight(new replaceable bulb type), speedo and cable in.
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=247
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=248(picture here)

(picture here)

The engine is being cleaned for paint. The side covers pulled off. The right side cover has been repaired. All through this project there has been evidence of a spill. The inside of the engine is very clean as the bike only has 6800 miles on it. I will have new gaskets made from thicker material than original. This will eliminate leaks the best. The seals will be replaced as well.

Most likely I will paint the whole engine a nice silver with a clear coat. But maybe, just maybe, If I get creative, I might paint the engine side covers the same color as the bike. The paint is two part and is fuel and oil resistant. The engine sides don't get real hot.

Spokes
07-18-2010, 08:55 PM
7-18-10

The front brake cable and cable have been installed. All of the hardware was polished before installation. The engine case and sides have been painted high heat aluminum with a hight temp. clear coat. The cylinders will be painted with 1500 degree header paint. When the paint is fully cured the engine will be reassembled and mounted.

Spokes
07-19-2010, 06:34 PM
7-19-10

Here are two pics for today. The front hub polished and the engine and starter painted. Several parts will be polished. The starter aluminum housing was polished to set off the paint.
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=250
(picture here)

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=251

Spokes
07-20-2010, 02:56 PM
Time Stamp 7-20-10

Engine painted, oil seals and engine gaskets replaced. The pic shows the motor bolted in place.

Soon to be finished.

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=252

joeficsit
07-20-2010, 04:13 PM
write up on the lighting please! I've read your write up on the signals, but would love to see what you did for the LED tail lights and the replaceable bulb headlight. These bikes can use as much help as possible when it comes to current draw.

Spokes
07-20-2010, 05:57 PM
The tail light on both the Honda CA95 & CA160 (and maybe others) uses a standard 1157 dual contact, staggered pin base bulb. I sourced a 6V 1157 L.E.D Red bulb and simply inserted it into the original socket.

The replaceable headlight was purchased off of eBay. The Canadian lights at the time were replaceable bulb type. In the USA during the 1960's and up to the 1980's, sealed beams were law. That law has since changed.

The light purchased from eBay had to be modified. The blue wire needed a dual connection to connect to both the high beam switch and to the high beam indicator on the speedo.

The rim had to be widened a bit using a dremmel on the inside to allow it to fit to the headlight bucket. If I was to do it again, I would transfer the bulb body to an original headlight trim to avoid the fitting step.

don warren
07-23-2010, 11:32 AM
Spokes, just stumbled upon this forum while looking for LED light sources for my restoration...great job on the CA160! I have a 1966 CA77 that I'm doing the same thing with. I have picked up an unbelievable number of NOS parts for it. For turn signals, I've got a pair of the original cast aluminum Honda "clamp-on the handlebar" style which was supposedly standard equipment on the Asian CA77 models, and I have a pair of Buco Twinmasters which I plan to convert in the rear. Apparently they made the Twinmasters with or without light fixtures, as mine are just 4 hollow lens housings. No biggie to convert though... I still haven't picked up the right-hand switch module for the signals. Getting your hands on the orginal Honda part can be pretty pricey from what I've seen on Ebay. I've seen them go for anywhere between $99 & $199. Still waiting for that killer deal to come along...

When you restored the Buco bags for your friend, were you able to source replacement locks, or did you just rechrome what you had? I saw someone selling a pair of bags on ebay & they were including a pair of replacement latches w/ locks in a plastic bag. Made me think there's a source for them out there somewhere. I'd also like to find a source for that type of rivet. I know I'll never get the orginal Buco rivet, but something the same size would be good.

I can't wait to get to the point of putting it all back together. Right now I'm down to bare metal on all body parts, but still have to find a couple of decent body side covers & repair or replace my front fender. I'll post some pics. Mine was a rust-bucket, but it shouldn't be too much longer until paint happens.


Don

Spokes
07-23-2010, 02:27 PM
Cool. I did a signal kit for the CA77 for a guy in Florida. I fabed a front bullet light kit and use an external switch. The back used a bracket that I mounted on the tail light/license plate bracket with bullet lights on each side.

Buco Twinmasters had two types of lens bodies. Early models had cone bodies where late models had the shallow flat type. The cone shaped bodies will convert to L.E.D. easily, but the flat type is harder to do because of the size of standard L.E.D. bulb. I build my own L.E.D. lights to fit the shallow body. I have also converted the Buco light bodies to double contact type to have both running and turn signals in the bags. As far as the latch, I have the originals rechromed. You can find new/near perfect latches at www.vintagevibe.com Look for Rhodes Piano Case Latches. They don't have locks and need some minor mounting base mods, but they are real close and under $10.00 ea.

I have not found a source of Buco Rivits. I use a 3mm stainless hex button head screw and nuts and washers to replace the rivits. Usually I use 1/4 or 1/2" length in place of the rivits.

A great source for Buco stuff is by a seller on eBay called photolobo Tell them Chip sent ya.

Spokes
07-23-2010, 03:49 PM
Time Stamp 7-23-10

This will be the final "in process" pic. Within a couple days the project will be complete. Final pics then.

(picture here)
http://www.fourwheelforum.com/picture.php?albumid=15&pictureid=255

Spokes
07-26-2010, 12:02 PM
Time Stamp 7-26-10
Project Honda Dream CA160 is complete.

Below is an assortment of final pics. Thanks to all who have followed this thread. It has been a pleasure sharing this build with the forum. And now for your pleasure,

http://www.fourwheelforum.com/forum/picture.php?albumid=45&pictureid=574

Spokes
08-15-2010, 06:34 PM
The bike was sold. On to the next project!

Smithers
08-16-2010, 09:45 PM
Wow that is one pretty machine!

Brewster
08-17-2010, 04:07 PM
Yes it is very nice. Spokes it should have went for $2500+, thats my opinion. Such great attention to detail and not a thing missed.
Whats the next bike?

Spokes
08-18-2010, 07:59 PM
I have an agreement with a guy in Alabama to restore his 1954 Harley Hummer 165. I will let all know when that starts.

I have also started a slow "restart" of the Honda CA95 project that was cashed in to finish the CA160. So as soon as that story grows I will be reviving the thread "Building a Honda CA95 from scratch, where is the bike now?

Smithers
08-28-2010, 10:01 PM
Can't wait to see the 165 project. Can't recall seeing one of those ever run.

Spokes
08-30-2010, 08:29 PM
Well it's been 3 weeks since I heard from the guy with the Harley Hummer. I am beginning to doubt his intentions. I will let you know if it happens.

Spokes
03-18-2012, 05:28 PM
I stumbled on a ride video I forgot about. This video was taken in Bowling Green, KY. A short ride on the finished 1968 CA160.
http://www.youtube.com/watch?v=qOC5F7Pqfm4&context=C4aa7b19ADvjVQa1PpcFNkBhIntEoQ2RZLOKHQQUDB Wu_sGwapDEI=

Spokes
04-04-2012, 05:39 PM
Here is another great pic. The CA160 parked next to a Veit Nam era fighter jet used in the same year as the model year of the Honda, 1968
http://www.fourwheelforum.com/picture.php?albumid=45&pictureid=800