Project 1966 Honda CA160 Project

[Spokes]

This is a start of another Honda CA160 restoration project. The bike was found on ebay. Basically a barn find. The bike should be in my newly relocated shop in two weeks. The story and pics will begin then. The starting pic:
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=397

[Spokes]

Time Stamp 11-18-10

The bike was loaded on a truck in Kansas this afternoon. In a few days, in the shop and "start pics" will be posted along with a starting description.

[Spokes]

Time Stamp 11-20-10

The bike arrived today. Barn fresh. It has been sitting for the last 6yrs I am told.
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=407

After a nice hot water bath (need hot water as it is 28F)
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=409

One noticable flaw one muffler is damaged
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=410

The engine turns over smoothly ( loaded the cylinders with motor oil first) and there is some sheetmetal damage. The tires are bad, speedo broken, seat is trash, battery way dead, side cover screw is gone and the handlebars are bent. But $203.00 for the bike and $300.00 to ship makes it a good value and very restorable. The fuel tank is sound as well. Back to thinking about color. I have to say I like the Honda Red.

For those of you who have been following my threads starting in Bowling Green, Ky., below is a pic of my new shop in Eden Prairie, MN
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=411

[Smithers]

That bike isn't in bad shape at all! NIce one. Those 160's run so nice. Hmm look at all that free space you have in that new shop. I remember when my garage was empty... :)

[Spokes]

Time Stamp 11-25-10 Thanksgiving.

The bike is 1/2 torn down.
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=417
So far the unsalvagable items are: handlebars, fuel petcock, all control cables, speedo, side covers, right muffler. The gas tank is sound. I am soaking it in a solution that will not attack the metal, only the iron oxide (rust) (This solution is not available to the public)

I am expecting some front end damage as the front wheel is out of alignment. I have collected many of the parts needed to replace the unsalvagable parts. I may make an adapter for the fuel petcock so I can install a new upgraded one. The tank is so nice I hate to modify it.

[Spokes]

Time Stamp Dec. 7, 2010

My Buco saddlebags arrived yesterday. The mounts are wrong, but by spring I will find used ones or have my stainless copies made by my fab shop. Just collecting parts at this stage. The shop is unheated and is about 15F. Too cold to do anything. Sub-zero weather is due soon. So just small prep projects I can bring in for now. No real progress expected until spring.

[Spokes]

Time Stamp 12-15-10
Rec'd a gift of a 30K-80K BTU heater for the garage. Great for a couple hours of play at a time.

I pulled the front end off of the bike. It appears that the front shocks are bent. No problem as I have spares. I also found a copper wire in place of the fuse. I will be breaking down the wiring harness to check for shorts. The bike is just sitting on its back wheel for now. Soon to be completely torn down.

[Spokes]

Time Stanp 12-18-10

The bike has been broken down completely. I will be replacing the rear drive hub as it is broken. I have located a sandblasting business that also does bead and glass media, so in mid Jan. the bike will be sandblasted and stored dry until I can get it primed. In the meantime I will be sending out some parts to be rechromed and polishing aluminum componants. I plan to build turn signals and modify CA95 rear fender braces to fit the bike and signals

[Spokes]

Time Stamp 12-27-10
I have cleaned all of the painted sheet metal parts. Except for some dings and some small dents, the paint is close to nice, about 96% good. The rear wheel has been broken down to install a good hub and then needs to be re-laced.

I should get the new MN title soon and have purchased plates good to Dec. 2012

[Smithers]

Ok I'm ready to see some pictures. :D

[Spokes]

OK! Here are some shots. The bike is completely broken down with the exception of the engine, for which I am awaiting a manual and parts book.

Sheetmetal
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=418

Parts that needs work
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=420

Hubs to be polished along with other aluminum parts
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=427

Loose small and medium parts in storage tool box
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=422

The engine with covers off
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=423

Warm storage of both the build from scratch and the 160 frame and clean parts
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=424

Small basement cove with wiring (to check out) Speedo repair and Buco Saddlebags
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=427

There is much polishing and custom light building. I will start a thread on "how to build lights for your Buco Saddlebags" Also many small jobs to complete until warm weather allows me to paint.

[Spokes]

Time Stamp 2-13-2011

It's been awhile since my last update with this project. All of the sheet metal parts have been cleaned and are awaiting sandblasting. I have collected replacement side covers (found metal ones) a carb cover, wheel bearings and cables. The controls have been polished and stored. I have found a rear hub and will relace the rear rim. The engine will be cleaned up and tuned with new ignition parts. I am going to mount the engine and try to start it. The bike should be assembled in June or July.

This bike already has MN plates waiting to mount.

[Spokes]

Time Stamp 2-27-2011
It's been a long and snowy winter. Most of the sheetmetal parts have been stripped and in warm storage. The engine has been cleaned spotless and rests in the basement shop. I have cleaned and serviced the clutch and oil spinner. I have started polishing aluminum parts as well. A friend of mine gave me a new front fender,so the original front fender will go on the build from scratch CA95 project. I am ordering new chrome case screws for the engine.

Hopefully I can get to painting in two months. This bike will be Metallic Red Candy Apple. I will use two colors of primer to give the bike a two tone paint job look

[Spokes]

Time Stamp 3-25-2011

Still working on the project small bits at a time. The rear hub on this bike was broken. A used replacement hub was found, the original rim was clean enough to reuse. The pic below shows the used hub, spokes, Spoke Nipples and rim polished up and re-laced.
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=475

[Spokes]

Time Stamp 4-7-2011

Finally the weather is warming up. only 6 ft piles of snow remain in the shopping mall parking lots. Today all of the cleaned and partially stripped metal parts have gone to the sandblaster. A slight crack in the rear fender will be welded.

I will be truing the newly spoked wheels in a week or so with my new truing stand. Paint in May and reassemble.

[Spokes]

Time Stamp 4-13-2011

All of the parts plus some extra's are back from the sandblasters.
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=476

Some body work and priming is next. I will drill holes for wiring my CA95 trim I intend to use as a base for my bullet light turn signals.

[Spokes]

Time Stamp 4-30-11

Today was mod the aftermarket handlebars. I used a sample of the internal throttle opening from a original set of CA95/CA160 handlebars as a pattern. With my die grinder, a stainless steel cutoff wheel, Dremel and tool & die files, I now have a new set of bars that will fit the original internal throttle assembly.
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=492
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=491

[Smithers]

Risky! Wow that must have taken a couple hours. You gotta do what you gotta do! Looks awesome. Can't wait to see pictures of them assembled on the bike.

[Spokes]

I have finished the bars tonight as they needed on outlet for the throttle cable. I have an original set of CA95/CA160 handlebars that are nearly refinished and need to be chromed. So I'm not sure which bars will go on the bike in the end. The new bars are about 2" higher than originals and I don't know if that is going to be a problem with the cables and wires.

I have ordered tires, tubes and rim strips.

Painting has started. The inside side surfaces have been painted and I need to complete some light body work.

Final color will be candy apple metallic red over a grey base. This bike will sparkle in the sun.

Pics next week

[Spokes]

5-7-2011

The inside of the frame is painted along with the insides of the metal side covers,forks and under belly of the tank.
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=517

Below is a sample shot of the tail light bracket.
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=529

[Smithers]

Oh man that bike is gonna be nice! Are you going to put any white on it anywhere? Seat piping or anything?

[Spokes]

Don't know about any trim color yet. Usually those ideas hit me when I'm assembling. Chrome edging on the fenders and side covers for sure. Possibly a nice white double pin stripe somewhere. I have some real nice tan textured vinyl I may use for the solo seat. The big kick for me comes when the project is coming together..that's when the ideas start to flow.

[Smithers]

I'm always on the lookout for nice color combinations for bikes and stuff. When I do my custom streetfighter type motorcycle I want to use the blood red metallic I'll have leftover and then compliment it with some florescent orange. :D Can't wait to see this bike here come together.

[Spokes]

Below is a pic of my refinished rear wheel with my new 3.00 x 16 tire. The tire was the best find for under $35.00. Inside is a new tube and rim strip.

The original rear hub was broken so I needed to clean and polish a used hub, re lace the rim and true the wheel.http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=530

[SinjinLe]

Below is a pic of my refinished rear wheel with my new 3.00 x 16 tire. The tire was the best find for under $35.00. Inside is a new tube and rim strip.

The original rear hub was broken so I needed to clean and polish a used hub, re lace the rim and true the wheel.http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=530

where did you get the tire from?

[Spokes]

I found the tire at:

Dennis Kirk (www.denniskirk.com) out of Rush City MN. 1-800-328-9280

Tire Part# 54-368 ID NR-21 3.00 x 16
16" Rim Strip part# 53-5196
16" Tube w Chrome stem part# 54-131

[Spokes]

Time Stamp 6-5-2011

A lot of time has been put into restoring the metal to new condition. The frame and remaining parts will be finished painted within 10 days. Then while waiting for chrome spokes, I will begin installing the wiring (including turn signals)
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=569

[SinjinLe]

Thank! just ordered a set for my 64 ca95!

[DC2.2GSR]

Nice progress so far. I'm very interested to see more! I will be watching this thread closely and I hope to pick up some knowledge along the way. I'm just about ready to take ownership of an old CA160 myself. It will be a perfectly restored "daily rider". The only problem is that I, being a custom painter, will have a hell of a time actually deciding on a color for the bike!

Again, great progress on a very cool bike.

[Spokes]

I argue with myself for weeks when it comes to colors for my builds. I really kinda sold myself out as I had 3/4's of a gallon of candy apple metallic red just sitting around. I have one more build waiting for this winter which I may go off the deep end and do a no chrome and/or a military green CA95. I could go bonkers and build a race bike. Half the fun is in the planning.

[DC2.2GSR]

This new obsession of mine might take me to a place where I could someday own quite a few classic bikes and I have different plans for each :D I would love to build a meticulously restored+ CA160 (the color and a slight modernization of the electronics would be the "+"). The bike I mentioned in my other post will be that bike. I can then see myself moving to another that is done cafe racer style, etc.

The problem with my job is that I can page through thousands of color variations at any given moment. I spray PPG paint and they furnish us with quite an impressive color chip selection. Every OEM color to date from nearly every manufacturer around the world, plus hundreds of custom colors. It's pretty overwhelming. I think I'm just going to stick with black for this build :p

[Spokes]

6-19-2011
The frame and all parts have their 1st coat of paint. Wet sanding next and a 2nd coat due soon.

The job scope will then be:

Wire the frame, including turn signals
Lace the polished hubs with new chrome spokes
True the wheels and mount the tires
Assemble the shocks and front suspension
Mount rear fender mounts with bullet light turn signals
Install engine and remaining parts


I have two side tasks.
1.)I have finished my stainless Buco Saddlebag Hangers, now they need to be polished (they are stainless steel!) Then refinish my Buco Saddlebags.

The saddlebag assembly will be wired into the bike as well.

2.) Build a fiberglass seat pan to fab a solo seat. This will give the bike that "old school" look.

Hope to be finished in 6 weeks and on the road...

[Smithers]

DC2.2GSR sounds like a good guy to know. :)

[Spokes]

Time Stamp 6-25-2011

The CA160 restore project is part of a two bike project. The pic is both the CA160 and the "build from scratch" CA95 parts. When I am finished, there will be a matching set of bikes. A 1965 CA95 and a 1966 CA160. The only real difference will be that the CA160 gets the Buco Saddlebags. I am not sure at this point if I will paint the bags to match the bike or paint them white to contrast the bike.
http://www.fourwheelforum.com/forum/picture.php?albumid=23&pictureid=584

[Spokes]

Time Stamp 7-4-2011

All parts painted. The build begins today 7-4-2011

http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=603

[Spokes]

Front end of the CA160 and the Build from Scratch CA95 loosely assembled.
http://www.fourwheelforum.com/forum/picture.php?albumid=23&pictureid=604

[Spokes]

7-28-2011

Quick Pic today. Should be done soon.http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=618

[Spokes]

7-28-2011

This evening, got the wheel, brake assb and the kickstand mounted.
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=619

[Spokes]

8-1-2011
Front Wheel assb. Front fender & Headlight bucket mounted
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=621

[Spokes]

Time Stamp 8-13-2011

Wiring in, after market handlebars modified and installed. The controls have been cleaned, polished and installed. Very soon the engine will be reinstalled.
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=623

[Spokes]

Time Stamp 8-18-2011

Engine mounted. Speedo & Cable installed
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=633

Rear Signals wired
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=634

[Spokes]

Time Stamp 8-29-11

Getting close. New pic with Droid. Better color quality. Maybe this weekend to fire up!
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=636

[Smithers]

Wow... extremely clean. The rubber bits actually being dark black is impressive too. :D

[Spokes]

Time Stamp 9-4-2011
The 66 CA160 as she was delivered in November 2010
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=655


This evening the bike sits 98% finished. The new battery is charging overnight and the bike will be fueled up.
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=658

[Spokes]

Time Stamp 9-6-2011

The bike runs. Took it down the road slightly stripped as she is not complete, but I had to see if the tranny works.

The bike did not start on the 1st attempt. The carb over flowed due to the bowl gasket interfering with float. The machined aluminum bung mount & Harley stopcock leaked at the screws, so I used my CA95 tank that I had the bung welded in. Workes great. After 6 years with the cylinders open to the air, and having the cylinders oiled for months...she smoked real well. I also cleaned the carb in a industrial degreaser in a ultra-sonic bath, which cleaned the carb inside and out.

The throttle was sticking as well.

But a little adjusting and running the bike for 30 minutes, the oil burn stopped and the throttle is smoother.

When she is complete I will take some shots and this project will be complete.

[Spokes]

The CA160 close to finish. Here's a treat. Enjoy!

http://www.youtube.com/watch?v=0HRT5k-RB5E

[Spokes]

Time Stamp 9-17-2011

The 160 is finished. The only parts not on the bike is the carb cover & passenger foot pegs which are in the shop ready to install. The pics below show the bike at the gas station.

http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=659
http://www.fourwheelforum.com/forum/picture.php?albumid=32&pictureid=660

[Smithers]

Whoa that bike is looking pretty. She's got the chain gaurd and everything. The chrome looks very bright. Someone will be getting a very well built motorcycle. I can't guess the hours that took.