Repairing a Damaged Stamped Honda CA Frame

Spokes · Post by **Spokes** » Fri Apr 23, 2010 8:57 am

What makes the Honda Benly Models unique is the "frame" is actually an welded assembly of stamped steel parts. What sucks is that people bolt accessories to the fender and within time the metal will fatigue and break. Sometimes people will sit on an aftermarket item and rupture the metal. Below is how I repair such damage.

Below is the damage

Cut out all of the damage back to strong metal

Grind the metal sides to see the high and low spots and work the metal to as close to the original form as possible.

Tape off the section that your are working on and have the area sandblasted on both sides. Cut a piece of the same guage metal and weld the patch in place.

From this point the weld will be ground down and frame will go back to the sandblaster. Once back in the shop some automotive body filler will be applied, feathered out and finished. Then the frame gets repainted.

Frame back from the sandblaster

I made a mixture of fiberglass resin and a little polyester body filler (for flexability) and sealed the bottom of the repair

First application of automotive polyester body filler

Filled, feathered and primed waiting to be painted

Spokes · Post by **Spokes** » Sat Jun 12, 2010 10:57 am

Finished

Sam Green · Post by **Sam Green** » Thu Jun 17, 2010 12:04 am

Nice work there Chip, wish I had the time to do a nice roadster.

Sam.

Spokes · Post by **Spokes** » Thu Jun 17, 2010 1:31 pm

Thanks Sam. I was just looking through your pics of your CA95 race bike. I have a nice CA95 frame, forks, wiring and misc parts. I could do a small race bike.....thinking about it..

Spokes · Post by **Spokes** » Mon Feb 28, 2011 3:59 pm

Not more to add..just bumping a chicon spammer from this thread