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Gaz's Honda Chaly


gazguy
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Just before New Years I sent the frame, swingarm and wheels away to get blasted. I was charged a bit more than my usual guy but he wasnt open over the holidays.

After a bunch of primering and sanding the frame and other parts were ready for paint. doing body work really sucks! I dont know how anyone can do it for a job.

I can pretty much say I've spent most of my time off waiting for paint to dry.

Once the paint had a chance to cure, which was all of 3 hours I started bolting parts on cos I'm really impatient haha. The engine is a manual Lifan 125 which was in my CT90. Following numerous trips to MBike more and more parts were acquired. 

Over the weekend I'll try and get the wiring and fuel lines sorted out.

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  • 2 weeks later...

I really wasnt feeling the tiny side stand and it was pretty pointless to be honest. So I opted for the centre stand. With it being lowered quite a bit it lifted the rear wheel so far off the ground it became unstable. I cut off 25mm from the bottom and made new pads from some 25mm shs.

I purchased a chaly big bore exhaust from mbike, its for a standard chaly so the rear mount doesnt meet up due to the bigger engine. Other than that it looks pretty sweet. To stop the centre stand from hitting the swing arm and the chain i whipped up a small stainless bracket  with a rubber stop and bolted it to where the passenger pegs would go.

I tried the kickstarter from my C50 to see what the fitment would be and it was touching just by millimeters. I didnt want it scratching my new exhaust everytime I kicked it over so I managed to get an old c50 kickstarter from my mate Jeremy, pie cut it and bent it forward and tig welded it up with stainless rod. Plenty of clearance now!

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  • 2 weeks later...

On my lunchbreak at work I knocked up a rear brake adjuster on the lathe, its an old 3 phase colchester and runs like a champ.

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I made up a battery box that also held the voltage regulator and the flasher unit. I'll get around to powdercoating it at some point

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  • 2 weeks later...

As the weathers been pretty shit here in CHCH over the weekend I got stuck into the chaly. Another trip to mBike and a good few dollars lighter I walked away with a tinted windshield and some widend rims. the front is 3.5 inch and the rear 4 inch.

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The battery box has been powdercoated at work and installed, I used those cable tidy velcro straps from Bunnings to hold the top down.

Also a sneak peak at my kicker pedal I made, its getting pinstriped tomorrow to finish it off.

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This thing is nearly complete now. I just need to make a bracket for the horn which I'll do tomorrow.

I put some feelers out for an air filter cover, to no avail. So my way of thinking is cant find it, make it! So thats what i did. I used a combination of pressing and hammer forming. I used 2 75mm OD 6mm thick discs and 1 2mm 75mm OD disc cut to the profile I need.274214675_10158823758563857_1805734852626321208_n.thumb.jpg.20d27f852f648df18d70813afc98fb76.jpg

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It just needs some minor massaging then prep it for paint.

The last major piece of the puzzle was the seat which I got this morning thanks to Andy and Wei at mBike. Bolted it on and couldnt be happier then took it for a hoon down the street

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  • 2 weeks later...

Its normally the smaller jobs that take the longest, but im gradually ticking them off the list.

1st up is the painting of the air filter cover

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2nd is the air filter cover. I found some old mag wheel centre caps at work, drilled some holes and put a 6mm rivnut in the air filter.

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3rd is the kicker pedal I fabricated out of some flatbar, plate and an old vans phone case i had hidden in a drawer.

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Lastly I bought some side boxes at the winchester swapmeet last year when swapmeets were actually a thing and you could go to them. Just toying about with the idea of them but Im pretty keen to make some brackets, colour code them and have them fitted ready for syds run this year to store some tools, spares and a few BRB Hazy Pale Ales

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  • 1 month later...

I got the chaly registered and road legal and took it out for its first shakedown run a few weeks back around the hills and through Lytellton to Wunderbar.

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Those side boxes I got from the swapmeet last year were on the back of my mind so I pulled the pin and started making some brackets for them

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The boxes themselves are pretty rough and have a few cracks and pieces missing, so I'll address them, paint them and maybe add some gas struts.

 

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  • 2 months later...

Whilst the blue panniers were a great addition theyre just too brittle and small parts kept breaking off after every ride. So I bit the bullet and decided to start making some from steel. 

To start with I made some channel out of 18g with a slight radius, not a breaked edge. 

Then I had to modify my shrinker stretcher stand as once I got to certain point it would hit the stretcher stand upright. so I moved them apart .

Using the shrinker I incrementally started shrinking the sides. Shrinking one side then the other so they'd both be the same.

One end is 90 and the other is just under.

Next is to make the sides and get them welded in289157179_10159014650053857_1473632984545544707_n.thumb.jpg.4eacef1e2eb629d96d08d98b0f66aa8f.jpg289309385_10159014650043857_2500762976063189541_n.thumb.jpg.7077f1a2cccfd964791b9e0e7faa2e81.jpg289403729_10159014650048857_6498070550050798268_n.thumb.jpg.1b7ee9de3d78a45c513294383d68aa22.jpg

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