Project 1966 Honda CA160 Project

DC2.2GSR · Post by **DC2.2GSR** » Mon Jun 06, 2011 9:01 pm

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

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

Spokes · Post by **Spokes** » Sat Jun 18, 2011 10:18 pm

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 · Post by **Smithers** » Mon Jun 20, 2011 9:13 am

http://www.fourwheelforum.com/forum/member.php?u=942 DC2.2GSR sounds like a good guy to know.

Spokes · Post by **Spokes** » Sat Jun 25, 2011 6:54 pm

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.

Spokes · Post by **Spokes** » Mon Jul 04, 2011 7:42 pm

Time Stamp 7-4-2011

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

Spokes · Post by **Spokes** » Sat Jul 09, 2011 7:53 pm

Front end of the CA160 and the Build from Scratch CA95 loosely assembled.

Spokes · Post by **Spokes** » Thu Jul 28, 2011 5:46 am

7-28-2011

Quick Pic today. Should be done soon.

Spokes · Post by **Spokes** » Thu Jul 28, 2011 7:34 pm

7-28-2011

This evening, got the wheel, brake assb and the kickstand mounted.

Spokes · Post by **Spokes** » Mon Aug 01, 2011 7:41 pm

8-1-2011
Front Wheel assb. Front fender & Headlight bucket mounted

Spokes · Post by **Spokes** » Sat Aug 13, 2011 10:15 am

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.

Spokes · Post by **Spokes** » Thu Aug 18, 2011 9:15 pm

Time Stamp 8-18-2011

Engine mounted. Speedo & Cable installed

Rear Signals wired

Spokes · Post by **Spokes** » Mon Aug 29, 2011 9:39 pm

Time Stamp 8-29-11

Getting close. New pic with Droid. Better color quality. Maybe this weekend to fire up!

Smithers · Post by **Smithers** » Tue Aug 30, 2011 12:44 am

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

Spokes · Post by **Spokes** » Sun Sep 04, 2011 8:34 pm

Time Stamp 9-4-2011
The 66 CA160 as she was delivered in November 2010

This evening the bike sits 98% finished. The new battery is charging overnight and the bike will be fueled up.

Spokes · Post by **Spokes** » Tue Sep 06, 2011 6:43 pm

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.