View Full Version : Ruining a completely fine '86 Honda Rebel 450

10-18-2016, 1:10 PM
Hello chaps! It's the wonderful time of the evening when we start yet another build thread.

To give some info about myself; I'm a young dude from northern Finland, turned 18 this past June and looking forward to getting my motorcycle license. I'm studying machining on trade school, it's sadly my last year out of the three but I'm already making plans to educate myself further, maybe aeroplane technology or some other form of machining and working with metal? Who knows. Anyway, back to the point; I've always been into motors. I've raced four-wheelers my whole childhood and when the money wasn't there I turned into two-wheelers. First motocross as a hobby, next were mopeds as builds and forward onto motorcycles of all sorts. I've always loved to ride whatever the machine between my legs is, but a few years ago I found the great form of art of expressing myself through building two-wheelers. I'm trying to make building motorcycles my profession in the future but it doesn't hold too much hope back here so we'll see.

I come tonight with a build thread on my mind. It won't be nothing too crazy since this needs to be on the road as my daily driver in about 8 months time, but we'll see what I gather up on my garage. This will be my first real motorcycle that I build, before this one I've built a couple mopeds, some fab heavy and some not, and a 125cc supermoto that I had. I've been dying for to start hacking on a real motorcycle and finally the time was right and the money was there. Let's start!

I bought this '86 Honda Rebel 450 the past summer. It's an import bike, from the US I gather, and it's in fairly original condition. All I really looked for when eye-balling a bike for myself was how well the suspension handled, how the engine sounded and rode and how well the frame flowed since my plan is to keep it stock with the swinger. Everything else I pretty much left aside since I knew it'll change a fuckton before I take it out on the streets. I've been in love with the Japanese style Harleys/chops over all for a couple years now, so that's what we're going for with this bike. Also I'm a perfectionist who only accepts everything to be period perfect, so you'll most likely see things done over twice or the smallest nooks and crannies being worked over for way too long. Anyway, this is how she sat right after I had bought it:

http://i1280.photobucket.com/albums/a482/emppage/rebel/20160801_180739_zpsgpn92wgu.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20160801_180739_zpsgpn92wgu.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20160801_191634_zpsvuhe2bbx.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20160801_191634_zpsvuhe2bbx.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20160801_191642_zpskl8vb733.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20160801_191642_zpskl8vb733.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20160801_191701_zpscvtjtsls.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20160801_191701_zpscvtjtsls.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20160801_191709_zpsidgx9whw.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20160801_191709_zpsidgx9whw.jpg.html)

The bike has racked a bit over 41 000 miles already but she runs like a champ regardless. I'm not looking to do anything to the motor for now since my plan pretty much is to build it to suit my taste, ride it for the mean time when I'm building another bike and then sell it away. My goal for a bike for now is a 650-750 parallel twin with kickstart, something along the lines of a XS, CB or a KZ. But more about that later.. The guy who sold me the bike said that he had changed some gaskets on it and used some sort of sealer on the head gasket so don't worry, it's not oil! Also the carbs seem to be leaking from somewhere but that shouldn't be a too big of a problem since I'm planning on polishing, rebuilding and jetting them anyway.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20160801_191825_zps35drv91a.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20160801_191825_zps35drv91a.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20160801_191842_zps6evjhdn5.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20160801_191842_zps6evjhdn5.jpg.html)

Now its time for some recent pictures. These were taken yesterday when I finally got to start working on this build; this is how we started. Also don't mind the god awful phone quality on the next photos, I'll try to turn bringing a real camera to the garage a habit.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161018_163752_zps1arb1bgm.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161018_163752_zps1arb1bgm.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161018_163808_zps67rrbwlw.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161018_163808_zps67rrbwlw.jpg.html)

I started working on the bike straight away, stripping down the usual (for now) useless stuff around the frame. First the exhaust, moving to fenders, blinkers and cables and so on. You'd never believe how hard it was to get rid of that rear fender, it has built in brackets for wiring harness that are welded shut. Like for real? Yes it's important to make sure the wiring harness is sitting tight but god damn I've never seen anything like that before!

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161018_183523_zpsrbvyocrh.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161018_183523_zpsrbvyocrh.jpg.html)

After that I moved on to the part that I hate the most on any bike: The wiring. I decided to rip down to the roots of the wiring straight away and get as good grip on it as I possibly could. Pretty much needless to say but I'm a total lost cause when it comes to wiring. The only thing I can do is wire up a totally new one if I have a diagram of the old circuitry. Anyway, pretty much everything was packed between the frame post, seat and rear fender. I'm thinking I'll go the usual route of fabbing up a fake oil tank and hiding most of my electrics in there, but we'll see.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161018_192222_zpsqef2vp4i.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161018_192222_zpsqef2vp4i.jpg.html)

Routing down the wiring harness down to the battery and beyond took a couple hours and it was getting time to call it a night for day one. For the last thing of the night I couldn't help but disassemble the right side forward controls and start thinking a way I'd fab up mounts for some high mid controls. The engine seems to be wide as all hell but I think I'll work something out that won't stick out to the eye too much. This is how I left her after the first day of disassembling.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161018_212431_zpsxafnaawr.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161018_212431_zpsxafnaawr.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161018_212630_zpshvbdo0gd.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161018_212630_zpshvbdo0gd.jpg.html)

Current mounts for the controls look as is. I'm thinking of just smoothing out the existing mounts, turning new slicker ones and moving them back on the frame a good few cents to get them on the middle of the bike. I might also use the existing bracket with the bore axle on the image but I think then the controls would be a tad too back. We'll see

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161018_212512_zpsvppo1vym.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161018_212512_zpsvppo1vym.jpg.html)

As I said, I like the older swinger Harleys and how their frame flow. As I eye balled my frame for a while I started to think that the vertical bar that comes up from under the motor to the shock mounts are in too big of an angle. I know, it was meant to be not too fab heavy of a build but these things stick out like a sore thumb to me. I'd like my frame posts to be a bit more upright, in a steeper angle. That way they'd look like they hold weight a bit better, there would be more room for the oil (electric) tank and it'd just look overall better to me. Also I don't really like the swinger as is, it looks too long or "high" to me, you feel me? Am I getting ahead of myself already? God damnit, its already going downhill..

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161018_212539_zpsvqn7tkit.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161018_212539_zpsvqn7tkit.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161018_212546_zpscoli0sya.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161018_212546_zpscoli0sya.jpg.html)

And for last but not least - everything she lost weight on on day one!

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161018_212345_zpshc3vfiog.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161018_212345_zpshc3vfiog.jpg.html)

And that's pretty much everything. Hope I got someone interested in this little build, I'll update more as I make progress since I like to narrate what I do with my shit. As said I'll try to turn bringing a real camera a habit and not just get overflown by the thought of building haha.

If you have anything to ask, fire away! Cheers.

10-19-2016, 1:53 PM
Looks like a great project, I'm struggling with ocd on my planned 'rat, chopper, bobber' and being a perfectionist is causing me no end of issues. I had decided on a quick build from whatever was cheap but I can feel it snowballing in my head. Have taken a step back for a while.... Good luck with the build, subscribed and looking forward to where you go with this.

10-19-2016, 3:08 PM
Sounds really good! I wish I could afford to be a perfectionist, but I'm just too sloppy. I'm looking forward to seeing how your bike progresses.

10-19-2016, 8:34 PM
Looks good so far and I myself just got a 2006 pearl white Rebel that I am going to chop. I am thinking of doing a late 60's early 70's chopper with ape handle bars and a fabricated peanut tank. I am a metal worker as trade.. I will start my build thread when I get the bike home tomorrow, 10/20/16..
Looking forward to it..

What are you going to do for your exhaust?

10-20-2016, 1:25 PM
Thanks everyone for the interest towards my build! Always makes me more motivated and ambitious when I see that people actually are looking out for my stuff.

What are you going to do for your exhaust?
I really can't put my finger on it yet. For me the exhaust either makes or ruins a bike, it must be made for the bike it belongs to. It's all about the lines and the overall style of the bike, they need to go along with the exhaust. That said, I'll most likely decide on the exhaust as the last thing I do so I don't do any unnecessary work which doesn't go well with the finished framework etc.

Been working on the bike for another two days now. Day two went by as I tried to work my way through the wiring harness. As I said my goal was to source down what component does which stuff and where do all the wires gather up. Turns out I had two fuse boxes on my bike, kinda unpleasant surprise but oh well what you gonna do. I'll try to cut off everything unnecessary from the wiring when it's time for that but there's a long road still ahead of us, no need to worry about that yet.

I won't bother with posting boring pictures of wiring and stuff so I'll just give out the more noticeable changes on the bike. These are from day two when I was sourcing for the front wiring on the bike. My goal simply was just to get all the wiring from the handlebars sorted out so I could throw the handles, levers, speedometer and such away. Here I've already made some small progress by removing the headlight and a fuse box.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161019_174810_zpshw7pwao4.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161019_174810_zpshw7pwao4.jpg.html)

I don't know too much about wiring but one thing is sure; Everything is awfully big on this bike for such a little Honda. I mean the speedo is huge, so is the headlight, the aftermarket handlebars, levers, everything is HUGE. I mean look at this god damn ignition switch. Please do tell me if you've seen a bigger one in any vehicle and you win a virtual cookie

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161019_174916_zpsibtkrnpr.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161019_174916_zpsibtkrnpr.jpg.html)

Once I had got rid of everything on the handlebars I just felt like tucking everything away and looking at the thing for a while. Partially because wiring is god damn tiring to do and secondly because I felt like I was making progress. I kinda remotely liked what I was seeing. Also I apologise for the inconvenient angles on these photos but as you might have noted I have pretty small area to chop away and the other bikes aren't helping in sharing the space at all. I'll try to get a bit versatile with the photos as I keep chopping the bike to smaller pieces.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161019_211503_zps0gijuyyg.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161019_211503_zps0gijuyyg.jpg.html)

On day two I actually got everything regarding wiring on the front end done, I achieved my goal I had set for the day. Everything was loose and I had marked every wire where they came from so that I'll get off easier when it's time to weed out everything unnecessary from the wiring harness. On day three my goal was to get rid off the harness and throw it on the shelf to wait for better days to come.

First thing to do was to source out every wire and hose that connected the gas tank to the frame and then remove it.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_160507_zpsalbuyct9.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_160507_zpsalbuyct9.jpg.html)

I got greeted by a surprisingly big, but thankfully a straight, single backbone. This was one of my requirements for the bike since I don't want to do too much frame fabrication work due to the small-ish amount of time I have on my hands. Also one thing that I didn't know about the Rebel frame was that the backbone is hollow and it's already open from under the seat. That eases my job for making routes for wiring a ton.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_160616_zpswao3upmn.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_160616_zpswao3upmn.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_160642_zpsakynhz9x.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_160642_zpsakynhz9x.jpg.html)

Can anyone ID to me what is this hose? It starts from the cylinder head and went under the Rebel's "airbox" to its separate section, sorta like a very small tank. Then there was another tube that lead under the bike from that tank. The hose that lead under the bike was plugged and once I took the plug off there was some sort of liquid. It didn't smell like gasoline or oil, it didn't smell like anything at all almost. Could this be the breather hose (don't know the actual english term, correct me) and the liquid just condensed water that has been sitting there and got dirty due the time?

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_160806_zpsltr3xgsw.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_160806_zpsltr3xgsw.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_163743_zpsgl9bn1gt.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_163743_zpsgl9bn1gt.jpg.html)

Anyway, I continued on my journey to piece out the bike and the next to come off was the airbox. I can't imagine what the people at the Honda factory have thought when they invented this thing. It's hideous and seems very impractical. The carbs lead to an opening and there was some mesh separating the air filter and the carbs' "air space". When I took off the air filter there was a tiny gap where light could shine through, it seems to me like the bike is just starving for air with this contraption. I wonder how the bike acts when I put on regular airfilters on it for the first time..

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_164903_zpsjspfgqfe.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_164903_zpsjspfgqfe.jpg.html)

And about how the look changes when the airbox gets out of the way. Yeah, I prefer this much more.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_165909_zpsjjy3ecc6.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_165909_zpsjjy3ecc6.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_202730_zpsvroayuy1.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_202730_zpsvroayuy1.jpg.html)

More big frame tube to drill a hole in and route my wiring on. Every wire and hose in and out of the motor will most likely get routed through this vertical tube.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_170020_zpsyz5ifcfx.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_170020_zpsyz5ifcfx.jpg.html)

Slick without the god awful wiring harness. Hopefully the frame will look even slicker when wired and routed properly when I do the final assembly. I just left some odds and ends from the harness still on the bike, like the wires coming from the engine and brake light censor etc.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_180905_zpszb17vr6s.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_180905_zpszb17vr6s.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_181102_zpshmtcsy3n.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_181102_zpshmtcsy3n.jpg.html)

10-20-2016, 1:26 PM
And I managed to fill the huge 10 000 character limit per post so I have to spread this update to two separate posts:

And for the final of day three I just had to attempt my luck at jacking the bike up and removing the god awful rear fender brackets. I need to go fetch some cargo straps to tie the bike to the jack on, until that I won't risk tipping the bike over and breaking something. I like what I'm seeing but still, there's something not quite right on the back end and I'll figure it out. Other than that I'm pretty pleased where I've got in only three days. God it feels great to be able to wrench again..

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_202659_zpslvqguaib.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_202659_zpslvqguaib.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_202826_zpsmguhbxqs.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_202826_zpsmguhbxqs.jpg.html)

Like I said on the original post, I like the skinny chops that the Japanese build and thats what I'm trying to replicate with this bike. I've been thinking about the front end for a couple weeks now and I've been thinking of milling new narrow triple trees for myself. My only "but" is that I can't wrap my head around can I even do that? I mean, I have a whole lot of empty space on the right side, but it seems a bit tight on the left side already if I were to go with the stock hub. And if I mill narrower triple trees it'll "take" space from both sides, won't it? So basically I can only take the same amount of space off from both sides so I won't lose the center alignment of the front wheel, right? I don't know, I've thought about this too much and I can't think of it too much anymore..

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_203137_zps1nyouogn.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_203137_zps1nyouogn.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_203145_zpsjddadbtj.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_203145_zpsjddadbtj.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_203151_zps8jzm3gzl.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_203151_zps8jzm3gzl.jpg.html)

But if I decide/need to go the stock triples route, I need to smooth and/or mill these trees, too. They look hideous and I don't like the disparities between the upper and lower trees. I'll most likely smooth them both out and then notch the front on the upper tree like the lower one has been notched.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_203216_zps59ewoznz.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_203216_zps59ewoznz.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161020_203208_zpswnbqouxe.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161020_203208_zpswnbqouxe.jpg.html)

Anyhow, that's it for today I guess. A lot of pointless pictures and chatter but I hope someone is still interested enough to switch through my stories. Once again fire away your questions and opinions, always loving to hear some feedback.


10-20-2016, 10:57 PM
I really like what I am seeing. Keep up with the post. I just got my 06 Rebel today and will post a build thread tomorrow when I start.
I really like these little bikes..

10-22-2016, 4:55 PM
Not too much has happened for the last couple days, been mostly just looking at the pile I have and making up some plans for it. I'm not too pleased with it as is though, there's something wrong in the rear end but I can't quite put my finger on it. Is it the small rear rim and huge hub? The swingarm being too long and bulky? The frame structure? Or is the clean frame just pulling tricks on me and a proper fender, battery box and seat would fix it all up? I need help with this one, what pops on your eye on the stripped down rear end?

Anyway, I started to oogle out the up coming controls I'm going to make. I didn't get too much into it tho since I need to figure out the fenders, seat and all that stuff before I can decide the height of my controls. First of all I need to smooth all of this out on the lower frame tubes. I'll turn some new bungs to weld onto the frame once I figure out where and how I want to mount my controls.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161021_221933_zps7mpmw2xi.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161021_221933_zps7mpmw2xi.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161021_181919_zpschhz9a1g.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161021_181919_zpschhz9a1g.jpg.html)

I guess the wisest choice for these straight through holes is to weld them shut completely and then sand them smooth?

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161021_221920_zpsxsuj2r4g.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161021_221920_zpsxsuj2r4g.jpg.html)

I also broke my footpegs into pieces..

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161021_221549_zpsfivp6ime.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161021_221549_zpsfivp6ime.jpg.html)

..to recieve these two. I'll grind the actual pegs off and only use the ends for the new ones. I'll use them "in reverse" as in mounting the new pegs into the "pit" and fasten the pegs through the bolt hole.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161021_221639_zpssuhzdroc.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161021_221639_zpssuhzdroc.jpg.html)

And they most likely will get set around these parts

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161021_221710_zpszotuwxhd.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161021_221710_zpszotuwxhd.jpg.html)

Also when looking at the possible places to mount the brake pedal on I found out that the pedal follows some certain lines pretty well all originally. Might leave this one almost untouched and use it as is.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161021_221808_zpsp5pj6hvy.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161021_221808_zpsp5pj6hvy.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161021_182000_zpsv86spw9k.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161021_182000_zpsv86spw9k.jpg.html)

What should I do with the neck? I'd like to have it cleaner, just two tubes connecting onto the head tube and some cross brace, not this monstrous looking horrible thing. Anyone know where the actual frame tubes go in there? Would it be "safe" to strip the bike down to the bare frame and start hacking onto this one and making something more suitable for my eye as I go? Is there any way to secure that the frame stays straight and doesn't bend as I grind off the excess material except for a frame jig?

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161021_182126_zpslzmnoc8d.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161021_182126_zpslzmnoc8d.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161021_182521_zpszqgapyrg.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161021_182521_zpszqgapyrg.jpg.html)

And now we come to my actual questions for you, dear possible readers: What should I set on doing next? I've got basically a roller with a motor in it at the moment. I need to grind off the unnecessary tabs and mounts and I need to look more into the rear end and what's the cause of the massive eye sore. Should I grind off all the tabs excluding motor mounts? I mean, I most likely won't use any of them and I'll most likely be better off making my own tabs just where I need them when I have some more bits and pieces done. I feel like what I need to do next is get the motor and all the remaining wires and tubes off the bike and make it a proper roller, smooth down the frame by shaving excess tabs and then put it back together to see where I'm at. At least I could think that it's easier to fab around the bike without the motor being in the way since I don't pretty much need it at this point. This is where she's at now tho:

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161023_000101_zpsxzaufciq.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161023_000101_zpsxzaufciq.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161023_000156_zpsy4mlm7rc.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161023_000156_zpsy4mlm7rc.jpg.html)

I need some opinions what to do with the rear end and/or with the bike overall. I feel like it sits pretty neat now, but it's nothing that is worth celebrating for you know? It needs that little something on the bodywork to make it look good. I don't know, give me your opinions about shaving the tabs, the rear end setup and what to do with the neck. Cheers.

10-22-2016, 10:06 PM
I'm in no way qualified to comment but wanted to offer some words of encouragement. Keep it up!

Personally, I don't like the square cross section of the swing arm tubing. I'm not sure what you can realistically do about that, short of fabbing a new swing arm, or swapping one in from another bike, but you did ask. :D

10-23-2016, 2:00 PM
No, everyone is allowed to weight in their opinion. If anything it only helps me to try and figure out what I'm missing here. But yeah, you're right. The swinger is one thing that bugs me out a ton, it's too long and bulky. I really question that I could make the stock swinger look good. I've been thinking of making my own swinger but the only thing I'm hesitant about is the insides of the mounts for the swingarm. Would a basic roundstock turned to tight measurements be enough or does it need some bearings or something done to it? If someone knows more about doing a swingarm, especially the mounting points to the frame, I'll gladly read about it!

Anyway, let's up some filler pics to the post to show where I'm at. Pulled the motor out today, just decided fuck it I'll strip it all to bare frame and build from there.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161023_165023_zpskuqemklp.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161023_165023_zpskuqemklp.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161023_165142_zpsoktes13o.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161023_165142_zpsoktes13o.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161023_161832_zpsidgyrznf.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161023_161832_zpsidgyrznf.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161023_161846_zpsvoivo9ep.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161023_161846_zpsvoivo9ep.jpg.html)

Did some ghetto stuff to try to see what I want to do with the neck. It seems like the "plates" are just welded on the frame tubes and you could get them off fairly easily. Might go and take the chance of hacking it all off since it looks f'ing ugly and I've decided to do something about it. Most likely it isn't there for structural reasons so it shouldn't pull anywhere, right? The green part is which would get cut off and the bar is there to assemble the up coming new cross brace for the neck.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161023_193757_zps93ccjpd4.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161023_193757_zps93ccjpd4.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161023_204124_zps62j8ho40.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161023_204124_zps62j8ho40.jpg.html)

And I cut up the current handlebars and tried to get a look at what I have in my mind for the frame. Would this make sense? I feel like more vertical tubes like this would look better than the existing ones. Also making these shouldn't be all that hard since it's just one simple bend with turned slugs in the ends to join the original frame tubing. Weight in your opinion, I seriously need it.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161023_204112_zpsa4shdstu.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161023_204112_zpsa4shdstu.jpg.html)

And this would be something a bit closer to the final product after the frame mods

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161023_204103_zps9gskz2h7.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161023_204103_zps9gskz2h7.jpg.html)

I'll shave the useless tabs and mounts from the frame tomorrow, it got too late and dark to do it today. Might look into the neck area at the same time, don't know yet. In which order should I do all the mods? Should I try my hand at the swingarm first and then move on to the frame or? I also looked at used 18" rear wheels with disk brakes from motocross bikes but they get spendy fast with all the brake equipment involved. Think I just should stick with the 15" rear wheel on this bike and leave the 18" rear wheel for the next bike build I'll do. But the 15" is so hideous tho.. Gah... I need some opinions what to do in which order, this is pushing me down quite a bit.

10-23-2016, 7:12 PM
There is no "right" way to attack things, however this would be my opinion.

#1: Put the motor back in. It sucks to make a frame mod an then find out it wont clear a side cover or whatever (ask me how I know)

#2: make it a roller, thus you would need to mod your swing arm and reinstall

#3: then do the frame mods

#4: tank mounts, seat mounts and so on

I will sometimes make a full functioning mock up prior to tearing down for paint. I.E. wire and everything and ride the bike some. That allows you to make changes easy

Good luck

10-25-2016, 2:33 AM
Also, let me say that you've inspired me - I must definitely add a comfy chair to my garage. :)

10-25-2016, 3:07 AM
Nice work so far look . fwd to seeing where this goes

10-30-2016, 10:37 AM
I gotta say, to begin with that bike was in a great shape for an 86. Damn. Looks good what you got up to now. I think the stock 15" wheel looks fine I wouldn't bother with that. Its a rebel after all. I think it suits it.

11-01-2016, 2:01 PM
Haven't got too much done lately, been just thinking what to do and how to attack things the smart way. But I finally got things figured out what I want to do with the bike. It has been decided, it's going to get a hardtail coupled with a car tire on the stock 15" rear wheel. I've been trying to gather some info about ground clearances but haven't found too much info about how low or high you should/could hardtail your bike without the out come looking like an ass. I'm thinking something like 14cm (5,5 inches for you imperial guys) could be pretty good for the clearance, not too high or low and it still looks good. Also the frame lines seem to meet up pretty well on that height.

I have a couple questions about hardtailing tho. If I hardtail, I need to lower the bike significantly from rear and front. If I go with 14cm ground clearance, I need to lower the front end by ~9cm (3,5 inches). How will this affect to the handling of the bike? Will it change the trail or steering or something in some way? My other concern relates to the actual building process of the hardtail. I guess the smartest thing to do is to build the hardtail "around" the swingarm as in jacking the bike to the proper height, taking off shocks and placing the axle plates "inside" the swinger so I'll have the right height and width on the rear wheel automatically. Right? Then bend the tubes to meet with the axle plates on the right angles and so on. If you've done this and want to give me some tips and pros, please do, I'm eager to hear anything regarding this subject.

I'll post some pics so it won't be just a dull text update where we're headed with the build atm. I shaved off everything excess material from the frame.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161024_153843_zps1fzu069k.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161024_153843_zps1fzu069k.jpg.html)

I shaved the top triple to fit the lower triple, too. I'll finish it up with a belt sander and polishing it all up nicely, don't worry it wont stay like that.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161027_132139_zpsstk7uzzk.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161027_132139_zpsstk7uzzk.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161027_132151_zpsuy61rng8.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161027_132151_zpsuy61rng8.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161027_174811_zpsog8zhkak.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161027_174811_zpsog8zhkak.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161027_174832_zpsg6dxrlpo.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161027_174832_zpsg6dxrlpo.jpg.html)

... And the forks.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161027_175034_zpswtljehny.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161027_175034_zpswtljehny.jpg.html)

And here's the roller frame in around the ride height I've been wanting. 14cm off the ground, 9cm lower forks, rear wheel and swinger resting on the ground so I can bend upper and lower tubes to meet up with the axle plates nicely

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161027_194020_zpsizdaszyf.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161027_194020_zpsizdaszyf.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161101_174139_zpswslvf5sw.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161101_174139_zpswslvf5sw.jpg.html)

That's all for now, stay tuned. Comments and any tips regarding the process of hardtailing a bike are very much appreciated. Cheers.

11-11-2016, 8:29 AM
Hey! I'll buy that rear fender off ya, if you're within an hours drive from the capital area. PM me, I can't send you a message for some reason.

11-13-2016, 10:20 AM
This thing's new stance is so mean, very cool
As for hardtailing, I would remove the rear vertical section at all, from the seat portion to the lower tubes and make a full tail you can slug and weld to them

11-13-2016, 11:52 AM
Thanks for the input!

Even tho I already sais that it was 'confirmed' what I wanna do, I somehow cant put myself into getting the car tire. I'm real hesitant about running it and just thinking to myself that could I make it work with the current tire and maybe a slight knobby on the front? Something like this Duro maybe? (https://www.allrightshop.fi/productImg/0/323482) Or should I keep both of the current tires? Afterall theyre both almost brand new and I guess I could try to make them work?

I seriously need some proper input here, I've been pretty much stuck with the build because of this problem..

11-13-2016, 1:21 PM
What car tyre are you thinking about? A modern radial would ride ok just straight, an old bias ply tall sidewall tyre would be better but best maneuverability will come with your current setup imho.
Do you have a sketch of your project?

11-13-2016, 2:02 PM
I have my eyes on an old well aged bias ply tire, the vintage style ones that get used alot on motorcycles as well as VW Beetles for example.

What do you mean with a sketch of my project? Picture or plans where Im trying to head with the build or?

11-13-2016, 2:21 PM
Yeah some drawing or rendering about where the project is heading looks wise, in this initial stage it's difficult to give advice on things like tyres without knowing how the bike will look.
An advice I can give for sure is, do not ever use old tyres, there is nothing worse than being surprised by rain and slippery roads and having an old dry rotten tyre...ask me about my ex-2008 front tyre that almost sent me into a ditch, and the 2001 rears that actually sent me in a guardrail in my old bmw e30, to know how I know LOL

11-24-2016, 3:48 PM
Well, I'm still continuing on the path of boring text updates but what you gonna do. Getting pissed how the build is pretty much stumped upon the tires.

I tried to do some rendering and copypasting on GIMP to get a picture out showing where I'm headed with the bike, but it just turned out shit everytime I tried. I just said fuck it, went with your and a couple others' advices and bought new tires. 145SR15 XZX Michelin for the rear and a Heidenau K34 3.5"x18" for the front. The front tire was a hard choixe too since I wanted vintage look but not a ribbed tyre however. Something just makes me doubt ribbed fronts ride wise.

I'll update some pictures as soon as I get the tires. Then I'm off to piecing the frame into two and starting to hardtail this turd.

01-14-2017, 4:48 PM
Let's get a quick recap to current form of the build. I'll try to keep the talking in minimum and just let the pics do the talking.

Was looking at the frame and thought "those bolts look ugly outside the frame tubing. Let's make them invisible."

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161108_203057_zpsnoyf0tv1.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161108_203057_zpsnoyf0tv1.jpg.html)

Like this:

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161108_203028_zps0mbrtcns.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161108_203028_zps0mbrtcns.jpg.html)

It didn't go quite as planned and I had to quit the job. The tap twister-holder-thingy broke and I had to get a new one

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161204_202933_zpsygs7llmb.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161204_202933_zpsygs7llmb.jpg.html)

I started molding the old gas tank mounts from the neck area with some bondo. Not quite ready here but getting there. Dont have a picture off of the finished product.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161204_202505_zps8dtcxhbs.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161204_202505_zps8dtcxhbs.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20161204_202518_zpsmzw8tn7o.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20161204_202518_zpsmzw8tn7o.jpg.html)

But I did see boomboomthump's shovel build thread, got inspirated and thought fuck it since I had nothing better to do at the moment. Here's his frame (sorry for posting your pics):


And here's mine after a good while with the good ol bondo. Not fully done on these, but the sides are almost finished so I'll let it slip:

http://i1280.photobucket.com/albums/a482/emppage/rebel/DSC_0485_zpsfqajkz86.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/DSC_0485_zpsfqajkz86.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/DSC_0488_zpskerl14br.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/DSC_0488_zpskerl14br.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/DSC_0487_zpsv00y5zjk.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/DSC_0487_zpsv00y5zjk.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/DSC_0489_zpshfi52r68.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/DSC_0489_zpshfi52r68.jpg.html)

Here you can see the inner arch of the neck finished too, this is pretty recent material. I was thinking of measurements for the axle plates and I ended up with these. You'll see them on the pics. I'll plasma cut these out of 8mm steel:

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170110_221933_zpsfmevtupv.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170110_221933_zpsfmevtupv.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170110_221945_zps9wiyoyuj.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170110_221945_zps9wiyoyuj.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170110_221958_zpsrdbwickm.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170110_221958_zpsrdbwickm.jpg.html)

Some more neck area:

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170110_222028_zpsdeueiuuj.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170110_222028_zpsdeueiuuj.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170110_222035_zpsyjp0t9fq.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170110_222035_zpsyjp0t9fq.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170110_222123_zpsyvn49iu9.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170110_222123_zpsyvn49iu9.jpg.html)

I shinied up the top triple and turned some straight into handlebar-risers.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170114_201024_zpsiic7kegf.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170114_201024_zpsiic7kegf.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170114_201058_zpsnxuo8leg.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170114_201058_zpsnxuo8leg.jpg.html)

Grinded and cleaned up the lower tree all around. I like the look of it now. This will be the mounting point for the headlight

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170114_201110_zpsxo1r3jgb.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170114_201110_zpsxo1r3jgb.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170114_203213_zpsqbbkb4lr.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170114_203213_zpsqbbkb4lr.jpg.html)

And this is from today. Mocked up the bike and tried to find proper stance but ended up giving up with it cause it just doesn't look right with the frame at that form. I need to get the tires, axle plates made, tubing, preferrably the tank and some other stuff before I start to mock the stance. Until that it's most likely break time.

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170114_200907_zpsg0diukob.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170114_200907_zpsg0diukob.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170114_203535_zpsklyzil9m.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170114_203535_zpsklyzil9m.jpg.html)

http://i1280.photobucket.com/albums/a482/emppage/rebel/20170114_203549_zpsuamcicxs.jpg (http://s1280.photobucket.com/user/emppage/media/rebel/20170114_203549_zpsuamcicxs.jpg.html)

And since I had the bike mocked a bit and found the right height but it looked bad, I thought to myself to make a little mock up image what im trying to do with it. This is what Fruttolo suggested me to do and now I (kinda) delivered. Still lacks the handlebars, motor, right tires etcetc but I'm not too bothered. It looks pretty good for me and I think I'm heading the right way with the shapes of the bike. Any feedback regarding the looks of the build are greatly appreciated.

http://i1280.photobucket.com/albums/a482/emppage/rebel/mopooumlljypenkkiaxed_zpsm6f4eh2k.png (http://s1280.photobucket.com/user/emppage/media/rebel/mopooumlljypenkkiaxed_zpsm6f4eh2k.png.html)


02-03-2017, 9:39 PM
What did you do to remove the rear fender bracket? How did you achieve that?

04-15-2017, 11:34 PM
Just wanted to bump to see if you were still doing this build?

06-26-2017, 10:05 PM
I guess he got in over his head and gave up