2017
My CX500 project started back in August 2015. I’ve always had a passion for making, design and motorcycles, but had yet to combine all three. The opportunity presented itself after I won an auction for a box of bits which made up a 1978 Honda CX500. It was in a sorry state and hadn't run since 1985. With a tight budget and eagerness to learn new skills, I planned to do all the work myself and where possible make performance upgrades. I wanted a clean cafe racer/brat aesthetic to showcase the unique transverse V-Twin power-plant mixed with some modern touches. Equipped with an owner’s manual I got straight to work tearing down the bike, rebuilding, replacing and modifying as I went.
I created a concept render and designed all of the parts including the new subframe, in CAD. I don’t have an elaborate workshop or fancy tools and was often working where I could. Friends garages, my living room floor and my parents shed. Over the next year and a half I cleaned, rebuilt, and restored down to every nut, bolt and washer entirely myself.
It’s been a great project which has taught me a multitude of valuable skills. In a bitter sweet end, I have now put the bike in storage as I have relocated to the UK. However, before leaving I managed to get a couple of rides on the bike which I will never forget. There’s nothing quite like riding a bike you've invested money, hard work, time, and above all passion to bring life back to an old machine.
Before August 2015
I purchased the donor bike off a man who intended to do a full cafe racer build but with a young family and stressful job, didn't find the time. Prior to that, the original owner was an elderly women who used to ride with her husband. After he passed away the bike was left outside and hadn't run since 1985. It had suffered years of neglect and had obviously had a hard life when it was running. Rust, rotten electrics, dents, cracks, missing parts, you name it (my personal favourite is the bodge job of a cracked clutch cover). However, I saw the potential and wasted no time stripping the bike down.
After March 2017
There has been extensive modifications to this bike. No part has gone back on which hasn't been rebuilt, modified or replaced entirely.
Custom designed, fabricated and certified rear subframe. I designed this all in CAD. The steel tube was CNC mandrill bent, while the spacers, lugs and suspension mounts were CNC machined.
3D printed, flush mount LED tail light with indicators.
Engine tuned, full fluid change, rebuilt where needed, and seals/gaskets were replaced. I then scrubbed, chemically cleaned and painted the engine with bake-on high temp enamel with a mix of satin and gloss. All hardware was replaced.
Cooling system was fully rebuilt.
Custom built radiator overflow reservoir relocated to clear space for electronics.
Carbs were fully rebuilt and re-jetted to run the K&N pod filters and high flow exhaust.
Stainless steel reverse cone 'shorty' exhausts with heat wrapped headers.
Handmade wiring loom to accommodate the new electronics and replace the rotten OEM loom. New gauges, headlight, LED indicators, tail light, digital coolant temp gauge (mounted under tank), horn, charging system with MOSFET regulator/rectifier, starter solenoid, blade style fuses and hidden lithium-ion battery.
Front end fully rebuilt and stiffened.
Trimmed front mudguard
Rebuilt front brake with stainless steel braided line and new master cylinder.
Rebuilt rear brakes with stiffer stainless steel brace and new pads.
Custom built Hagon rear shocks, straight from the UK factory.
Custom built composite seat with leather upholstery.
Gas tank was repainted in a cream white from a 70's Porsche colour code. Internally treated and sealed. Gas tank was relocated rearwards and raised in the rear to straighten the lines of the bike.
Custom designed and built rear sets to provide a 'cafe racer' riding position on the bike. Made from aluminium, carbon fibre and steel. Stainless steel linkages.
Clip-on bars with bar-end mirrors and rebuilt OEM switch gear.
Handmade leather lever grips.
Aluminium license plate bracket with discrete LED lights.
