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                        1965 Honda CP77 — Ulsan Metro City, Rep. Korea
                        Restored with original parts — Owner: J. Doe
                    Missing plastic and tin bits
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				Geoff Hastings
 - honda305.com Member
 - Posts: 374
 - Joined: Wed Feb 22, 2017 2:59 pm
 - Location: Epsom, Surrey
 
Missing plastic and tin bits
As I can't bring myself to pay the rediculous us postal rates and then customs duty I've had to improvised on my CA77 restoration. The carb covers were quite simple and I was quite pleased how they turned out. The plastic rear shock covers I made from 1mm thick sheet steel and cut the end pieces with a jigsaw and welded them up. The chain guard was one I bought brand new for a 125 Honda, it only cost £20 and the top section fitted with almost no modification except to relocate the fixing holes, the lower section however needed additional metal added along its length and a couple of captive nuts attached. If you look closely you can see the joint is upside down but as it's not an oil bath I can live with that. It also needed a skim of two pack filler to hide the seam where I had welded it up and then a coat of paint. Oh yeah, just remembered, I also made the air filter cover and the battery bracket that retains the filter cover and the battery. I used photos from eBay and obviously used my bike to get accurate fitting.
			
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				LOUD MOUSE
 - honda305.com Member
 - Posts: 7818
 - Joined: Mon Aug 15, 2005 8:23 am
 - Location: KERRVILLE, TEXAS
 
Re: Missing plastic and tin bits
the rediculous us postal rates and then customs duty ????????????????
WHO gets the $$$$?. ................lm
			
			
									
									
						WHO gets the $$$$?. ................lm
Geoff Hastings wrote:As I can't bring myself to pay the rediculous us postal rates and then customs duty I've had to improvised on my CA77 restoration. The carb covers were quite simple and I was quite pleased how they turned out. The plastic rear shock covers I made from 1mm thick sheet steel and cut the end pieces with a jigsaw and welded them up. The chain guard was one I bought brand new for a 125 Honda, it only cost £20 and the top section fitted with almost no modification except to relocate the fixing holes, the lower section however needed additional metal added along its length and a couple of captive nuts attached. If you look closely you can see the joint is upside down but as it's not an oil bath I can live with that. It also needed a skim of two pack filler to hide the seam where I had welded it up and then a coat of paint. Oh yeah, just remembered, I also made the air filter cover and the battery bracket that retains the filter cover and the battery. I used photos from eBay and obviously used my bike to get accurate fitting.
- 
				LOUD MOUSE
 - honda305.com Member
 - Posts: 7818
 - Joined: Mon Aug 15, 2005 8:23 am
 - Location: KERRVILLE, TEXAS
 
- 
				Geoff Hastings
 - honda305.com Member
 - Posts: 374
 - Joined: Wed Feb 22, 2017 2:59 pm
 - Location: Epsom, Surrey
 
Re: Missing plastic and tin bits
LOUD MOUSE wrote:the rediculous us postal rates and then customs duty ????????????????
WHO gets the $$$$?. ................lm
Geoff Hastings wrote:As I can't bring myself to pay the rediculous us postal rates and then customs duty I've had to improvised on my CA77 restoration. The carb covers were quite simple and I was quite pleased how they turned out. The plastic rear shock covers I made from 1mm thick sheet steel and cut the end pieces with a jigsaw and welded them up. The chain guard was one I bought brand new for a 125 Honda, it only cost £20 and the top section fitted with almost no modification except to relocate the fixing holes, the lower section however needed additional metal added along its length and a couple of captive nuts attached. If you look closely you can see the joint is upside down but as it's not an oil bath I can live with that. It also needed a skim of two pack filler to hide the seam where I had welded it up and then a coat of paint. Oh yeah, just remembered, I also made the air filter cover and the battery bracket that retains the filter cover and the battery. I used photos from eBay and obviously used my bike to get accurate fitting.
- Attachments
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- As a follow on, I wanted to do as much of the restoration as I could. I took photos of the wheels and the spoke pattern before stripping and polishing the hubs. I got the stainless spokes from Tailand and the rims in the uk. Trueing them up is not as hard
 - image.jpeg (282.19 KiB) Viewed 2725 times