1978 Honda 400 Build

[jim v]

Terrific stuff Xrocket.

Back in my younger days I would've skipped right by this thread - old Honda, searching for parts, whatever. Now this is right up my alley

Hope your collarbone is healing up!

[xrocket21]

Terrific stuff Xrocket.

Back in my younger days I would've skipped right by this thread - old Honda, searching for parts, whatever. Now this is right up my alley

Hope your collarbone is healing up!

Thanks! I'm glad my efforts aren't wasted. It's fun to document things and be able to look back.

I agree, I wouldn't really see myself getting too excited about a 1978 aircooled Honda 400 lol, but here we are.

I have really grown to believe it will basically be both my kids first bike and they will get their licenses on it.

It is frustrating to stall out and not be able to make good progress these days, but I can't really ride it anyway, but it HAS taken over my garage for quite a few months now.

Collarbone... well, its been broken for 10 months now, and it has felt broken the entire time. I THINK I am on the upswing, but still can't really use it. I would really love to be better by Ju ly, as JDay is doing a new 6 hour team race at Hemonds that I'd like to run with the boys.... But I don't have high hopes. Thanks for asking!

Any bites on the RC51? How are you healing since the crash? Are you able to ride at all?

[jim v]

Thanks! I'm glad my efforts aren't wasted. It's fun to document things and be able to look back.

I agree, I wouldn't really see myself getting too excited about a 1978 aircooled Honda 400 lol, but here we are.

I have really grown to believe it will basically be both my kids first bike and they will get their licenses on it.

It is frustrating to stall out and not be able to make good progress these days, but I can't really ride it anyway, but it HAS taken over my garage for quite a few months now.

Collarbone... well, its been broken for 10 months now, and it has felt broken the entire time. I THINK I am on the upswing, but still can't really use it. I would really love to be better by Ju ly, as JDay is doing a new 6 hour team race at Hemonds that I'd like to run with the boys.... But I don't have high hopes. Thanks for asking!

Any bites on the RC51? How are you healing since the crash? Are you able to ride at all?

Part of the excitement of the 400 must be sharing it with your kids. Passing down the knowledge that you've built up over the years to the younger generation is a good feeling

I'm doing great, a complete recovery, physically and mentally. Even back to playing basketball one night per week. Took a few rides in the fall and plan to get the VFR out whenever the rainy weekends stop. Signed up for some track days as well - some of my friends think I'm crazy. Hell, I think I'm a little bit crazy.

Hope the collarbone keeps making progress. Be easy with it, we're older now and takes longer for things to heal, don't push it too hard. Easy to say from here though

RC51 has been sold, hope it treats you well Ben. He has a mint RC51 with NLA mods - Satos, that sort of thing - more a collector bike. He wanted a rider that he wouldn't worry about, that RC fills the bill. Its in good hands

[xrocket21]

Pretty stalled on progress trying to figure out what to do about the missing mounting tabs.

All that is left at this point is the wiring harness, blinkers, mount battery and rectifier/figure out tabs, hook up the cables to the carb, change the oil, and mount the tank and seat!

I couldn't help it though, I dropped it off the hoist and put the seat and tank on and I think it looks pretty cool!



One question though, I think there is some sort of stop for the center stand missing, in the up position it hits the rear brake rod and the chain, it just swings up too high, but I don't see any empty mounting points for a stop.

Oh, and also I have to figure out how to mount the mufflers, I think another mount is missing.

I should be hearing from that guy local about buying that parts bike, that would answer most all my questions.

[xrocket21]

So, what you're supposed to do with a motorcycle project, is work on it all winter then in the spring around April, you stop and let it sit all summer parked in your way, right?

I started attempting to re-create the side panel, battery box, and cdi mounting tabs out of Kydex (thermoformed plastic).

This tab will double sided tape to the frame for the sidepanel:





Then this tab wraps around the frame some and will be double sided tape too, but I think I will also drill 2 holes and zip tie around the frame too becasue it will need to hold up the battery.





The tape is 3M VHB (very High Bond). With a good clean smooth connection, it is very strong, we will see though.

Also just ordered a kickstand stop, a passenger side exhaust shield, and some new grommets for the body panels.

[xrocket21]

All these other guys posting about their projects/builds got me inspired.

Built and installed the tabs. I am pretty confident they will work, if not they can be templates for metal. Pretty sturdy though. Rainy weekend, so I have high aspirations of doing this to the other side, installing the wiring harness, changing the oil, then attempting to fire the thing this weekend!



Battery fits



Side panel snaps on and off nicely

[xrocket21]

3 of 4 tabs done

[csmutty]

Fixed.

[xrocket21]

Your photoshop skills are impeccable!

Got a third tab fabbed, the last one is really gonna be a bitch



Got the oil changed and a new filter as well as a new drain plug so it should stop dripping oil now!



I had hope to start it this weekend, but I still have 1 more tab to make and mount the rectifier, install the exhaust, and finish the wiring harness. Soon though. I hope it starts.....

[xrocket21]

Had to take a mulligan on the third tab, I attached it with no way of getting a nut or bolt in, so I peeled it off and made a stud setup.





The rectifier mounts pretty well so far



Bought some new grommets! Only the good stuff! Best Quality! Genuine Parts!



but they are toooooo tight compared to the originals, Im going to have to open them up a bit. It just takes too much effort to snap the panels in and out with them.

[typeone]

Grasshopper say, Better too tight than too loose.

[xrocket21]

Grasshopper say, Better too tight than too loose.

But its a snap in snap out situation, and these tabs are just held on with double sided tape! When I yank on the side panel, I don't want to yank my homemade tabs off too! Each panel hangs from a vertical hard pin on top, then 2 snaps. The old ones had a nice click to them, but thye are cracking and coming apart, the new ones..... I almost can't even press hard enough to get them to pop in.

This last 4th tab is going to be a real bitch because of where it lies. Not quite sure what I can do yet.

Also, I think I discovered I need to pull the airbox and carbs to be able to attach the throttle cables and the choke cable, I don't think I can do it in place.

[typeone]

i am sorry my joke failed so badly.

[xrocket21]

i am sorry my joke failed so badly.

lol my bad

[typeone]

lol my bad

s'all good. i don't have anything constructive to say except that i'd be fiddling with the same ideas ... on the tight fit, i'd try a round Dremel attachment to ease up the female rubber, then use some grease on the male pin. but i get it on double-sided mount.

[xrocket21]

Shits getting real when you get the cardboard and scissors out



It proved to be very difficult shaping two ends at once....



Some cutting and drilling. Got way too close to the stud hole, but ya can't put it back on after you cut it off.



Actually not a bad fit. it is attached with 3m tape and zip ties



Rectifier/fuse block mounts okay, a little floppy, I think I need to replace the rubber mounts.



Cover also snaps on okay.



I think I need to heat the piece up again and push the mount in toward the bike a bit to tuck everything in better.

Pretty glad these mounts are done, it really stalled out the project.

What's left:

-Hook up choke and throttle cables
-finish exhaust
-run wiring harness
-mount blinkers
-bleed front brake

I think that's it?

[loudbeard]

Awesome. Should be ready for snow riding?

[xrocket21]

Awesome. Should be ready for snow riding?

yeah, I know!

These tabs missing really made me set the project aside for.... 6 months.... through the entire summer lol

I think I put 200 mile on the RC8R so its not like I missed out on riding.

Maybe next summer?

[xrocket21]

Well, I haven't touched it for 6 months....

Got the choke and throttle cables attached



I know the cables move freely, but when I have them in, the routing does not look correct at all, they rest right on the head, and they bond severely as well.

[nick5446]

Yeah...those look like they're probably 2" too long. Did you change the bars? If you start zip tying them to the frame you can probably pull them back a bit and make them work.

[xrocket21]

Yeah...those look like they're probably 2" too long. Did you change the bars? If you start zip tying them to the frame you can probably pull them back a bit and make them work.

The bars are different now that you mention it. I think I am going try to route them in front of the forks.

I still have an oil leak too, and I replaced the damaged stock plug which looked to be the source.

All that's left right now is front brakes, wiring harness, blinkers, mufflers. SO CLOSE! Maybe actually ride it this summer? If it starts?