1978 Honda 400 Build

HUGE shoutout to @nububba for the bike!

Here is how the bike looked coming home from NH:

https://i.imgur.com/YpGrKTW.jpeg

Here is the bike in its former glory:

https://i.imgur.com/4jJpIMA.jpeg

Step one will be painting the frame. Considered powder coating, but not looking to spend a ton of money on this.

I have been holding off because of my broken collarbone, but my light project got me hyped to start another project.

I got the frame hung up. it was sandblasted years ago, but has developed some minor rust I need to clean up.

https://i.imgur.com/Lq2yIXk.jpeg

I plan on putting some dual sport tires on it, I think they will look cool.

something like this:

https://cdn11.bigcommerce.com/s-xnv6...1675097550.jpg

I look forward to this build, and I can envision both my kids getting their motorcycle license on this bike. I expect to have it for many years. Hopefully it just needs tires, fluids, brakes, a chain and a plug.

This will be my 4th bike rebuild, so I'm pretty comfortable with all this.

:twothumb:

Typically, Powder Coating isn't super expensive, if you were closer I'd say hit up Cobratec for a quote, dunno who to suggest near you.

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Originally Posted by Kurlon

Typically, Powder Coating isn't super expensive, if you were closer I'd say hit up Cobratec for a quote, dunno who to suggest near you.

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A friend of mine is going to a place in Troy for his RC51 wheels.

I was guessing like $3-400

I have an HVLP gun and some nice-ish automotive black paint I have from another project, so it would be better than a rattle can.

I believe this is what I have:

https://www.autobodytoolmart.com/pro...11a0458b849bf9

Fahk...laced wheels would look SO sweat on that. I'd motorboat it!

I may have just got talked into powder coating the frame and swingarm....

I always found the comstar wheels part of that bike's charm.

Attachment 61721

This is probably 1994-ish, not far from where I grew up. I wish I had a better copy of this photo.
Everyone in my family got their licenses on the back of that bike.

Quote:

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Originally Posted by nhbubba

I always found the comstar wheels part of that bike's charm.

Attachment 61721

This is probably 1994-ish, not far from where I grew up. I wish I had a better copy of this photo.
Everyone in my family got their licenses on the back of that bike.

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I think it's pretty cool my 2 kids will get their license on it as well!

Found a manual in the boxes!!!!!

https://i.imgur.com/SWcMTMU.jpeg

Quote:

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Originally Posted by xrocket21

I may have just got talked into powder coating the frame and swingarm....

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Frame and swingarm are dropped off for gloss black powder coat!!!

Put a mirror polish on the front fender with my son's help

https://i.imgur.com/ISP8Xru.jpeg

Frame and swinger have been sandblasted, ready for powdercoat

https://i.imgur.com/LZVqKwp.jpeg

Very cool project, keep the updates coming.

Nice blast cabinet!

Quote:

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Originally Posted by nhbubba

Nice blast cabinet!

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Not mine! That's at the powder coaters.

Dual Sport tires aren't going to happen, these just have an odd size setup. 100/90-19 front, 110/90-18 rear. I just ordered a set of Shinko 712's. They fit, aren't crazy expensive, and look okay

https://cdn11.bigcommerce.com/s-nhcb...1654809334.jpg

Internet search says SOME Comstar wheels need tubes, some dont.

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page62 said:
The Comstar rims to not require tubes; only the spoked rims do.

longdistancerider said:
Not quite true, some of the early Comstar wheel do require tubes. It really depends on IF there's a safety bead on the rim itself, not all have that.

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https://www.hondatwins.net/threads/1...-tires.119932/

IIRC that motorbike came to us with tubes in it and we always ran them.

Quote:

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Originally Posted by nhbubba

IIRC that motorbike came to us with tubes in it and we always ran them.

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Great, thanks!!!! Do you know why it has ONE fork boot on it? I was going to order one for the other side, and then noticed all the stock pics, as well as the pics you sent me never show any fork boots. I think Ill just run none, just didnt know where the one on it came from lol.

https://i.imgur.com/pyiXrSG.jpeg

Just ordered rear shock mount bushings as the powder coater had to remove them and they got destroyed as well as an AGM battery.

Ah, too bad the shinko 50/50 tires won't fit. That would look rad. But all these fat tire restomods must require a fair bit of modification to get the wheels to fit.

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Originally Posted by Paul_E_D

Ah, too bad the shinko 50/50 tires won't fit. That would look rad. But all these fat tire restomods must require a fair bit of modification to get the wheels to fit.

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Yeah, I'm bummed I can't put a better tire on, I was excited for that, but the tire sizes are just pretty odd. I spent not very long screwing around trying to find something I liked and ended up just going with something that will work.

Are you doing the spoked wheels? You could likely change sizes, but there would be some wrangling for sure.

Quote:

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Originally Posted by Paul_E_D

Are you doing the spoked wheels? You could likely change sizes, but there would be some wrangling for sure.

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No, sticking with the stock Comstar wheels

https://i.imgur.com/4jJpIMA.jpeg

This is a low budget build.

I found partzilla very helpful finding small missing parts and part numbers. if you didn't already use them.

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Originally Posted by MUZ720

I found partzilla very helpful finding small missing parts and part numbers. if you didn't already use them.

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I use hondapartshouse.com but pretty much the same thing. Thanks for the tip though.

Did a simple spray wax on the tank, and I think it looks great for a 1978

https://i.imgur.com/EPOzJXM.jpeg

But there is some chipping on the bottom. I'm not really worried about it cosmetically, I am more worried about it rusting. Any way to repair this without painting the whole tank?

https://i.imgur.com/Xm6hLFb.jpeg

I'm thinking find some Rustoleum that's a close match and carefully painting it on?

Those paint chips have been like that since I was 17 or so. I had that tank on and off a gazillion times.

Boot on the shock was me fucking around. I had visions of a scrambler kind of look. Wouldn't be surprised if there is the other boot somewhere in one of the tubs I handed you.

Attachment 61775