My 2nd CF70 Chaly restoration report

extermin8tor · 2014-01-16T01:42:42+00:00

Hi guys and girls, My name is Alex, I'm a bike and car enthusiast in my 20's - started a restoration on a Chaly a few years ago, but never completed it 100% and I sold it for $150: http://www.aussiestreetbikes.com/forum/ ... p?t=12843I It actually comes up as first google search for 'honda chaly' (at least in australia). I've since got more resources to do a proper restoration, so recently I found a grungy looking Honda Chaly in red colour on GumTree for $550. Bargained down to $400. I feel I paid a bit much for a basket case that had already had the engine dropped out. Luckily this one had been previously registered in Australia which is great so its a lot easier to re-register once its rolling. Luckily the last owner gave a few bits like spare head, spare valves and some gaskets here and there. This is she: Original 6700 miles on the old girl: Petrol tank looking grungy: Absolutely everything covered in rust: The Shocks need replacing: Front wheel was totally gone: Once stripped off it had major rust holes in the wheels on the front, the rear had old chain grease protecting it: The engine casings are aluminium so they restore well, this is before any work: Tried restoring the chain guard but its too pitted, too expensive to rechrome so I've put it into a pile for rainy day: I love how you can rebuild nearly every honda component. I took apart this entire lock and rebuilt it in 5 minutes. Polished the lock shaft, painted the housing: Just the swingarm, in good condition just surface rust. Took quite a while to derust. In hindsight sandblasting is so much easier. I had to rebuild some of the stripped screws on the carb and gave it a polish and lick of engine paint: How does she look?: This is my growing pile of restored bits: Starting to strip down the frame and prepare it for rust repair: The last owner took the bike apart to fix a smoking problem. Turned out it had bent intake valve if I remember correctly. I replaced it with a spare from extra head. It wasnt in great condition but after a clean and seat grind it should be fine. Ideally I would fit a new valve at some point: Old owner handily included a brand new piston and bearing for the 70cc engine: Some idiot at some point welded the kickstarter pedal onto the shaft, god know why. I had to grind it off to remove the housing. I had to sacrifice the kickshaft rod. Have ordered a new one from CMSNL Grotty engine casing was lightly wire brushed by hand, then sprayed with paint stripper and then painted with good quality engine enamel. Growing pile of bits: Wheels were positively grotty and the tires were 40 years old. Dated 1974 All the aluminium cleaned up easily with wirebrush and engine paint: I decided to keep the bike as original as I could, I ordered about 80% OEM parts. some little unobtanium knick knacks like headlight housing I had to source from thailand. I wanted to paint the bike a custom colour like metallic blue however I wanted to keep it original so I had the choice of Red Green or yellow. Red makes the bike look like a cheap Postie (Honda CT110) bike and I didnt want that when I would be asking top dollar if I sold the chaly. I decided on yellow so I got some Honda Y-56 Sunset yellow from a honda civic matched up in 2 pack paint and I shot the frame in one go with my new compressor: Has a mirror finish! Whats the opinion, lads?: Replacement badges on: Knocking the bits together for a mockup photo while I wait for critical parts from overseas: Currently the frame is together, waiting for the 47 degree celcius heatwave to be over here in Australia, then going to source new 10mm bolts for the wheels and then started changing the kickstarter on the engine. Then I have to bolt the loom in and start wiring up everything! Cheers, More progress soon!

Started by extermin8tor · 10 replies · 8896 views

Cosmic-WizardStandard MemberPosts: 23
Joined: Feb 2014

Re: My 2nd CF70 Chaly restoration reportSat Apr 19, 2014 4:32 pm

That's a lovely job you've done there mate

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