1963 Honda CB77 Superhawk

Ever since owning a CB160 Baby Hawk, I wanted to get the original SuperHawk - CB77.   They were always hard to find in restorable condition.  If I saw any, they were already restored and with a high asking price.   I found this one on the local Craigslist ads, where I find most of my bikes.   There was no picture just a number.  I looked at it and it was in sad shape.   Repainted gold then black and it was originally white.  It had not been started for seven years and it sat mostly outside under a tarp.  The rust was not bad, the tank inside was fairly clean and the numbers matched.  It was only really missing the correct bars and exhaust.   After selling the cb175, I went back and bought it.   Cool!!  I can't wait to tear it apart!

Here are the clip-ons fitted.   They were a little too wide.  So I cut off an inch.   I may cut more.

almost there!

11/07:  All the parts are now bagged and tagged.   Next, I took pics of the parts with the matching bolts.   I'll be plating everything so all the parts will get mixed up.

After several attempts to start it, I found the compression to be really low (60-70 psi).  Wow, not even enough to create a combustion!

11/16:  Here are the pistons.  The top two rings were pinched in the grooves and did not provide any sealing.   The second picture shows part of the ring still stuck.

Here's the head.  Pretty rich on the right while lots of rust on the left.

I put in some phosphoric acid.   One - cleans all the surface of the rust and carbon deposits.  Two - it checks for valve leaks.  I twisted the valves with a screwdriver a few times until the slow leaks stopped.

Here it is after cleaning.  Much improved!

I used some stripper on all the painted parts to get off the paint. What a mess!   I should have just blasted it from the start.

12/01:  Here is a shot of my sandblasting/paint booth.  I just tape up some plastic and its all set.  I use a 40 lb pressurized blaster.  Should be ready in a couple days.   Still blasting the small crevices that are hard to get to.

12/12:  The powdercoating is done!   I powdercoated the frame, swingarm, center stand, headlight shell, bottom triple clamp and the tank bracket.  Looks like a great start to a cool project!

The swingarm is missing because the shock bushings are getting replaced.  I will be pressing in the new bronze pivot bushings when I get it back.

12/15:  I started to sand the hubs, first with 400 grit wet paper.  I will follow up with 600, 1000 and 1500.  Then I will polish it.  These are after sandblasting and 400 grit.

Here are the spokes after soaking in Super Agitene and rubbing with ScotchBrite and a brass brush.

12/16:

Today, I got back the swingarm with the shock bushings pressed in.   I pressed in the new pivot bushings with a vice.

Here, I start the build!   I fitted the swingarm and shocks.  I had to polish the powdercoating on the frame for the swingarm to fit.  Tight!   No bolt or hardware yet since I need to get them plated.  I got some Rustoleum enamel and brush painted the grease caps.