Honda Rc163 Replica, Getting Started

I have reached a point on the Astor where I need some bits so while I am waiting I thought I would have a better look at the rc163 project and try and work out how to approach it. Lots of bits need to be made or adapted to make them more authentic, I need to make 2 exhaust pipes for starters as mine has a 4 in to 2 arrangement and it needs to be 4 in to 4. I have to confess to having no idea whatsoever how to do this, I know I need to make a cone shape but have nothing to form it on, a quick call to a local company suggested it may be more difficult than I thought due to the thin end only being about 35mm, their rollers are too big. I shall see what I can find on youtube, somebody will have the answer. The rest of the job will be dead easy except the footpegs will definitely be in the wrong place. I'm not happy with them anyway, they are a bit of a bodge to be fair so making something better is no big deal. Ideally I don't want to be welding to the frame as it's very nicely powder coated but I should be able to make something that does the job and looks authentic - I am trawling the net for photos at the moment to build up a reference library.

I had another look at the handlebars and how they foul the fuel tank, trying to do something with them is rather tricky. Looking at some of the reference material I think the yokes are wrong so the bars are too close to the tank, I will have a look in my stash and see if I have something that will work but put the whole fork assembly further forward. I may end up having to make something custom but would rather do it so it looks mor original. No hurry to decide, that's a fair way out.

I had a sudden urge to make the tank restraining strap today, don't know why just fancied doing it. It's a fairly simple part to make except I have no idea what the original one was made from. My reference data helped a bit but you can't just go and look at one of these bikes so some of it is guess work. I guess the original was ally but I didn't have any so mine is steel, nobody will know when it's finished and painted. If anybody asks, I didn't tell you, right?  I suppose it could have been rubber but I don't think so as the photos I have seen appear to show the rear end of it being secured with a rubber band, which would not have been needed if the strap itself was rubber. I dunno, no doubt some anorak that has never built anything will go to great lengths to tell me the error of my ways the first time I show it. Anyway, I am well chuffed with how it's come out, I wanted it to look properly engineered and I think I succeeded. Don't care what anybody else thinks really, I am making it for me and I am happy with it.

The tacho works now, the in built battery was as flat as a pancake but took a charge from my regulated bench supply that I have from my electronics days. I might put a lithium one in there at some time, I will see how it goes. You can buy a charge lead from Scitsu - the folk that made it but I have more important issues first, like what the feck am I going to do about the fairing? I have neither the confidence nor skill to build one from scratch in either ally or fibre glass. I can buy a fully prepped one for about 800 quid but that stings. There are no used ones about at the moment and I doubt more than one in 5 years come on to the market so I may have to bite the bullet and spend the cash. I will definitely have to sell one of the other bikes first though, no matter, it can be one of the last things to do.

The coolant needs changing, I think it may not be the right stuff in there so it needs to come out sooner rather than later and the right stuff be put in, easy job but defo one for the to do list.

Quick update on the exhaust thing, I rewatched one of Allen Millyards excellent videos from 3 years ago when he was building his RC166 replica and he showed how to make the exhausts for that. I don't have anything like the master's skill but I will give it a go. Fortunately they have to be painted black so perfection is not required as it would be if they had to be chromed.