CB500T Turbo Punsun Hardtail Bobber

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DieselFly
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CB500T Turbo Punsun Hardtail Bobber

Post by DieselFly » Tue Oct 20, 2009 1:25 pm

We are back at it here in Canada and this year we are building two street legal bikes. I got a call from the freight company and the three engines we ordered direct from Punsun have hit the dock in Vancouver. We have purchased to rolling frames from the salvage yard for conversion. These bikes will be built up as classic hardtail bobbers as we don't plan on using them for long trips. We are going to install the Comet 94C duster CVT set up with a geared top speed of about 105 kph. This will give us good bottom end in town and still allow for use on secondary highways as the limit is only 80 kph (50mph). I am doing both bikes in my high school class here in Napanee Ontario. The students are currently finishing there skill building projects and four are already onto our CAD program for 3D tube structures. I will start posting pictures as soon as we are out of the design phase. Spring can't come soon enough :twisted:

Sean
Last edited by DieselFly on Mon Apr 30, 2012 8:22 pm, edited 2 times in total.
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: Honda cb500T Punsuns

Post by Curtis in Texas » Tue Oct 20, 2009 1:30 pm

DANNNNGGGG! All I got to build in Shop Class was horse trailers.

Way to go. Keep us posted with pictures.

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Re: Honda cb500T Punsuns

Post by DieselFly » Mon Nov 02, 2009 5:05 pm

Engines are in customs hope to pick them up from Toronto tomorrow. I faxed off the order to CVTech for two sets of clutches four belts and two calibration sets. At $258 cnd per set they are a bargin as the Comets were $299usd. plus $33 per belt then the springs and weights are on top of that. The driven clutch will still stick out like a sore thumb just like the Comet but we will work around this. Frame design is progressing the students have finished the centre line drawings and will move to the 3D tube CAD program this week. We should be cutting tube by the end of next week.

Sean
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: Honda cb500T Punsuns

Post by Sphere » Tue Nov 03, 2009 5:00 pm

I think it would be helpful if you posted partnumbers that amount to "a complete set" so people interested in getting a CVT drive train will have a feel for what is required. Price difference is indeed staggering.
'92 Enfield + Hatz 1B40: street legal, weld up stainless exhaust, check engine rpm and change final drive sprocket.

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Re: Honda cb500T Punsuns

Post by DieselFly » Tue Nov 03, 2009 8:21 pm

My friend and partner in the V twin project howed up an hour ago with our three new Punsun. They are now in the back of my Santa Fe for the trip to the school.We will fire them up to make sure they run okay and let them run in for a few hours each then drain the oil cut open the filters and look for chunks.
Sphere here are the part numbers and prices for the CVTech parts.
06 Serie drive clutch p/n 0600-0021 $120.00
LP3 driven clutch p/n 5600-0171 $ 70.00

Calibration Set
Driver pulley spring White/green/white p/n 0651-1100 $5.00
Driver pulley spring silver/pink/yellow p/n 0551-1119 $5.00
Driven pulley spring orange/silver/yelow p/n5051-1015 $10.00
275 weight p/n 0135-3065 $5.00 You need three of thses for $15 total
The belt I have chosen is a 242mm centre to centre distance at a cost of $16.87 each
Contact CVTecfor more details. They also make a CVT that allows engine braking but I did not ask the price. I'm going to have to rethink our final drive as the new clutch has a high ratio of .43:1 more overdrive than we need
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: Honda cb500T Punsuns

Post by DieselFly » Mon Apr 26, 2010 1:33 am

Okay the snow is gone the birds are singing and our bikes are almost done. We still need to design seat mounts, battery mount and fuel tanks. The next step is the paint shop and as luck would have it our school has one of those also. Enjoy the picture

Sean

15004_397777489864_516439864_3937993_1864931_n.jpg
CB500T Punsun Cvtec
Finished and riding 1975
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Re: Honda cb500T Punsuns

Post by coachgeo » Mon Apr 26, 2010 2:43 am

DieselFly wrote:...
What model CVtech is that?

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Re: Honda cb500T Punsuns

Post by IgorVigor » Mon Apr 26, 2010 10:08 am

Looking good :)

Only thing that I am not so keen on, is the exhaust.

I personally prefer on a cruiser for them to be stacked on one side... :oops:

But thats each to their own really... :)

I am thinking of building a hardtail diesel cruiser...

I was thinking for a seat about using an old tractor seat, and spring :P
For the agricultural look :D

What is that back wheel of btw?

And when will you post a video of it running/riding :P

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Re: Honda cb500T Punsuns

Post by Sphere » Mon Apr 26, 2010 10:10 am

I take it the frame required elongating by over 60mm :mrgreen:
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Re: Honda cb500T Punsuns

Post by TedV » Mon Apr 26, 2010 3:48 pm

coachgeo wrote:
DieselFly wrote:...
What model CVtech is that?
Coach, look up a post or 2. :wink: :lol:

My question is on the pricing, is that a price break for schools? I know they have some special pricing for the SAE students making Baja and FSAE cars.

I've emailed CVTech and have not received a reply. Better to call them??

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Re: Honda cb500T Punsuns

Post by DieselFly » Mon Apr 26, 2010 8:09 pm

The price we paid for the first one was $100 through the Mini Baja sponsorship and $258 for the second one. What I'm thinking is if they work very well and enought people want then we could set up a group buy to keep the price cheap. I plan on spending the summer playing with the weights and springs to find out what works with this engine. I gave Sphere the contact email address so he can find a EU dealer. I would also like to try their unit that has the engine braking so I can put an exhaust brake on just because it would sound so cool. I'm thinking another six weeks till we are on the road
sean
TedV wrote:
coachgeo wrote:
DieselFly wrote:...
What model CVtech is that?
Coach, look up a post or 2. :wink: :lol:

My question is on the pricing, is that a price break for schools? I know they have some special pricing for the SAE students making Baja and FSAE cars.

I've emailed CVTech and have not received a reply. Better to call them??
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: Honda cb500T Punsuns

Post by DieselFly » Mon Apr 26, 2010 8:16 pm

We did a 100mm stretch just for looks. We built 90% of the frames and kept the part with th serial number for registration and insurance reasons. The rear wheel is off a CX650

Sean



Sphere wrote:I take it the frame required elongating by over 60mm :mrgreen:
Last edited by DieselFly on Mon Apr 26, 2010 10:22 pm, edited 1 time in total.
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: Honda cb500T Punsuns

Post by Sphere » Mon Apr 26, 2010 8:23 pm

Well, if it would fit in a honda frame that would not elongate the wheelbase by more than 60mm, it would be legal without extensive recertification procedure in Holland :)
'92 Enfield + Hatz 1B40: street legal, weld up stainless exhaust, check engine rpm and change final drive sprocket.

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Re: Honda cb500T Punsuns

Post by DieselFly » Mon Apr 26, 2010 10:28 pm

Sphere wrote:Well, if it would fit in a honda frame that would not elongate the wheelbase by more than 60mm, it would be legal without extensive recertification procedure in Holland :)
I measured the bike we built last year from an old RD350. If the vertical support was 2.5cm further back from where we put it the Punsun would drop right in. We did not alter the wheel base on that bike. As you can see there is lots of room behind the driven clutch to take 40mm away you would stll have alot of room for the battery
:twisted:
Sean
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: Honda cb500T Punsuns

Post by DieselFly » Mon Apr 26, 2010 10:37 pm

TedV wrote:
coachgeo wrote:
DieselFly wrote:...
What model CVtech is that?
Coach, look up a post or 2. :wink: :lol:

My question is on the pricing, is that a price break for schools? I know they have some special pricing for the SAE students making Baja and FSAE cars.

I've emailed CVTech and have not received a reply. Better to call them??
They are sometimes slow to respond. I have had luck phoning (It helps if you speak french) There are several companies that sell there products for the ATV market but I'm not sure of the retail price. Comet was purchased and may be back on the market from what the website says

Sean
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: Honda cb500T Punsuns

Post by coachgeo » Wed Apr 28, 2010 2:38 pm

TedV wrote:
coachgeo wrote:
DieselFly wrote:...
What model CVtech is that?
Coach, look up a post or 2. :wink: :lol:
...
Well smack ma self with a 2x4.. see it now. thanx

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Re: Honda cb500T Punsuns

Post by DieselFly » Tue Jun 22, 2010 8:43 pm

Okay the end is insight. I have finished the fabrication now it's off to the spray booth lucky for me our school also has a complete body shop. I will then bring all of the parts home and do the final assembly and wiring in the garage durning summer holidays. The good part of doing it at home is I get to spill beer on it while working :twisted: . The second bike is about one week behind and My friend will be home from work in Korea for a couple of weeks so we can knock off rest of the fab on his. Our plan is to use spray can for this summers paint ride the bugs out then give them proper paint work over the winter

Dreams of black smoke whirling through my head
Sean
Bike Right side.jpg
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: Honda cb500T Punsuns

Post by albertaphil » Wed Jun 23, 2010 7:02 pm

Looks great! Are you putting the sheet metal back on the engine?

Phil

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Re: Honda cb500T Punsuns

Post by DieselFly » Wed Jun 23, 2010 7:19 pm

albertaphil wrote:Looks great! Are you putting the sheet metal back on the engine?

Phil
Yes the cover was off getting the big dent from shipping out of the bottom and a cover over the hole where the oil cooler was mounted
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: Honda cb500T Punsuns

Post by DieselFly » Fri Aug 06, 2010 7:39 pm

Its alive!! I finally have had some time to get at my bike and do the final assembly. I'm still short a front brake line (on order) and a cover for the CVT which I'm currently working on. I took it for a slow run around the block 25mph the CVTech clutch is very smooth. I should have the MTO inspection done and the plates on next week I hope. I wll get some video of it in motion when it has plates but here is a taste to get you started. http://www.youtube.com/watch?v=MRadb91o-pc
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: Honda cb500T Punsuns

Post by BoxerOtto » Sat Aug 07, 2010 2:29 am

nice job!!! i have the same type of engine kill. GO CANADA!!!!!

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Re: Honda cb500T Punsuns

Post by Stuart » Sat Aug 07, 2010 8:21 pm

Excellent job there Sean :D I've taken the liberty of tweeting a still of the bike and the video. The bike sounds good too which is important. Should be a real head turner :D

Stuart
Attachments
DieselFlys Bike.jpg
Still from the Video

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Re: Honda cb500T Punsuns

Post by DieselFly » Tue Aug 10, 2010 9:50 pm

I'm still waiting for a front brake line the local shop I ordered from did not phone to tell me it would arrive in October. I found the hose and fittings they are coming from the states I finished the CVT cover and took three stiches in the process when a drill bit snapped and I jambed the stub across my finger. The good news is it was my left hand. The better news is it was my middle finger very handy to signal other drivers with. Here is a picture the CVT cover featuring a stainless steel bowl from Wal Mart. Big expense for a custom spun cover at $6.

Sean :P
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Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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cb500T Punsun Hardtail Bobber 1000miles

Post by DieselFly » Mon Sep 27, 2010 12:59 am

Turned over a 1000 miles on the bike since the build. Other than twisting the jack shaft in two at 953 miles it has been very reliable. I have been trying to source some hardened slotted shaft no luck yet I may just change it out for 1" when the snow flys. The front head gasket is weeping when the engine is cold. I have taped over the oil cooler and will start chocking off some of the air to the fan to keep some heat in the engine. The bike is a little buzzy with vibration at 30mph so I ride above or below that speed in hope it will live longer but so far the Punsun has been flawless. I have a tiny tach on my Christmas list so I can collect better data. I also want to put a oil temp and pressure gauge on it. It still turns heads and draws a crowd any place it stops. My wife says its like dropping a chocolate in the middle of a weight watchers meeting. I have turned the max fuel stop in 16 turns and now have blue smoke only under hard acceleration. I passed a car a few weeks back that was well under the speed limit and wandering down the road the guy was texting while driving and his window was down. You know what happened next :twisted: as I pulled along side I cranked it and smoked the bastard out I'm leaving the screw where it is the smoke screen is handy. I plan on getting at the final build up of the second bike this week I have till spring to finish it and will tear mine down for paint and inspection.

Sean :lol:
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: CB500T Punsun Hardtail Bobber

Post by DieselFly » Fri Jun 17, 2011 1:34 pm

I rolled over 2000 miles yesterday and other than a breaking the Jackshaft off I have had no other failures. I have been riding the bike to work every day I can . Each trip on the bike saves me $12 in fuel cost and this adds up fast. I took to cheap $7 mufflers ment for 10hp and up engines welded to a short piece of pipe and made two slip on mufflers. These are all metal baffles no glass and work much better than I thought. They don't seem to affect power or mileage. All you here now is the knock of the engine makes. Keeps the peace when I ride to work at 7am. It take five minutes to put them on or take them off. The tiny tach is working like a champ.

Sean
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: CB500T Punsun Hardtail Bobber

Post by balboa_71 » Mon Jun 20, 2011 11:42 pm

DieselFly,
That is a super cool build! I don't know how I missed it here on the forum, but have to say it is and "A1" build!!! The Punsun engine is cool and starts easier than the single cylinder units from what I saw. I have the same brand of battery, mine is a PC-625 and can give me trouble from time to time if I don't stay on top of it. There has been some discussion regarding the torque converter brand you're using and to be honest, I don't know how to communicate with the manufacture to get any usable information on specs, cost and who to talk to regarding a US dealership and buying parts/components here.
It sounds like they only supply colleges and OEM folks...that doesn't make much sense to me, not wanting to sell to the public. Good luck with the safety check and getting 'er out on the road :D

Cris
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Re: CB500T Punsun Hardtail Bobber

Post by naron » Thu Nov 10, 2011 6:00 pm

Awsome work. Now that I suppose you've worked out the ratios to suit you, will the bike cruise at 55mph without being too harsh on the engine and yourself?

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Re: CB500T Punsun Hardtail Bobber

Post by DieselFly » Sat Nov 12, 2011 7:39 pm

It is very happy to roll along at 55mph all day long. It has the aerodynamics of a garden shed and has to drag me sitting up right and I'm 6'2" and 210lbs. At 60mph the wind is really trying to push you off the bike. And it has no problems at that speed climbing any hills I can find around here.
Last edited by DieselFly on Mon Nov 10, 2014 1:48 pm, edited 1 time in total.
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Turbo installation begins

Post by DieselFly » Tue Feb 14, 2012 10:44 pm

Okay lets go turbo!! I started working on my bike last week. So far the exhaust "Y" pipe into the turbo and the mounts have been completed.
428009_10150588811889865_516439864_9098942_781824850_n.jpg
Next is the intake maifold it has been cut in half the compressor outlet is done we are making the new pipe to join the two halves. Just for fun I have the students cutting radial cooling fins with the horizontal milling machine and index head.
426310_10150588812414865_516439864_9098943_328128677_n.jpg
431641_10150588815059865_516439864_9098947_868893376_n.jpg


We will finish the compressor to intake plumbing then the tail pipe and new custom made stainless muffler then the oil system.

Stay tuned
Sean
Finished and riding 1975
CB500t Turbo Punsun powered
hardtail.

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Re: CB500T Punsun Hardtail Bobber

Post by XLerate » Thu Feb 16, 2012 5:52 am

Looks pretty slick there! Those kids will remember this & talk about it for the rest of their lives. Tremendous advantage for some quality character building.

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