Creating Carbon Fiber Components for a Custom Cafe Racer

Abstract

The objective of this project was to design and produce a caf racer style motorcycle. Eventually, the project became more focused on creating a caf style bike from a 1974 Honda CB360 that made use of custom carbon fiber parts, as well as a host of purchased components that complement a complete overhaul of the existing engine, frame, gas tank, and other features. With respect to aesthetic design, several designs were considered and sketched, narrowing the range of motorcycle models from which the project could begin. Various motorcycle models were researched, and the decision to make use of the HONDA CB line was made. Due to the smaller engine and general lightness, as well the high popularity in the modifying scene, the CB350/360 line of bikes was selected. Eventually, a suitable 1974 CB360 was found in New Hampshire, and was purchased. Aftermarket components as well as necessary OEM parts were researched and purchased during the course of the project. Components were selected based on compatibility with the bike, aesthetic and performance decisions, and reputation with other CB360 owners. SOLIDWORKS was used to design the carbon fiber components of the motorcycle, after foam models were roughly carved and used for dimensions. Creo will be used to generate tool paths and carve molds out of foam, over which the carbon fiber composite will be laid. As of now the project has cost between $4000 and $5000 dollars, with all physical components of the motorcycle coming from personal resources. Department funds were used to purchase tools, software, and composite materials. In addition to being an endeavor in design, mechanical learning, manufacturing, CAD, and machining, this project has been a labor of love. Though not everything was accomplished by the time this report was written, a huge amount of time has been invested, and a host of invaluable experience has been gleaned. In the coming weeks the motorcycle will be finished; this is not merely a desire but a necessity, as I lack most of the necessary tools to complete the project at home.