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-   -   R100RT chop hack and slice without remorse. Looming 56K death (http://www.advrider.com/forums/showthread.php?t=844297)

digger440 11-27-2012 10:21 AM

R100RT chop hack and slice without remorse. Looming 56K death
 
Firstly hello this is my first post nice to make your aquintence.

Now that the salutatory BS is out of the way here is the long and the short of it. I was given an 1981 R100RT that was severely neglected and pretty rough. The layer of of oxidization ad rust were pretty deep so I dont feel sad at all for what I am about to post in this thread. It was given to me by a friend of my parents, at first I just left it to sit in a corner of the garage wondering what I was going to do with it. I could not sell it as that was part of the "gift conditions" so it sat and sat and sat. I rode it once up the driveway after I got it. It ran which is about all I can say that is nice. The brakes were bad, both masters leaked fluid as fast as you could add it. The exhaust was falling apart, it was ugly, and there is a ton of slop in the rear end as the splines are toast.

So a little about me, I come from a 2 wheeled family my dad puts more miles on his Tiger than I do in my daily cage. My mom on the other side has a Triumph Legend side-hack that she motors about. I think there might have been a very brief time in my late teens that some sort of gyro balanced motor transportation was not in my life (but that time was long ago and is fuzzy to say the least).

So fast forward a bit I was working managing an automotive shop where I had been for 13 years. I hated my job, I had been hired to change oil and sweep floors but throughout the years I somehow ended up in the office writing work orders and running the shop. I was much happier back in my bay doing diagnosis and building cool stuff, (which I am aggressively mediocre at :evil). The shop fixed your everyday mundane vehicle issues but we also built hotrods, mostly Model A's but there were many others to mix it up. Prior to being the head lackey I had a good gig I was an ASE master with L1, X1, and (the newer) A9 certs. I did all the custom fab work and a few of our cars ended up in magazines (Nov 2004 American Rodder inside cover and a nice write up).

Did I mention I hated my job? Not just hated it but loathed every minute I spent there. I would come home a ball of stress turning me into a shitty father and a shitty husband. So I decided to drastically change careers, which I did. When I quit I hated working on things with motors just as an extension of of unhappiness in my career. I brought my tools and equipment home and packed them into my garage not even so much as changing oil for quite a while.

It took months but in May I saw that poor old RT sitting in the corner and a lightbulb went off. I was working nightshift in my new career and I had a ton of time to myself, so rather than drink and watch netflix I put it on the lift and started this journey. I quickly remembered what I loved about building mechanical stuff and I could do it in a leisurely manner and whilst drinking beer.

I tend to lean toward sportbikes (my elderly Kawi is in some of the pictures) so this hack I am shooting for a cafe-esque look but with some modern influences. If you can picture an Airhead, a Norton Manx, and a Triumph Speed Triple getting wasted and having an inter-species orgy, the illegitimate bastard that came of that union is what I am looking to create.

So with that said welcome to my therapy.

So here is where I started
http://imageshack.us/a/img834/9016/dscf0420h.jpg




More to follow I am uploading 140 pics to imageshack as I type hence the dial up warning in the title





:D

walkingbear 11-27-2012 10:33 AM

can wait
 
love watching cafe builds:clap:1drink:bmwrider

caponerd 11-27-2012 11:12 AM

My 1982 r100rt looked worse than that when I got it, and I paid money for it!
You can give me whatever you take off that in the process of cafe-izing it, it would probably be an upgrade for me.
:rofl

chasbmw 11-27-2012 11:42 AM

This bike was bought in about 1994 as a very well shagged 1982 RT.

It now looks and goes very much better and it's funny how many people don't realize that it is not a R90s

http://i46.photobucket.com/albums/f1...e/IMG_1461.jpg

digger440 11-27-2012 11:47 AM

And here is where I am as of this morning :1drink as I said in the first post I uploaded a metric shit-ton of photos to imageshack and I will try and update this tread as time permits

http://imageshack.us/a/img843/4483/dscf1184w.jpg

http://imageshack.us/a/img706/3098/dscf1182b.jpg


This project has snowballed from its beginnings, becuase at first it was just going to be the standard cafe fare. I.E. Clip ons, new exahust, bobbed tail, and some detailing...


...I am so not done:wink:

Wirespokes 11-27-2012 02:31 PM

I like your style! :wink:

Riding them is therapy, but so is working on them and customizing them as well.

Sounds like you've made some good changes and the quality of life has improved drastically. Well done!

digger440 11-27-2012 02:43 PM

So here is where it all started I got the bike up on the lift and started looking. I knew that I wanted to go cafe-ish but I also knew I needed to strip the poor old beast prior to any hacking

http://imageshack.us/a/img844/3929/dscf0419l.jpg
http://imageshack.us/a/img545/1839/dscf0421y.jpg
http://imageshack.us/a/img33/4208/dscf0422n.jpg
http://imageshack.us/a/img18/7415/dscf0423u.jpg
http://imageshack.us/a/img829/2039/dscf0425hn.jpg


So now the big pieces start to come off starting at the back and moving forward


http://imageshack.us/a/img62/2711/dscf0432rt.jpg
http://imageshack.us/a/img231/2927/dscf0434lx.jpg
http://imageshack.us/a/img831/8973/dscf0433k.jpg


Once the fairing was off I put the tail back on to look. Now I am old enough to have had Sir Mix-a-Lot on cassette (now on my iPod) and while I agree with his proclamation of love for large round backsides this was too much Ghetto Booty, that ass is huge

http://imageshack.us/a/img442/5592/dscf0438t.jpg
http://imageshack.us/a/img5/985/dscf0437hp.jpg

I knew I was going to bob that tail when I started so I needed to get down to the seatpan


http://imageshack.us/a/img577/29/dscf0442o.jpg
http://imageshack.us/a/img22/2472/dscf0443y.jpg


After putting the seatpan back on I measured that I could lop 8 inches out of the middle to get the look I desired but because I was bobbing the seat I had to bob the frame too

http://imageshack.us/a/img11/5239/dscf0445hb.jpg
http://imageshack.us/a/img854/5907/dscf0446v.jpg
http://imageshack.us/a/img197/6669/dscf0449u.jpg
http://imageshack.us/a/img62/6825/dscf0451j.jpg
http://imageshack.us/a/img33/9890/dscf0452p.jpg
http://imageshack.us/a/img855/5443/dscf0454l.jpg


Now that the frame was bobbed I could get to the tail and seatpan. I have to mention that before the big snowball I was going to use the factory seat hinges and mounting so it would still lift and pivot as it was designed to do.

rusty and dirty

http://imageshack.us/a/img12/1683/dscf0457l.jpg


needs some patchin

http://imageshack.us/a/img9/8400/dscf0458y.jpg

Here to being 8 inches short

http://imageshack.us/a/img254/7460/dscf0460k.jpg
http://imageshack.us/a/img16/3962/dscf0462h.jpg
http://imageshack.us/a/img132/6121/dscf0465b.jpg

the tail is now ready to be cut to match the seatpan

http://imageshack.us/a/img690/4060/dscf0466wm.jpg
http://imageshack.us/a/img203/4938/dscf0467rh.jpg
http://imageshack.us/a/img248/2282/dscf0468r.jpg
http://imageshack.us/a/img837/8591/dscf0469n.jpg


Oh TIG welder how I love thee

http://imageshack.us/a/img217/7800/dscf0470f.jpg
http://imageshack.us/a/img831/5937/dscf0471zh.jpg


and here is the tail mounted up looking much better than the ghetto bootied start

http://imageshack.us/a/img5/7558/dscf0472s.jpg
http://imageshack.us/a/img856/5212/dscf0473i.jpg
http://imageshack.us/a/img526/5709/dscf0475t.jpg
http://imageshack.us/a/img528/6237/dscf0479z.jpg


But I still have the rusty seatpan to deal with, in the below photos I joined the sections, patched the rusty hole, and installed new metric Nutserts to attach the tail

http://imageshack.us/a/img4/7574/dscf0489jy.jpg
http://imageshack.us/a/img547/4499/dscf0491m.jpg
http://imageshack.us/a/img818/3221/dscf0492w.jpg
http://imageshack.us/a/img217/3196/dscf0493x.jpg
http://imageshack.us/a/img687/117/dscf0494c.jpg
http://imageshack.us/a/img10/7296/dscf0496w.jpg
http://imageshack.us/a/img547/213/dscf0497q.jpg
http://imageshack.us/a/img526/5299/dscf0498q.jpg
http://imageshack.us/a/img69/9346/dscf0499x.jpg
http://imageshack.us/a/img267/2549/dscf0500e.jpg
http://imageshack.us/a/img849/4224/dscf0501k.jpg
http://imageshack.us/a/img21/3236/dscf0502s.jpg


Done and painted

http://imageshack.us/a/img197/7402/dscf0509.jpg
http://imageshack.us/a/img593/2500/dscf0510fp.jpg


I wanted the tail to have a cleaner look so I stared at it for a while, had a couple beers and got this bright idea to pinch the subframe supports inward to the battery box mount leaving room on the outside to lay down the shocks I figured I would just make some new shock mounts and leave the subframe pretty much factory (with the exception of the pinched support bars)

http://imageshack.us/a/img849/6306/dscf0511e.jpg
http://imageshack.us/a/img803/1426/dscf0512o.jpg
http://imageshack.us/a/img268/1851/dscf0516lm.jpg
http://imageshack.us/a/img211/6237/dscf0515o.jpg


With this idea the snowball began to roll I ordered a pair of external reservoir off ebay that were just a bit longer than the factory ones. but once I got them I found that my idea of pinching the subframe supports didnt pencil out like I thought,so the cutting and chopping began in earnest. I distinctly remember putting the recip saw to the subframe mounting tab and asking myself if I was making a good decision :1drinkso I had a beer and ignored the stupid naysaying voice.



To be continued......

digger440 11-27-2012 03:21 PM

You cant do it all
 
As with any project you are going to have some epic fails and while I am good at many things I suck at upholstery. I tried dear lord I tried and I found that I have neither the patience or willingness to learn this skill. Needless to say I will be farming out the upholstery to someone who knows WTF they are doing

I started with the Ghetto Booty foam that was in the seat and I began to piece it together

http://imageshack.us/a/img18/9735/dscf0505f.jpg
http://imageshack.us/a/img607/7379/dscf0506e.jpg
http://imageshack.us/a/img12/5194/dscf0507qs.jpg
http://imageshack.us/a/img690/2291/dscf0508f.jpg
http://imageshack.us/a/img197/268/dscf0517e.jpg
http://imageshack.us/a/img834/5981/dscf0518o.jpg


I shaped the foam to something that looked like I wanted and went to the fabric store and purchased some marine grade vinyl. I tried to make a seat cover in the photo below but it ended looking like I had put pickled eggs and oatmeal in a plastic grocery sack, it was hideous and shameful.

http://imageshack.us/a/img835/5489/dscf0519p.jpg


Needless to say that is why in the latest photos there is only foam to protect my tender tushy



More to follow.....

Bill Harris 11-27-2012 03:22 PM

Good deal on the career change.

Remember, a motorcycle can get you through times of no money better than money can get you through times of no motorcycle. Or sumptin' like that...

--Bill

digger440 11-28-2012 10:24 AM

<!--[if !mso]> <style> v\:* {behavior:url(#default#VML);} o\:* {behavior:url(#default#VML);} w\:* {behavior:url(#default#VML);} .shape {behavior:url(#default#VML);} </style> <![endif]--> This is where the whole project changed, I had purchased the longer shocks and had found they would not work with the pinched subframe support idea. So I got out the recip saw and cut of the subframe mounting tabs. Once the tabs were cut off I had some rather ugly growths that needed to be smoothed

http://imageshack.us/a/img854/5656/dscf0563k.jpg

http://imageshack.us/a/img829/3267/dscf0564rv.jpg

http://imageshack.us/a/img825/3571/dscf0565x.jpg

http://imageshack.us/a/img210/6899/dscf0566y.jpg

http://imageshack.us/a/img594/452/dscf0568y.jpg


http://imageshack.us/a/img834/3104/dscf0569c.jpg



Now to build a new subframe, I used threaded rod bolted through the battery box holes in order to be able to adjust the seatpan and tail to the correct height and angle prior to tacking together a subframe. It worked pretty well and I used a 3rd bolt on the tire to get the rear at the correct height.

http://imageshack.us/a/img248/7195/dscf0570z.jpg

http://imageshack.us/a/img13/1210/dscf0571qv.jpg

http://imageshack.us/a/img51/1923/dscf0660n.jpg




And now the shock mounts need built so I had a beer and l stared for a while. My first thought was to make the shock mounts support the seat. so I mocked up a bracket from card board.

http://imageshack.us/a/img42/9431/dscf0576bm.jpg

http://imageshack.us/a/img211/8959/dscf0577z.jpg



And I got ready to make some cuts

http://imageshack.us/a/img138/6024/dscf0578g.jpg

http://imageshack.us/a/img38/2128/dscf0579g.jpg


Flame cutting is ok but I really need a plasma torch

http://imageshack.us/a/img267/7325/dscf0580k.jpg

http://imageshack.us/a/img443/8486/dscf0582.jpg



Since I had flamecut ala freehand the brackets they needed some work to look respectable so I clamped them together for some judicious grinding and shaping

http://imageshack.us/a/img33/5295/dscf0583x.jpg

http://imageshack.us/a/img844/7097/dscf0584a.jpg

http://imageshack.us/a/img405/6339/dscf0585lr.jpg[/img]



After shaping them I have 4 brackets that look exactly like each other and match the template I had made

http://imageshack.us/a/img196/4909/dscf0586i.jpg

http://imageshack.us/a/img542/9890/dscf0587h.jpg

http://imageshack.us/a/img62/5387/dscf0589b.jpg


Now to drill the holes the shocks will bolt through

http://imageshack.us/a/img15/8431/dscf0591jx.jpg

http://imageshack.us/a/img145/9941/dscf0595h.jpg



Everyone has a supervisor and mine says he is not convinced that the shockmounts I am making will look good. He said some other stuff too but it was mostly about Batman and Lightning McQueen.

http://imageshack.us/a/img855/2764/dscf0598q.jpg



Once I got the hole drilled and the mounts bolted to the shock I had to form the mounts to match the curvature of the frame.


http://imageshack.us/a/img547/4081/dscf0600z.jpg

http://imageshack.us/a/img526/821/dscf0599p.jpg


And this is where I end up not happy I really should have listened to my supervisor as he has an eye for aesthetics. With the mounts fomed and the tail in place on top of them it looked clunky and like an afterthought. The mounts did not flow with the shape of the tail or the frame. So I sat in my rocking chair, had a beer, and cried while staring at the damn thing. My supervisor would have my ass if I screwed this up, so I continued to cipher until I had a better idea.
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digger440 11-28-2012 09:21 PM

Ok I got done with my man tears and asked myself what kind of look I liked in bikes that I could apply here. And the answer I came up with was a Ducati steel trellis frame. While that is not what I built, I wanted something that would be simple, lithe and strong. I didnt tell the supervisor but I started to build shock mount pockets that I figured I would weld to the frame with triangulated tubes.

As always I made a pattern and beer helped me get started

http://imageshack.us/a/img713/9559/dscf0666x.jpg

http://imageshack.us/a/img577/7316/dscf0667c.jpg

The old shock mounts were good for something

http://imageshack.us/a/img22/7451/dscf0668ed.jpg

http://imageshack.us/a/img211/6973/dscf0669g.jpg

Once I had the rough cut I shaped them the same way I did the old shock mounts and got ready to tack it together

http://imageshack.us/a/img5/205/dscf0709xg.jpg


I started my tacks at the top of the semi-circle and closed it up with the vice before I finished welding

http://imageshack.us/a/img689/7772/dscf0711i.jpg

http://imageshack.us/a/img689/7772/dscf0711i.jpg

http://imageshack.us/a/img14/9708/dscf0714c.jpg

http://imageshack.us/a/img547/4403/dscf0715.jpg

http://imageshack.us/a/img442/6720/dscf0716k.jpg

http://imageshack.us/a/img534/4287/dscf0717ay.jpg


With the shock pockets done I began to build the seat mount, I used M/S tubing, chamfered the edges in the lathe and istalled nutserts in the end to hang..... .....stuff

http://imageshack.us/a/img339/6388/dscf0654p.jpg

http://imageshack.us/a/img825/8947/dscf0657e.jpg

http://imageshack.us/a/img844/769/dscf0656g.jpg



I welded a spreader support onto the frame and tacked together the seat mount in the vise

http://imageshack.us/a/img87/2958/dscf0661o.jpg

http://imageshack.us/a/img96/2482/dscf0659b.jpg



Then I tacked the frame to the spreader

http://imageshack.us/a/img87/2903/dscf0664c.jpg

http://imageshack.us/a/img4/4697/dscf0665gl.jpg



I cut two small spacers and clamped the shock pockets to the seat frame and tacked it into place.

http://imageshack.us/a/img641/2282/dscf0752m.jpg

http://imageshack.us/a/img31/6669/dscf0753w.jpg

http://imageshack.us/a/img708/9510/dscf0754gx.jpg



This looks a little better the Supervisor will be pleased

http://imageshack.us/a/img69/2224/dscf0755t.jpg

http://imageshack.us/a/img853/115/dscf0756x.jpg




I used pieces of the old subframe to make the triangulated shock pocket braces that will bear the brunt of the working load against the frame. I also added a second set of triangulated braces to the spreader between the two shock pockets. I moved the location of the shock pockets to lower the rear 1.75 inches for the short and wide look (kinda like me).

http://imageshack.us/a/img831/7804/dscf0777a.jpg

http://imageshack.us/a/img13/6649/dscf0778q.jpg

http://imageshack.us/a/img803/6154/dscf0780z.jpg

http://imageshack.us/a/img594/3218/dscf0783z.jpg


When I finished the seat rested on the factory rubber buttons on top of the seat frame. This look both myself and the supervisor are more pleased with.

http://imageshack.us/a/img87/3431/dscf0785s.jpg

http://imageshack.us/a/img62/5527/dscf0786p.jpg

http://imageshack.us/a/img402/1228/dscf0787hm.jpg

http://imageshack.us/a/img29/6736/dscf0837j.jpg



Because I lowered the rear I also needed to lower the front the same amount to keep the correct geometry and look. So some shiny new parts were ordered. I am really trying to build everything I can on this, but for $120.00 the San Jose triple clamp was well worth the money spent. Besides a machinist I am not :lol3


http://imageshack.us/a/img197/4212/dscf0776s.jpg








Next up.... exhaust



To be continued

DiabloADV 11-28-2012 09:31 PM

This is humbling to watch.... :clap

Kt-88 11-29-2012 12:28 AM

Subscribed.

orangebear 11-29-2012 01:25 AM

a cool build and some nice welding you have done but i would not do the welding in rubber gloves as they will melt.

digger440 11-29-2012 07:18 AM

Quote:

Originally Posted by orangebear (Post 20139929)
a cool build and some nice welding you have done but i would not do the welding in rubber gloves as they will melt.


You would think they would melt badly but they dont. I started using the blue extra thick gloves probably 10 years ago when I was working as an auto tech. The first reason was women dont like the dirty hands, after I got used to wearing them you could not tell what I did for a living by looking at the stains on my cuticles.

As far as them melting the only problem I have had in the whole time is big drips of molten slag. It takes quite a bit to melt them actually however if you grab something hot or touch something hot they retain the heat for a long time; but they come off easy. :lol3


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