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Old 06-11-2007, 05:31 PM   #16
Udo OP
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Rear shock mounts

Spent part of today fabricating/reinforcing the rear shock mounts. Took some pics.
Thought a lot about moving the bottom mounts forward, making a single shock setup, and variations. Finally decided to go with the obvious and not over engineer it at this point. The plan, what there is of it, is to just build the bike based on common sense, not get hung up on too many details, see how it rides and handles. Then, redesign as needed, tear it down, make it pretty, and put it all back together again. No, haven't looked too hard at geometry. Too easy to get hung up on paper designing and never get to the building.
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Old 06-11-2007, 05:33 PM   #17
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Putting it to steel

Traced the cardboard pattern onto some 1/8" plate and cut it off with a simple cut-off wheel.
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Old 06-11-2007, 05:37 PM   #18
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Fitting to frame

After cleaning the cuts up on a grinder I attached the plates to the frame, using flat washers stacked to get proper spacing for the top shock eye. Then, torch to get it red hot, hammer to shape against frame.
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Old 06-11-2007, 05:40 PM   #19
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Welding to frame

Had Noah, our shops expert welder, do the final attachment.
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Old 06-11-2007, 05:42 PM   #20
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Finished

Ta da, bullet proof top shock mounts.
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Old 06-12-2007, 08:47 AM   #21
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i love this stuff.
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Old 06-12-2007, 07:55 PM   #22
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Nice. I've always wondered about doing that with an R65.
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Old 06-12-2007, 08:07 PM   #23
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Progress

Doing this show and tell is inspiring me to plow ahead full speed. Today, managed to mount the starter, alternator, diode plate, a nice set of 32mm Bings I found on e-bay (like most everything going into this bike, including the frame). What a pain in the ass it is to attach the drive shaft to the trans. I even managed to drop a bolt down the swing arm. A long, thin magnet fished it out. Thought I'd be tipping the bike up on its front end. The next problem is altering the sub-frame to fit. The vertical braces interfere with the new shock location. Looked at an R100GS and noticed how they bent the brace around the mono shock. I'll post pics as I do that modification.
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Old 06-13-2007, 04:35 AM   #24
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Damn, I was going to ditch the BMW project because I was building this;


I guess I've got to get the R65 frame back in the shop and start getting parts put together.

Stagehand glad to see all is well.
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Old 06-13-2007, 05:16 AM   #25
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Forgot to add Udo great project, simple is better.
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Old 06-13-2007, 06:47 AM   #26
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Quote:
Originally Posted by grimmboy
Damn, I was going to ditch the BMW project because I was building this;


I guess I've got to get the R65 frame back in the shop and start getting parts put together.

Stagehand glad to see all is well.




yeah, you too!

What you've got going on is not too shabby either. I have a soft spot for XT's as well.


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Old 06-13-2007, 05:52 PM   #27
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Grimmboy, nice to meet you.

Why not get the R65 frame out and do both? If you get stumped or bored with one, you can then play with the other. Isn't more better?
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Old 06-18-2007, 02:01 PM   #28
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Udo, bigger plans for the XT500 that must be met. Nice grass root fab, take what works, make it, ride it and fit it if it needs it.

Can't wait for more updates.
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Old 06-20-2007, 05:45 PM   #29
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Step by step

Moving right along. Parts have been arriving every other day. Love my UPS guy. Got a nice set of controls for the Renthal Handle bars. Rich at Repsycle BMW has been very helpful. Brake lever, master cylinder, throttle, starter switch/kill switch, and cables on the right. Clutch lever, choke control, light switches, and cables on the left. The Renthal bars were knurled on the left side, making the left a little thicker than the right. Made the mistake of trying to force the clutch lever perch over the knurling and broke the part. Stupid. Repsycle was able to get me another one. This time - a litle flat filing over the knurling and an adjustable reamer inside the perch, and all fit together nicely.
The alternator, diode plate, and ignition pick up were routine once I figured the wiring out. A used R65 harness is temporarily hung, just waiting for a battery.
Got a used, very large battery tray. Don't know from what. So, a little cutting wheel action, a little sand blasting and welding, we now have a battery box made to fit.
Had to hang a set of 32mm Bings, just to make it look like there's progress. Got them used without any real history. I suppose I should drop the bowls, check the diaphrams, just to make sure all the parts are inside.
Found an R80ST being parted - we now have a seat, center stand, air tubes, and ignition module heat sink enroute on some UPS plane between here and San Francisco. Once the seat arrives I can determine the angle of the subframe and fabricate the new vertical braces.
Here's some pics.
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Old 06-20-2007, 05:50 PM   #30
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Charging system

All routine here.
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