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Old 08-05-2010, 09:07 PM   #46
One Less Harley OP
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I scored a good price on a stainless Laser Produro muffler for a R100GS. I took a chance that it would fit a G/S, luckily it does. The only difference is that the muffler has two top mounting tabs. The back front one lines up perfectly, while there is nothing for the rear. I'll make a tab for it.

The muffler had the name brand label riveted on upside down, no big deal, just hit it with a wire brush. probably do something with it latter on.

1st on the agenda for making it fit is to make another muffler guard out of 3/8 metal rod and flat stock. here it is after two short nights of bending and welding. The 1st night the flat stock was bent and drilled the lower mount, then on the second night 3/8" rod was bent, cut and welded to the lower mount.




Stay tuned for more....

BTW- the muffler is more subdued than the Sito, w/ a little more pop from the cylinders at idle. I could drill the baffle holes larger, but am worried about making it too loud and not being able to go back.
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Old 08-06-2010, 02:10 PM   #47
mark1305
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Cool! I think I saw that same muffler in a thread on here somewhere and commented that if I hadn't already scored the Staintune for my ST I would be all over it just to try it out. Or I may have seen it on the Yahoo R80 ST group - can't recall. But it looks good!.
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Old 08-06-2010, 07:46 PM   #48
datchew
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It's amazing how much your final drive resembles the /2 units. Very very similar. The whole thing can be taken apart with a heat gun and a couple basic tools.
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Old 08-06-2010, 07:57 PM   #49
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It maybe a little harder w/o specialty tools, but can be done. The hardest part was removing the big ring gear bearing, then making the my cheap inside bearing puller fit the race inside the housing.

/2 is looking good.
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Old 08-06-2010, 08:13 PM   #50
datchew
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Quote:
Originally Posted by One Less Harley
It maybe a little harder w/o specialty tools, but can be done. The hardest part was removing the big ring gear bearing, then making the my cheap inside bearing puller fit the race inside the housing.

/2 is looking good.
Thanks mayne. Do you need the puller to get that big bearing out or would heat make it drop like the older models? I'm curious on this part because when the /2 is done, I'll be doing at least a full teardown, inspect, assemble type job on the GS and I suspect new seals for the final drive will be part of it.
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Old 08-06-2010, 09:22 PM   #51
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chewy- It takes a bit with chisels. I did use a heat gun, but worked the perimeter with lager chisels as the bearing slid off more. I'm sure it'd be easier with the right puller, it will need some narrow jaws. I'm sure some people would cringe at the way I removed the big motha...

Possibly I didn't heat it enough. I've seen Gunter Wurst, use a gas grill to heat up a tranny and flop it over and low and behold all the gears dropped out.......

Ok, back to your regularly scheduled program..

Did more finish work on the guard, completely welded the four rods together at the top back of the guard, just below the saddle bag mount. Can't see how it's finished. Aslo welded a mounting tab for the muffler. Welded a nut on the back side of the tab, then a stainless button head bolt to attach it..



Also made a mounting tab for the rear of the muffler, just bar stock w/ two nuts tack welded on it. You can see where the muffler name plate is, it was upside down so hit it w/ a wire brush remove the lettering.



Next project to finish welds w/ a sander then satin black powder coat.
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Old 08-19-2010, 09:05 PM   #52
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The guard has been powder coated and is done.




Rear bracket painted too.


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Old 08-19-2010, 09:08 PM   #53
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alright I'll be the first to ask, what's it sound like?
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Old 08-19-2010, 09:21 PM   #54
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Similar to the Sito, but more subdued, and has a little popping when coming off the throttle. I kind of prefer the Sito sound, but it isn't stainless.
Didn't like the shinny stainless at 1st, as the black looks more suited to the G/S, but I'm over that now.

Wanna buy a Sito, gotta sell to pay for the GS front end. Sold a bicycle wheel and a nice R100GS tank almost paid for the fork......almost.
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Old 08-31-2010, 07:41 PM   #55
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Latest update for the G/S and new front end from a 1992 R100GS. Some misc ramblings about the conversion can be found here.

(http://www.advrider.com/forums/showt...1#post13889111)

Got the R100GS forks, rotor (No GOOD), front wheel today, plus the Race Tech Emulators (FEGV S3802), only need one the other is for sale in the Old School flea market section.



Moto Bins supplied wheel bearings, head set bearings, and some brake parts.

The rotor wasn't any good, no need to measure it, so one was ordered from The Beemer Shop, plus the fork dust sliders.

Unfortunately I was off from work today, so the fork tubes were pulled apart and cleaned, new seals installed, the right fork got the emulator, and headset bearings greased and installed.

I won't go into details about the forks or emulator as Infracaninophile has a great writeup on it.
http://www.advrider.com/forums/showt...431153&page=36

The front wheel was sent to Woody's Wheel Works a regular contributor here. Where the hub will be bead blasted and sealed, a new Excell 21x1.85 tube rim laced with stainless spokes and trued. Maybe three weeks till I see that.

Still waiting on the Harrison Mini 6 caliper. Looking forward to seeing it and posting pictures.
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One Less Harley screwed with this post 09-01-2010 at 08:11 AM
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Old 09-10-2010, 03:15 PM   #56
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Things are going a little slow on the front end conversion, been waiting on parts still. I did get a left 4 pot caliper ( 'bout $40 for the Brembo and yeah I'll be using the Harrison 6 pot, but just have to try it.) from a 1995 R1100GS ( I believe any R1100 or K1100 will work). As mentioned the mounting hole spacing is the same, but metal will need to be removed from the caliper tabs.

Here's a nice writeup- http://www.airheads.org/content/view/275/98/
Or my writeup (here)

Here the caliper is mounted to the right fork, no machining yet.



I've spoke w/ Woody's Wheel works and the wheel shipped out today.

The Harrison Caliper was shipped yesterday.

New brake rotor will probably ship today.

So hopefully all the parts will be here by next weekend!!

Took some measurements of the pad area for the Four pot Brembo (approx 8.12 sq in of pad material)
The harrison Mini Six has 15 sq in of pad material

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One Less Harley screwed with this post 03-11-2011 at 08:10 PM
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Old 09-12-2010, 06:57 PM   #57
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Harrison 6

More eye candy, the Harrison Billet 6 arrived Saturday while I was sailing in Tennessee, great weekend for a little hull flying on Sunday.....You guys don't want to hear about that.

Good looking chunk of aluminum...






Not quite plug and play, as another type brake line will be needed, but no reason to use the OEM brake line. One end of the brake line needs a banjo type fitting and the other end needs to be compatible w/ the MC, be that a thread in or banjo fitting.
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Old 09-15-2010, 05:25 PM   #58
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Excell Rim

Recieved the Excell Rim today from Woody's Wheel works. The double butted spokes are huge.I don't think I'll have to worry about the rims holding up.

Note- the hub is a R100GS hub. The spokes are flared extra large to go into the hub where the GS hub had nipples and a flare at the rim. The Excel rim I wanted was the same style as the Akront, nipples on the rim. Nice looking rim which is polished and clear coated.



Now I just need the new EBC rotor to show up from Ted Porter. It's due Friday.
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Old 09-15-2010, 06:59 PM   #59
bgoodsoil
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nice wheel. I want a Talon rim too but I won't be able to afford that for a long time.
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Old 09-15-2010, 07:07 PM   #60
Airhead Wrangler
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Looking goooood.
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