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Old 09-01-2011, 05:15 AM   #1
Big Al_SA OP
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Wink BMW R100 CS from delapidated to Cafe Racer...

So here's my contribution to the 'Old's Cool" section. Enjoy my 660 Tenere' bigtime, but while browing here and there, discovered the 'Cafe racer's threads, and went mental. Finally dived in and decided to go the route of BMW Airhead for my rebuild. Discussed with my good friend max, a BMW specialist, and he felt the BMW would be a better bike to do this project with. So after a few weeks of looking around, we finally found one.

This is what the owner advertised.


But when we saw it in real life, it had been left outside in the Cape Town Winters for 2 years, and was decidedly under the weather. made him a good offer, and we got the bike.



Plan was to do a good cleanup, get the Roadworthy done, Registration and change of ownership, and THEN start the strip down.

General condition can be seen in these Pics. we have work ahead of us.







One of the nice things with this bike is it has everything intact and with it. Everything works, all the lights and indicators are good, and nothing's cracked. So, we decided to strip off the nose fairing, and give it a really good cleanup. Then take it to get the Roadworthy done.



Working hard..





Finally cleaned, battery charged, all running.. off to Roadworthy.



And he passed with flying colours. The Inspector was quite impressed with the old Boy, the Motor in this bike's in excellent condition, and has excellent pulling power. Clutch, Brakes are all good, but we'll uprate them as we do the conversion.
Got it home, and then we started the big strip. This has been done over a period of about 2 months, as time allows us.








Starting to get down to the bare essentials now.. My intention is to build a proper 'short-tail' look with a bum cone, which I decided I'd make myself.





First had to get a good idea of where we were going to cut the old tailpiece.



CUT IT...



More to follow..

Al
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Old 09-01-2011, 05:23 AM   #2
xavier296
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Looks great! Take and post all the pics you can, I get so many ideas from other inmates!
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Old 09-01-2011, 05:32 AM   #3
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Catching up to the previous thread. So we'd cut the tailpiece, and needed to do some welding here and there, as well as to create mounting points for the Indicators etc. Trying to have as much fabrication done before it all goes inf or painting.







Getting an idea of what to do for a mudguard.



Making the Bumbox myself before we cut the chassis. I got some soft foam, and shaped the shape I was looking for. I didn't like some of the commercially available kits, or their shapes. Doing it myself would be more personal satisfaction when it was completed.







Once finished. I then layed it up with Fibreglass and resin. and eventually handed it in to a spraying ship to smooth it down and spray it.



I'm really pleased with the size, and finish. it won't look too small or "lost" on the bike, and should add a decent finish and profile to the rear.



So, a few weeks later, we finally managed to get the Motor out. We decided to not split the motor, but instead, we'd clean it up as best as possible, but I'd get some panels resprayed, and cleaned up manually.



Bike Frame down to the last bits.









We're also going to do a Bigger Front Brake Conversion. Busy Getting the Disc made, and made up a bracket to support an old Caliper.



Got the Disc cut and drilled, but it's still too thick, so it's gone back to get some material removed.



More soon.
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Old 09-01-2011, 05:37 AM   #4
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Ok, more or less current.
Got all the parts back from the Paint Shop. Got the Matt Finish Engine Covers back, and proceeded to paint on Silver Detailing.





Came out clean and neat. so carried on.



Also did the BMW Logo on the top Motor cover.



Also gont the front fairing resprayed, although I'm not sure I'm going to use it, but in case, I decided to refurb the whole fairing.



So, that's where I'm at. Looking forward to the rebuild process now. Will continue in about 3 weeks time as I'm off on a well deserved break to the UK and Europe.

regards

Al
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Old 09-01-2011, 06:19 AM   #5
JonnyCash
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Wow, that's a particularly nice tail section you built there. Looking froward to seeing your progress.
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Old 09-01-2011, 08:14 AM   #6
squiffynimrod
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"Got all the parts back from the Paint Shop. Got the Matt Finish Engine Covers back, and proceeded to paint on Silver Detailing"

If you find the silver paint doesn't hold up, just sand off the paint and finish the aluminum with about a 600 grit waterproof paper. Did that with my valve and starter covers after they were powder coated. Turned out great!
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Old 09-01-2011, 08:15 AM   #7
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Old 09-01-2011, 10:55 AM   #8
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If you consider what you started with "dilapidated" then you'd consider mine "devastated."

Looking good so far.
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Old 09-01-2011, 11:17 AM   #9
LynxSS
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Quote:
Originally Posted by Big Al_SA View Post

I'm really pleased with the size, and finish. it won't look too small or "lost" on the bike, and should add a decent finish and profile to the rear.




Wow really nice job!
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Old 12-08-2011, 10:38 PM   #10
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Right, so almost 3 months later, got to do some more work.. Went to the UK in September, and bought some Stainless Steel Bolt Packs off eBay for the R100 rebuild process, as well as some clothing, Fuel Cap for the tank etc.
Then been busy finishing the stripping of every other nut and bolt and bit..

Then it went in for respraying, that was October sometime. Getting a little side-tracked, I see the Pics of the Motor covers were already here. Ok, so every other Nut and Bolt and washer were sent in a Nickel Plated. Also took a while, but finally got it all back, and re-assembly has started.



Pictured here, the left container is all the Stainless Bolts and bits from the UK. the middle and right container are the old, original nuts and bolts which have been plated. Top container the axles, motor bolts etc also plated. Makes the finished product look awesome. On the right, the hangers for my home made rearsets..



Ok the parts are obviously marked with prints as we're busy re-assembly, but that will all be cleaned properly again. Here, the brackets which hold the Coils under the tank, showing the Stainless Bolts, as well as the Satin finish on the chassis..







Also showing the Front wheel detail, Stainless bolts everywhere, and the new single front Disc conversion.







Rear wheel, and Diff detailing.. Nickel Plating is awesome..



Pictured, the newly sprayed Sump and SSteel bolts..

So, we're well on our way now. Motor's going to get some highlighting spraywork done, to give it an uprated clean look, and then in it goes. More to follow soon I hope.. itching to get this completed now..

Al
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Old 12-08-2011, 10:55 PM   #11
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Just WOW!

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Old 12-13-2011, 05:30 AM   #12
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Old 12-29-2011, 12:05 PM   #13
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Not going to elaborate too much as I have to repeat post this build in multiple places.. So Pics here. The Build can be found here: http://www.paterson.co.za/bikes/bmw/project.htm

Latest updates from Page 7.

Repaired my Diode Board with replacement "field" diodes.









Fitted some Gators on the front Shockws, as well as home made single Disc conversion, custom bracket and BMW Caliper.







Made some Nylon Spring Spacers..



Put the Tail on to get an idea of what he's going to look like..





More next year.. Happy New Year to you all.



Al
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Old 12-29-2011, 09:23 PM   #14
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Yeah, and a Happy New Year to you too!

I'll be expecting to see that old crock lit up and rocking before the years out!
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Old 12-31-2011, 06:10 AM   #15
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Went and finished cleaning up the Gearbox.. My fingers....

Here's a Pic of the finished top yoke, showing Nylon Washers under Shock Nuts. Looks nice and clean, ready for bars.



And the Gearbox, finally in.





More next year. HAPPY NEW YEAR...

Al
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