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Old 09-18-2011, 11:56 AM   #1
larryboy OP
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Joined: Jan 2005
Location: On a set of 50,000 mile tires.
Oddometer: 13,899
Overgrown Offroad Zombie

If BMW destruction bothers you, stick to the hover and resist the click.


I picked up this 2001 1150GS in a trade and realized that needed upkeep was more than I could afford...conversion to something better was my only choice or so the voices told me.


Start with this:




Watch the flea market and find an XRR front end:




Remove 149 pounds of crap to get to this:




Find a CR500 frame on the 'list for $65, it's steel and uses the same head bearings and races as an XR650R:




Cut a little bit at a time for mockup:




Tell silly Lily to stop bothering me:




Start making parts:






Enjoy the look on my Father-n-laws face when he sees what I've done to this fine BMW:




Start adding tube:




Realized I put the fuel tank mounts in the wrong spot, back bone hits the tank...hmm, I better put it on it's feet before I get too crazy with the welder.




That last picture was nine days into the build. I spent some time measuring and ordering parts between selling the 1150GS parts I don't need anymore. Figured out the tank mounting and some other stuff. Then I got the flu and lost 10 pounds, in recovery mode now...maybe some bike progress today.


Stay tuned...a buddy is helping me figure out how to run a stand alone electronic ignition without the Motronic and I'm putting carburators on it too.

I have to start test riding this thing by the end of October as my wife and I are riding it two-up in November all over Death Zombie Valley.
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Old 09-18-2011, 12:04 PM   #2
andyhol
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Joined: Dec 2008
Location: the Seven Seas
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weight as it stands? very very cool imho
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Old 09-18-2011, 12:05 PM   #3
bk brkr baker
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Joined: Jul 2006
Location: The Bluegrass
Oddometer: 5,312
Watch out !
Them propeller fellers are massing for an attack!
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Old 09-18-2011, 12:09 PM   #4
larryboy OP
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Location: On a set of 50,000 mile tires.
Oddometer: 13,899
I was at 430 before I started putting parts back on. I'll have to do a final teardown for paint and will weigh stuff as it goes back on.

Edit: I'm hoping for 480 pounds ready to ride, with hard bags and mounts I'll probably end up at 500 pounds. 81 pounds lighter than stock.
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Old 09-18-2011, 12:45 PM   #5
roadrage
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Location: San Joe's A, Ca
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Put the Harley wheels on it!!! :-)

Cool hackage!
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Old 09-18-2011, 01:49 PM   #6
sailah
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Joined: Aug 2005
Location: Turning expensive metal into scrap
Oddometer: 5,417
Sweet, I like your style
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Old 09-18-2011, 02:19 PM   #7
fatpony
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Location: Flatistan NW aka Fl Panhandle
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Thumb

YOU are my hero and an inspiration! Please continue. Thanks, Mike
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Old 09-18-2011, 02:48 PM   #8
CamoGreg
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Joined: May 2006
Location: Lewis & Clark Valley
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Quote:
He wasn't right...in the head.


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Old 09-18-2011, 03:04 PM   #9
rallyman1978
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Location: Worcester, UK
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Wicked

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Old 09-18-2011, 03:46 PM   #10
Wolfgang55
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Joined: Dec 2006
Location: Next to Rio Bravo
Oddometer: 3,335
So the BMW 1150 was to costly to keep up on the maintenance.

You keep the motor & put carbs on board.

You do have a vision & I too want to see it run & stop.

Good luck.
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Old 09-18-2011, 04:02 PM   #11
SFKLR
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Register it as a plated XR. Insure it as a cr500. Tell others it's a BMW. Ride it like you stole it.
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Old 09-18-2011, 04:47 PM   #12
larryboy OP
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Location: On a set of 50,000 mile tires.
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Oh yeah, I traded the gauges for a rear GSA model rear wheel with a new TKC on it. Gonna have to pick up a fresh rear rotor as I let the rotor go with the wheel set I sold.


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Old 09-18-2011, 06:35 PM   #13
Poolside
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Joined: Apr 2003
Location: Long Beach, CA
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Quote:
Originally Posted by larryboy View Post

I'm actually trying a small Magura clutch master to save weight, we'll see if it can move enough fluid.
The OE master bore diameter is 16mm and the slave is 24mm. Based on the 'engagement range' of the OE clutch I'd guess that a 10% smaller master bore diameter still might work. Say 14.5mm as a minimum diameter.

But since Magura makes the OE BMW master, you might find a 16mm Magura part. If so, on the old and new clutch levers check the centerline distance between the clutch lever pin and the piston pin. For the same bore diameter, that dimension determines lever throw.


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Old 09-18-2011, 06:46 PM   #14
larryboy OP
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Location: On a set of 50,000 mile tires.
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Quote:
Originally Posted by Poolside View Post
The OE master bore diameter is 16mm and the slave is 24mm. Based on the 'engagement range' of the OE clutch I'd guess that a 10% smaller master bore diameter still might work. Say 14.5mm as a minimum diameter.

But since Magura makes the OE BMW master, you might find a 16mm Magura part. If so, on the old and new clutch levers check the centerline distance between the clutch lever pin and the piston pin. For the same bore diameter, that dimension determines lever throw.


I'm more of a bolt it on, bleed it and see if it works kind of guy. Clutch master is in stock, I have a couple of different ones I can try. Probably get to it after the new springs go in the forks and front end is complete.
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Old 09-18-2011, 06:58 PM   #15
Poolside
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Quote:
Originally Posted by larryboy View Post

I'm more of a bolt it on, bleed it and see if it works kind of guy.
Yea, I am getting that feeling about you


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