Custom snub nose F800GS

[runnin4melife]

I am editing this to include the whole process from start to finish. I began this project after reviewing many other individuals threads about their own custom F800 snubnose and after seeing the realities of what can happen when the stock fender with the stock brake lines snapped I decided that this was imperative for my own safety given the fact that I ride a lot of aggressive trails and am often doing it solo.

I started with my 2011 BMW F800GS, I have already upgraded the suspension w/a Ohlins Nix kit and a rear Ohlins shock.



Removed the beak and began playing w/a variety of ideas of what I could/should do. In following Erling's work I began to look at carbon fiber to meet my needs of some custom parts.



Very basic idea of what I may do in terms of filling the void once I install a new front fender.





This is the biggest issue for installing a front fender from a MX bike. The 3 bolt pattern of the lower triple has to be converted to a 4 bolt pattern to mate w/a MX fender.



I chose to fabricate a piece of carbon fiber while making a piece to fill the gap of the front cowl to test out bolt patterns for the lower triple to MX fender.







Once I had the front fender, a KTM 690 front fender: http://www.ktm-parts.com/7650801000030.html
I could begin to finalize the bolt pattern.







I took the final bolt pattern from the CF piece and used that to fabricate a piece of aluminum to mount the fender to the lower triple tree.















From here you will need to complete the brake lines (I actually had these done before I mounted the fender. I went with spiegler lines. http://www.spieglerusa.com/

I went with Spiegler lines because they come w/the ability to swivel them. This was integral on one of the lines. I went w/a 38 inch line w/a 20 degree bend (caliper side) and a 45 degree bend (ABS side) and then a 39 inch line w/a 20 degree bend (caliper side) and a 90 degree bend (ABS side). This worked out nicely and I am happy with the lengths, not too much and enough for the suspension travel plus turning of the handle bars (and enough for a full turn and full suspension load/no load).












This is what it was looking like at this point.













Now on ward to the carbon fiber. If you want to do this sort of stuff you will need to do a modest amount of research. Read Erling's posts, get on youtube etc...









Right now I am currently working on a rear luggage rack for the bike as well as other things. I will adjust this post as I continue, and will update more information etc...



So I have almost completed the rear luggage rack, this is heavy duty, incorporates many layers of carbon fiber and a few layers of kevlar. Because I had so many layers in the layup I made a few beginners mistakes so I wound up with more air bubbles than I desired in the finished product. Instead of keeping it all glossy and carbon fiber looking I opted to paint it black and will rubberize it so it has more friction. Finding bolts was a pain in the butt and I had to order online via boltdepot.com

[Hucker]

[ebrabaek]

Whoooeeeeee.... Subscribed...

[guzzimike]

Here's mine, made from a piece of sheet ally.
Horn stays.

[runnin4melife]

Originally Posted by guzzimike

Here's mine, made from a piece of sheet ally.
Horn stays.

Yeah I had looked at this but because I want to make the front fender as close to the lower triple clamp and fill in the gap where the nose once existed I am opting to remove the horn from its current location as well as the plastic housing that goes around it (will serve no more purpose once I have the new fender and snub nose made.

If I am going to go through the trouble (labor of love) of a custom fab, I am trying to make it look as professional as possible. Given the current schema and lines of body work leading up to the location where the beak was it will be somewhat difficult to get a good looking piece that flows appropriately. I am going to get some foam today and try and come up with the finished design.

[runnin4melife]

ebrabaek, any recommended foam for a carve-able mold?

[ebrabaek]

Originally Posted by runnin4melife

ebrabaek, any recommended foam for a carve-able mold?

This is what I use...... strong.....sand able, but will not melt easy with acetone.....



http://www.homedepot.com/h_d1/N-5yc1...1#.UGhQhVH-lI0

Comes in 1/2 inch as well....

[JGoody]

Originally Posted by guzzimike

Here's mine, made from a piece of sheet ally.
Horn stays.

I've always hated the beak and would like to see how the whole bike looks now -- would you share a few shots of the full bike with the mod?

[runnin4melife]

Have the foam, will carve out a good mold here shortly. I am a med student so I am trying to learn as well. Motorcycles and medicine do not fair well when competing for my time... Done with pathology case write ups and on ward to foam carving!

[guzzimike]

Originally Posted by JGoody

I've always hated the beak and would like to see how the whole bike looks now -- would you share a few shots of the full bike with the mod?

http://www.advrider.com/forums/showthread.php?t=786750

[JGoody]

Thanks for the link!

[runnin4melife]

So here is the first model, I am waiting on the fender (KTM 690 fender) to get in as I need to test spacing etc... I had worked with a few things but kept cutting it down. This is preliminary right now.







I will definitely come up with a few models to determine. This is more rounded and I might make one that follows the lines of the body work more.

[runnin4melife]

Originally Posted by guzzimike

http://www.advrider.com/forums/showthread.php?t=786750

What front fender did you use? Also did you have to make that bracket so it did not interfere with your horn etc...?

[LukasM]

I like the DIY approach, but I assume you have seen the Wunderlich snub nose front beak replacement, right?

[runnin4melife]

Originally Posted by LukasM

I like the DIY approach, but I assume you have seen the Wunderlich snub nose front beak replacement, right?

Yeah, I have seen that but don't really like it. It retains the beak appearance and since I am going with the high front fender there is no need for the beak.