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Old 03-30-2013, 01:31 PM   #1
R-dubb OP
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Joined: Aug 2001
Location: San Francisco
Oddometer: 4,796
G/S PD + some R-dubb goodness

Too soon to tell, but something tells me I might like this bike. Well over five years in the making cause I been Lolly-Gagging more than a little. Yesterday she started right up for the very first time and was Christened just down the block, at the DMV, in a three hour ceremony. Yippie.

Project grew out of the R-dubb triple clamp escapade and was to be three dirt bike airheads of various shapes and sizes. Then I bought a KTM 690 and told myself why bother. With an entire shed full of parts, I had to do something. I make it sound like drudgery, and it is. Cleaning, filing, welding, fitting, pressing, replacing, fiddling away the hours and days. Pretty soon it all turns into something special.


R-dubb screwed with this post 03-30-2013 at 02:27 PM
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Old 03-30-2013, 02:03 PM   #2
Kainic
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Joined: Oct 2005
Location: SW, CT
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Wow need details and more pics


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Old 03-30-2013, 02:11 PM   #3
Clay Spinner
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Looking nice! Did you put a spacer in the fork internals to keep them standard height? I'm asking because I would like to do the same with my r80 g/s.
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Old 03-30-2013, 03:17 PM   #4
SOLO LOBO
airhead or nothing
 
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Joined: Mar 2004
Location: Shoreline, WA
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"something special" is a bit of an understatement R-Dubb!
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Quote:
Originally Posted by Stagehand
your bike is suitably dirty. Well done.
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Old 03-30-2013, 05:59 PM   #5
ontic
 
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Old 03-30-2013, 06:04 PM   #6
bgoodsoil
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Joined: Jul 2008
Location: Washington, DC, USA
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That's the way it should've come from the factory
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Old 03-30-2013, 06:41 PM   #7
shearboy2004
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Joined: Jun 2007
Location: Ft Collins ,Colorado
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Only one thing wrong with that bike ! It should be in my garage ! Let me know when you are sick of the bad handling ill tempered thing and I'll take it off your hands !
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Old 03-30-2013, 07:11 PM   #8
One Less Harley
OH.THAT'S GONNA HURT
 
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Joined: Nov 2006
Location: Bowling Green, Ky
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One thing wrong what idiot would ride that bike the way it should be ridden with that tank on it!!! It's just for show!!! Now remove that tank and put a POS tank on it and ride it like you stole it...of just ride it like Brad would....
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Old 03-30-2013, 08:04 PM   #9
R-dubb OP
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Evolution

After ruling out an HPN style dirt bike with tall forks and a long ass swing arm, what could I do to improve the old G/S performance and keep the good looks. Mind you, this pooch started out as a basket case. Here's what I bought:





OK, it's a bit of an exaggeration to say the new bike all came from there, but much of that shit, engine and frame ended up in the final product. About five years ago I bought a really sweet ST. I fully restored it and sold it as an ST, the catch was that it came with a new, prime coat, Paris Dakar tank. The guy was going to do a conversion and quit. Wouldn't sell the tank alone, so I bought the bike. That tank, a pair of WP4357's and the clamps along with the desert wreck became the starting point. I would build a well mannered, ground up replica PD with a modern suspension, a gentleman's dual sport.



First things first, I stripped down the engine and paired the crankcase with a nice fresh set of matching R80 jugs and a sweet pair of double spring heads. Most of it would be bead-blasted in a naked state. I had a new, mild lift, Andrews cam I came across on eBay a few years back, so tossed that in for good measure. We'll see how it does.



I did a hot rod boxer engine years ago for McPeeDee, and it was truly a joy. Fantastic power aside, it was smooth as silk. That came from balancing the crank, rods and pistons. This time I did the balance, clutch and flywheel included, but did not go for high end rods or the 1050 kit. I decided that this would be a garden variety R80 with the balancing alone. I had to pull the crank anyhow, so a couple hundred bucks to spin and give her a haircut was an easy decision.

Of course the motor got all new seals, rings and fresh electrics.



Replaced seals and re-shimmed the transmission.



The frame is gusseted ala HPN.









The hardest part was actually to collect ALL the black bits for powder coating in one batch. Took freaking forever to gather it all. Then I did a dry run assembly everything bare before sending it off. I adapted a pair of bag racks from some other model, but they worked out reasonably well. Gentleman's bike must have bags! I couldn't find any decent used or after market black engine guards, so I stripped and painted a set of the chrome ST version.

OEM side-stand had to go. Rolled my own and it works like a champ. Make special note of that shit bag weld. Sorry, that's really good for me. It's strong anyhow.



I set up the forks in the triple clamps and figured out how to mount the OEM clam shell. Worked out fairly well by cutting away flanges on a pair of aluminum angles and bolting it all together into the stock grommets.







Yes, I shortened the forks. First I tried a 65mm spacer, then decided to go back in and make it 35mm instead. Springs are the stiffest ones Jeff Slavens can fit into the WP legs (.54kg/mm). I cut them shorter and flattened the ends with a torch and hammer on the vise. So far the bike feels well balanced and plush.



I worked with Tom Cutter and Klaus Huenecke at EPM for months to setup the shock. We agreed early on that I would use a high-end YSS shock. No Ohlins, wanted to try something new. Klaus sent me a bare mock up shock, spring included, but no damping, to get the length right and dial in sag. It was hard because the bike was also mocked up in the frame before powder. I added sand bags to approximate weight and decided his suggested spring was far too soft. Klaus then talked me into a Hyperpro progressive spring. So far it feels great. I wanted as much height as possible and opted for 375mm in length. It barely fits into the swing arm fully extended, but the u-joint still works freely. I had the shaft rebuilt by HPM Guy (stock length swing arm).





I laced a front wheel, matching a KTM 20mm hub to an Excel 1.85 Euro rim. Didn't work. Whodah thunk, KTM used an American style hub on the 43's. Had to get another rim from Buchanan with the correct indexing. Second time it went together perfectly. This pic is the booboo.



Brake caliper and rotor is from a KTM950SE. I used the OEM master to keep stock controls.





Carbs, airbox, cables, clutch, are all stock, cleaned up from bits I had laying about. The pipes and collector are new flat black, which I sent out for ceramic coating. The exhaust is Sito, which I'm planning to switch out to OEM as soon as I can get the correct part. Interestingly, on the PD version G/S, the silencer is an ST part, chrome with a black metal guard. I have the guard powder coated and ready for the can whenever the boys in Munich decide to make a batch.



Electrical harness is from the desert wreck, but completely gone through and re-taped. Interestingly, I found out that the wreck bike was also an ST conversion. It had all G/S stuff planted on. The tell tale was a non-cleated brake pedal and mismatched connector at the headlight on the harness.



Lastly, the paint is, of course, Alpine White. I got a decal set, seat and rack from Boxxerparts.de. Josh with CycleFinish in Menlo Park did the painting. It is color, followed by decals followed by clear. He even painted that shitty dirt bike plastic fender material. Turned out beautiful, as you can see!!! Thanks Josh.





I'll post a list of full credits and sources later.

Cheers!!!

R-dubb screwed with this post 03-31-2013 at 11:25 AM
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Old 03-30-2013, 09:17 PM   #10
Spark Plug
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Beautiful bike!!
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Old 03-30-2013, 09:32 PM   #11
villageidiot
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Joined: Apr 2010
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Absolutely stunning.
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Old 03-31-2013, 06:38 AM   #12
Sutherngintelmen
around the bend
 
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Location: ATL
Oddometer: 1,186
Fantastic!
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Old 03-31-2013, 07:21 AM   #13
hardwaregrrl
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Joined: Jan 2006
Location: Atlanta
Oddometer: 7,054
Wowsa!!!! Don't let me near it.......it'll break and get dirty.
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Old 03-31-2013, 07:45 AM   #14
patrkbukly
52 Weeks of warm
 
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Location: Miami, FL.
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Damnit Janet

That this is sweet. But I am torn....should'nt it be sitting behind glass in Munich?

Damn good looking.
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Old 03-31-2013, 07:46 AM   #15
Beater
Is it broke yet?
 
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Joined: Sep 2009
Location: Atlanta, GA, USA
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I can not be trusted with something that nice.

That is beautiful. Go R-dubb.
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