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-   -   Custom snub nose F800GS (http://www.advrider.com/forums/showthread.php?t=830356)

runnin4melife 09-29-2012 06:13 PM

Custom snub nose F800GS
 
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.

http://i1116.photobucket.com/albums/...49767836_n.jpg

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.

http://i1116.photobucket.com/albums/...e/IMAG1246.jpg

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

http://i1116.photobucket.com/albums/...e/IMAG1251.jpg

http://i1116.photobucket.com/albums/...e/IMAG1283.jpg

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.

http://i1116.photobucket.com/albums/...e/IMAG1265.jpg

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.

http://i1116.photobucket.com/albums/...e/IMAG1298.jpg

http://i1116.photobucket.com/albums/...e/IMAG1316.jpg

http://i1116.photobucket.com/albums/...0_BURST002.jpg

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.

http://i1116.photobucket.com/albums/...3_BURST001.jpg

http://i1116.photobucket.com/albums/...e/IMAG1306.jpg

http://i1116.photobucket.com/albums/...e/IMAG1307.jpg

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.

http://i1116.photobucket.com/albums/...ps49f35f9b.jpg

http://i1116.photobucket.com/albums/...psc8f02dea.jpg

http://i1116.photobucket.com/albums/...ps87734da4.jpg

http://i1116.photobucket.com/albums/...4_BURST002.jpg

http://i1116.photobucket.com/albums/...e/IMAG1373.jpg

http://i1116.photobucket.com/albums/...e/IMAG1375.jpg

http://i1116.photobucket.com/albums/...e/IMAG1376.jpg

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/

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http://i1116.photobucket.com/albums/...2_BURST001.jpg

http://i1116.photobucket.com/albums/...e/IMAG1324.jpg

http://i1116.photobucket.com/albums/...8_BURST002.jpg

http://i1116.photobucket.com/albums/...e/IMAG1330.jpg

http://i1116.photobucket.com/albums/...e/IMAG1325.jpg

This is what it was looking like at this point.

http://i1116.photobucket.com/albums/...e/IMAG1381.jpg

http://i1116.photobucket.com/albums/...e/IMAG1379.jpg

http://i1116.photobucket.com/albums/...e/IMAG1377.jpg



http://i1116.photobucket.com/albums/...ps16d58553.jpg

http://i1116.photobucket.com/albums/...ps1ca9df0e.jpg

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...

http://i1116.photobucket.com/albums/...e/IMAG1398.jpg

http://i1116.photobucket.com/albums/...e/IMAG1400.jpg

http://i1116.photobucket.com/albums/...e/IMAG1402.jpg

http://i1116.photobucket.com/albums/...e/IMAG1403.jpg

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...

http://i1116.photobucket.com/albums/...e/IMAG1434.jpg

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

<a href="http://s1116.photobucket.com/albums/k571/Herman_Melville/?action=view&amp;current=IMAG1469.jpg" target="_blank"><img src="http://i1116.photobucket.com/albums/k571/Herman_Melville/IMAG1469.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1116.photobucket.com/albums/k571/Herman_Melville/?action=view&amp;current=IMAG1470.jpg" target="_blank"><img src="http://i1116.photobucket.com/albums/k571/Herman_Melville/IMAG1470.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1116.photobucket.com/albums/k571/Herman_Melville/?action=view&amp;current=IMAG1467.jpg" target="_blank"><img src="http://i1116.photobucket.com/albums/k571/Herman_Melville/IMAG1467.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1116.photobucket.com/albums/k571/Herman_Melville/?action=view&amp;current=IMAG1466.jpg" target="_blank"><img src="http://i1116.photobucket.com/albums/k571/Herman_Melville/IMAG1466.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1116.photobucket.com/albums/k571/Herman_Melville/?action=view&amp;current=IMAG1465.jpg" target="_blank"><img src="http://i1116.photobucket.com/albums/k571/Herman_Melville/IMAG1465.jpg" border="0" alt="Photobucket"></a>

Hucker 09-29-2012 08:02 PM

:lurk

ebrabaek 09-29-2012 08:50 PM

Whoooeeeeee.... Subscribed...:D

guzzimike 09-29-2012 11:05 PM

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

http://guzzimike.smugmug.com/Motorcy.../IMG5195-L.jpg

runnin4melife 09-30-2012 04:35 AM

Quote:

Originally Posted by guzzimike (Post 19710874)
Here's mine, made from a piece of sheet ally.
Horn stays.

http://guzzimike.smugmug.com/Motorcy.../IMG5195-L.jpg

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 09-30-2012 05:03 AM

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

ebrabaek 09-30-2012 07:02 AM

Quote:

Originally Posted by runnin4melife (Post 19711416)
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/catalog/pro...8290aa_300.jpg

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

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

JGoody 09-30-2012 07:58 AM

Quote:

Originally Posted by guzzimike (Post 19710874)
Here's mine, made from a piece of sheet ally.
Horn stays.

http://guzzimike.smugmug.com/Motorcy.../IMG5195-L.jpg

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 09-30-2012 10:04 AM

Foam in hand
 
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... :cry Done with pathology case write ups and on ward to foam carving!

guzzimike 09-30-2012 06:18 PM

Quote:

Originally Posted by JGoody (Post 19712211)
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 09-30-2012 06:27 PM

Thanks for the link!

runnin4melife 10-01-2012 05:40 AM

First model
 
Skipped the proposed rounded front...

runnin4melife 10-01-2012 05:42 AM

Quote:

Originally Posted by guzzimike (Post 19715668)

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

LukasM 10-01-2012 07:42 AM

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

runnin4melife 10-01-2012 08:38 AM

Quote:

Originally Posted by LukasM (Post 19718579)
I like the DIY approach, but I assume you have seen the Wunderlich snub nose front beak replacement, right? :evil

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.


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