1981 R80 G/S. repair/rebuild in Uganda

Discussion in 'Airheads' started by mennleo, Oct 24, 2012.

  1. mennleo

    mennleo Been here awhile

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    [​IMG]
    This is from about a year ago before wreck.

    History: I got the bike after it hit the back of a car at high speed. Frame, forks, handle bars, front wheel bent. I will get it back on the road!
    #1
  2. mennleo

    mennleo Been here awhile

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    So I found a R100ST frame. Basic frame seems to be the same. I will need to remove old brackets and fittings from old frame and put on new frame plus a few extra reinforcements. Above is part of my jig on old frame

    [​IMG]

    Added patch/doubler to lower front tubes because one side had small crack. Added gusset between lower tubes and bottom of head tube.
    #2
  3. mennleo

    mennleo Been here awhile

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    Here is the basic mock up. After looking for original parts and$$$. I realized I have a perfectly good 1991 Honda CRM front end. Why not put that on?? ;)

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    #3
  4. mennleo

    mennleo Been here awhile

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    Take your MIG or TIG and run a bead around it and the race falls out. Piece o cake.
    #4
  5. Beater

    Beater The Bavarian Butcher

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    Holy Crap. This is great.

    :lurk
    #5
  6. mennleo

    mennleo Been here awhile

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    #6
  7. mennleo

    mennleo Been here awhile

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    Even the kids are enjoying!!

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    #7
  8. Beater

    Beater The Bavarian Butcher

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    This is great.

    And I respectfully disagree.

    :D


    [​IMG]
    #8
  9. mennleo

    mennleo Been here awhile

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    Well that is just the old bent cover that a local "repair shop". Butcherd by welding and body filler. I have a better one.

    [​IMG]

    After accident the bike was taken to a local auto shop for insurance repair. They destroyed so much. :(. Above is there frame straightening repair.
    #9
  10. hardwaregrrl

    hardwaregrrl ignore list

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    Nice! Can't wait to see the end result!!!


    Fred, are you still at work? I just sent you a text.
    #10
  11. Clay Spinner

    Clay Spinner Been here awhile

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    Great thread so far... keep em coming!!! I like the fact that the forks match the tank decals (if you aren't too fussed about contrast) - blue on blue! Nice work
    #11
  12. mennleo

    mennleo Been here awhile

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    [​IMG]

    [​IMG]

    Doubler cut from old lower tube and welded under rear shock mount.
    #12
  13. mennleo

    mennleo Been here awhile

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    Frame painted!!!

    [​IMG]
    Leftovers from old frame. Lots of cutting, grinding and welding.
    #13
  14. hardwaregrrl

    hardwaregrrl ignore list

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    Ok, ok.....this is why I love ADV rider. We have people throwing stupid money at professionaly built bikes, and then we have threads like this. Someone home welding their frame and using 2x4's as a frame jig!!! I love it!!

    Thanks for the education mennleo!!!! Keep the story and pics coming!! Oh, can we have a close up of the steering head repair that YOU did, cause the one the insurance co did it scarey...:eek1
    #14
  15. Beater

    Beater The Bavarian Butcher

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    +1 !!!

    :lurk
    #15
  16. Cordless

    Cordless Two Wheel Addict

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    This is great. Keepthe story coming.

    Based on what you reported here I have decided to keep the old /5 frame I got in a parts cache I bought rather than throw it away because it has no title. I hadn't thought about how much good metal material it has that might help me or someone else with a damaged airhead frame.

    I saw some evidence of the inventiveness of African Engineering when I worked in Angola for a brief time.
    #16
  17. mennleo

    mennleo Been here awhile

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    I did not repair new frame steering head. That is why I got the new frame to start with straight strong frame. I did add the triangle "ish" gusset between bottom of steering head and lower tubes. There are some other threads that address frame reinforcements in same areas but do it differently.
    #17
  18. Stagehand

    Stagehand Imperfectionist

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    :lurk great stuff.
    #18
  19. mennleo

    mennleo Been here awhile

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    Ducati head bearings are 52mm od. 26mm id. 52 for BMW and 26 for Honda. The only problem is the honda head tube is about 5/8" taller. I was going put in 5/8" spacer under top clamp but that moves top bearing down to reduced dia. In center of shaft. I was able to press shaft out of lower clamp, cut off about 5/16" and regroove for keeper ring. Now it works with 1/4" spacer.

    [​IMG]
    #19
  20. mennleo

    mennleo Been here awhile

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    I am back from some travels. Got some more parts on and got the engine running. Sounds good with straight pipe!
    #20