BMW R100 CS from delapidated to Cafe Racer...

Discussion in 'Airheads' started by Big Al_SA, Sep 1, 2011.

  1. Big Al_SA

    Big Al_SA Adventurer

    Joined:
    Aug 10, 2009
    Oddometer:
    61
    So here's my contribution to the 'Old's Cool" section. Enjoy my 660 Tenere' bigtime, but while browing here and there, discovered the 'Cafe racer's threads, and went mental. Finally dived in and decided to go the route of BMW Airhead for my rebuild. Discussed with my good friend max, a BMW specialist, and he felt the BMW would be a better bike to do this project with. So after a few weeks of looking around, we finally found one.

    This is what the owner advertised.
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    But when we saw it in real life, it had been left outside in the Cape Town Winters for 2 years, and was decidedly under the weather. made him a good offer, and we got the bike.

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    Plan was to do a good cleanup, get the Roadworthy done, Registration and change of ownership, and THEN start the strip down.
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    General condition can be seen in these Pics. we have work ahead of us.

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    One of the nice things with this bike is it has everything intact and with it. Everything works, all the lights and indicators are good, and nothing's cracked. So, we decided to strip off the nose fairing, and give it a really good cleanup. Then take it to get the Roadworthy done.

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    Working hard..

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    Finally cleaned, battery charged, all running.. off to Roadworthy.

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    :clap And he passed with flying colours. The Inspector was quite impressed with the old Boy, the Motor in this bike's in excellent condition, and has excellent pulling power. Clutch, Brakes are all good, but we'll uprate them as we do the conversion.
    Got it home, and then we started the big strip. This has been done over a period of about 2 months, as time allows us.
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    Starting to get down to the bare essentials now.. My intention is to build a proper 'short-tail' look with a bum cone, which I decided I'd make myself.

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    First had to get a good idea of where we were going to cut the old tailpiece.

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    CUT IT... :eek1

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    More to follow.. :freaky

    Al
    #1
  2. xavier296

    xavier296 Alaska n'Back

    Joined:
    Nov 7, 2010
    Oddometer:
    286
    Location:
    Augusta, GA
    Looks great! Take and post all the pics you can, I get so many ideas from other inmates!
    #2
  3. Big Al_SA

    Big Al_SA Adventurer

    Joined:
    Aug 10, 2009
    Oddometer:
    61
    Catching up to the previous thread. So we'd cut the tailpiece, and needed to do some welding here and there, as well as to create mounting points for the Indicators etc. Trying to have as much fabrication done before it all goes inf or painting.

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    Getting an idea of what to do for a mudguard.

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    Making the Bumbox myself before we cut the chassis. I got some soft foam, and shaped the shape I was looking for. I didn't like some of the commercially available kits, or their shapes. Doing it myself would be more personal satisfaction when it was completed.

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    Once finished. I then layed it up with Fibreglass and resin. and eventually handed it in to a spraying ship to smooth it down and spray it.

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    I'm really pleased with the size, and finish. it won't look too small or "lost" on the bike, and should add a decent finish and profile to the rear.

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    So, a few weeks later, we finally managed to get the Motor out. We decided to not split the motor, but instead, we'd clean it up as best as possible, but I'd get some panels resprayed, and cleaned up manually.

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    Bike Frame down to the last bits.

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    We're also going to do a Bigger Front Brake Conversion. Busy Getting the Disc made, and made up a bracket to support an old Caliper.

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    Got the Disc cut and drilled, but it's still too thick, so it's gone back to get some material removed.

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    More soon.
    #3
  4. Big Al_SA

    Big Al_SA Adventurer

    Joined:
    Aug 10, 2009
    Oddometer:
    61
    Ok, more or less current.
    Got all the parts back from the Paint Shop. Got the Matt Finish Engine Covers back, and proceeded to paint on Silver Detailing.

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    Came out clean and neat. so carried on.

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    Also did the BMW Logo on the top Motor cover.

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    Also gont the front fairing resprayed, although I'm not sure I'm going to use it, but in case, I decided to refurb the whole fairing.

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    So, that's where I'm at. Looking forward to the rebuild process now. Will continue in about 3 weeks time as I'm off on a well deserved break to the UK and Europe.

    regards

    Al
    #4
  5. JonnyCash

    JonnyCash turd polisher

    Joined:
    Jan 22, 2011
    Oddometer:
    1,774
    Location:
    Midcoast, Maine
    Wow, that's a particularly nice tail section you built there. Looking froward to seeing your progress.
    #5
  6. squiffynimrod

    squiffynimrod maximum shrinkage

    Joined:
    Mar 23, 2010
    Oddometer:
    1,656
    Location:
    Flatskatchewan
    "Got all the parts back from the Paint Shop. Got the Matt Finish Engine Covers back, and proceeded to paint on Silver Detailing"

    If you find the silver paint doesn't hold up, just sand off the paint and finish the aluminum with about a 600 grit waterproof paper. Did that with my valve and starter covers after they were powder coated. Turned out great!
    #6
  7. groop

    groop So much to ponder

    Joined:
    Jun 5, 2007
    Oddometer:
    3,796
    Location:
    oc, ca
    :lurk
    #7
  8. Airhead Wrangler

    Airhead Wrangler Long timer

    Joined:
    Mar 4, 2008
    Oddometer:
    6,822
    Location:
    Back in Seattle, FINALLY
    If you consider what you started with "dilapidated" then you'd consider mine "devastated."

    Looking good so far. :clap
    #8
  9. LynxSS

    LynxSS Been here awhile

    Joined:
    Feb 20, 2008
    Oddometer:
    488
    Location:
    Santa Fe, NM
    :thumb

    Wow really nice job! :clap
    #9
  10. Big Al_SA

    Big Al_SA Adventurer

    Joined:
    Aug 10, 2009
    Oddometer:
    61
    Right, so almost 3 months later, :roflgot to do some more work.. Went to the UK in September, and bought some Stainless Steel Bolt Packs off eBay for the R100 rebuild process, as well as some clothing, Fuel Cap for the tank etc.
    Then been busy finishing the stripping of every other nut and bolt and bit.. :clap

    Then it went in for respraying, that was October sometime. Getting a little side-tracked, I see the Pics of the Motor covers were already here. Ok, so every other Nut and Bolt and washer were sent in a Nickel Plated. Also took a while, but finally got it all back, and re-assembly has started.

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    Pictured here, the left container is all the Stainless Bolts and bits from the UK. the middle and right container are the old, original nuts and bolts which have been plated. Top container the axles, motor bolts etc also plated. Makes the finished product look awesome. On the right, the hangers for my home made rearsets.. :wink:

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    Ok the parts are obviously marked with prints as we're busy re-assembly, but that will all be cleaned properly again. Here, the brackets which hold the Coils under the tank, showing the Stainless Bolts, as well as the Satin finish on the chassis..

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    Also showing the Front wheel detail, Stainless bolts everywhere, and the new single front Disc conversion.

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    Rear wheel, and Diff detailing.. Nickel Plating is awesome..

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    Pictured, the newly sprayed Sump and SSteel bolts..

    So, we're well on our way now. Motor's going to get some highlighting spraywork done, to give it an uprated clean look, and then in it goes. More to follow soon I hope.. itching to get this completed now.. :lol3

    Al
    #10
  11. WU7X

    WU7X The Old Fart

    Joined:
    Aug 21, 2007
    Oddometer:
    2,312
    Location:
    Spoke Can, WA
    :lurk
    #11
  12. Big Al_SA

    Big Al_SA Adventurer

    Joined:
    Aug 10, 2009
    Oddometer:
    61
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    #12
  13. Big Al_SA

    Big Al_SA Adventurer

    Joined:
    Aug 10, 2009
    Oddometer:
    61
    Not going to elaborate too much as I have to repeat post this build in multiple places.. So Pics here. The Build can be found here: http://www.paterson.co.za/bikes/bmw/project.htm

    Latest updates from Page 7.

    Repaired my Diode Board with replacement "field" diodes.

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    Fitted some Gators on the front Shockws, as well as home made single Disc conversion, custom bracket and BMW Caliper.

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    Made some Nylon Spring Spacers..

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    Put the Tail on to get an idea of what he's going to look like..

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    More next year.. Happy New Year to you all.

    :freaky

    Al
    #13
  14. Hawk Medicine

    Hawk Medicine Coyote's Brother

    Joined:
    Jun 8, 2008
    Oddometer:
    3,304
    Location:
    NOR CAL
    Yeah, and a Happy New Year to you too! :freaky

    I'll be expecting to see that old crock lit up and rocking before the years out! :evil
    #14
  15. Big Al_SA

    Big Al_SA Adventurer

    Joined:
    Aug 10, 2009
    Oddometer:
    61
    Went and finished cleaning up the Gearbox.. :cry My fingers....

    Here's a Pic of the finished top yoke, showing Nylon Washers under Shock Nuts. Looks nice and clean, ready for bars.

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    And the Gearbox, finally in.

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    More next year. HAPPY NEW YEAR... :freaky

    Al
    #15
  16. Les_Garten

    Les_Garten Been here awhile

    Joined:
    Oct 6, 2011
    Oddometer:
    744
    Location:
    PSL, FL
    Tasty Bits there!
    #16
  17. Big Al_SA

    Big Al_SA Adventurer

    Joined:
    Aug 10, 2009
    Oddometer:
    61
    Went and did some more today.. Decided to mount parts which were mountable..

    Front Mudguard.

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    Put the Bar on, as well as new Clock Mount Bracket.

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    Mounted the refirbished Coils, as well as a custm bracket for the Ignition Unit.

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    Put the Rocker covers on, and also checked the Aluminium covers which I'll fit on the side of the bike to clse up that see-through section..

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    And then put the Tank and Seat on to see what the finished bike "should" look like.. Herman's coming along...

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    Looking good I think.. A Cafe' Racer in the making... :D

    Al
    #17
  18. sjudge.nz

    sjudge.nz n00b

    Joined:
    Sep 19, 2011
    Oddometer:
    2
    Hi ya, was great to find your posts I'm also doing up an old BMW r100cs and want to change to a cafe racer style motorcycle this is as far as I've got so far... Will keep an eye on your posts

    Attached Files:

    #18
  19. Big Al_SA

    Big Al_SA Adventurer

    Joined:
    Aug 10, 2009
    Oddometer:
    61
    Hey,
    that's nice and clean, and definitely huge potential.. You're braver than me for stripping that wiring loom out the Headlight.. :D

    Cheers

    Al
    #19
  20. sjudge.nz

    sjudge.nz n00b

    Joined:
    Sep 19, 2011
    Oddometer:
    2
    I didn't have much choice, the wiring burn't out and needed replacing so I had to make a whole new main loom. I'm still hoping I can figure how it all goes back together.
    #20