Custom snub nose F800GS

Discussion in 'Parallel Universe' started by runnin4melife, Sep 29, 2012.

  1. runnin4melife

    runnin4melife Been here awhile

    Joined:
    Mar 23, 2012
    Oddometer:
    806
    Location:
    "No shit when I was back at Bragg!!!"
    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.

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    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.

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

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    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.

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    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.

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    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.

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    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.

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    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/

    <!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:TrackMoves/> <w:TrackFormatting/> <w:punctuationKerning/> <w:ValidateAgainstSchemas/> <w:SaveIfXMLInvalid>false</w:SaveIfXMLInvalid> <w:IgnoreMixedContent>false</w:IgnoreMixedContent> <w:AlwaysShowPlaceholderText>false</w:AlwaysShowPlaceholderText> <w:DoNotPromoteQF/> <w:LidThemeOther>EN-US</w:LidThemeOther> <w:LidThemeAsian>X-NONE</w:LidThemeAsian> <w:LidThemeComplexScript>X-NONE</w:LidThemeComplexScript> <w:Compatibility> <w:BreakWrappedTables/> <w:SnapToGridInCell/> <w:WrapTextWithPunct/> <w:UseAsianBreakRules/> <w:DontGrowAutofit/> <w:SplitPgBreakAndParaMark/> <w:DontVertAlignCellWithSp/> <w:DontBreakConstrainedForcedTables/> <w:DontVertAlignInTxbx/> <w:Word11KerningPairs/> <w:CachedColBalance/> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> <m:mathPr> <m:mathFont m:val="Cambria Math"/> <m:brkBin m:val="before"/> <m:brkBinSub m:val="&#45;-"/> <m:smallFrac m:val="off"/> <m:dispDef/> <m:lMargin m:val="0"/> <m:rMargin m:val="0"/> <m:defJc m:val="centerGroup"/> <m:wrapIndent m:val="1440"/> <m:intLim m:val="subSup"/> <m:naryLim m:val="undOvr"/> </m:mathPr></w:WordDocument> </xml><![endif]--> 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).
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    This is what it was looking like at this point.

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    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...

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    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...

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    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>
    #1
  2. Hucker

    Hucker Lost

    Joined:
    Dec 3, 2009
    Oddometer:
    706
    Location:
    Southern AZ
    :lurk
    #2
  3. ebrabaek

    ebrabaek Long timer

    Joined:
    Jan 12, 2010
    Oddometer:
    4,912
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    Grand Valley, Colorado
    Whoooeeeeee.... Subscribed...:D
    #3
  4. guzzimike

    guzzimike Long timer

    Joined:
    Aug 13, 2008
    Oddometer:
    1,405
    Location:
    Them Thar Hills WA Australia
    Here's mine, made from a piece of sheet ally.
    Horn stays.

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    #4
  5. runnin4melife

    runnin4melife Been here awhile

    Joined:
    Mar 23, 2012
    Oddometer:
    806
    Location:
    "No shit when I was back at Bragg!!!"
    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.
    #5
  6. runnin4melife

    runnin4melife Been here awhile

    Joined:
    Mar 23, 2012
    Oddometer:
    806
    Location:
    "No shit when I was back at Bragg!!!"
    ebrabaek, any recommended foam for a carve-able mold?
    #6
  7. ebrabaek

    ebrabaek Long timer

    Joined:
    Jan 12, 2010
    Oddometer:
    4,912
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    Grand Valley, Colorado
    #7
  8. JGoody

    JGoody Been here awhile

    Joined:
    Nov 20, 2011
    Oddometer:
    291
    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?
    #8
  9. runnin4melife

    runnin4melife Been here awhile

    Joined:
    Mar 23, 2012
    Oddometer:
    806
    Location:
    "No shit when I was back at Bragg!!!"
    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!
    #9
  10. guzzimike

    guzzimike Long timer

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    Aug 13, 2008
    Oddometer:
    1,405
    Location:
    Them Thar Hills WA Australia
    #10
  11. JGoody

    JGoody Been here awhile

    Joined:
    Nov 20, 2011
    Oddometer:
    291
    Thanks for the link!
    #11
  12. runnin4melife

    runnin4melife Been here awhile

    Joined:
    Mar 23, 2012
    Oddometer:
    806
    Location:
    "No shit when I was back at Bragg!!!"
    Skipped the proposed rounded front...
    #12
  13. runnin4melife

    runnin4melife Been here awhile

    Joined:
    Mar 23, 2012
    Oddometer:
    806
    Location:
    "No shit when I was back at Bragg!!!"
    #13
  14. LukasM

    LukasM Long timer

    Joined:
    Nov 15, 2006
    Oddometer:
    5,445
    Location:
    On a RTW ride - next stop USA!
    I like the DIY approach, but I assume you have seen the Wunderlich snub nose front beak replacement, right? :evil
    #14
  15. runnin4melife

    runnin4melife Been here awhile

    Joined:
    Mar 23, 2012
    Oddometer:
    806
    Location:
    "No shit when I was back at Bragg!!!"
    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.
    #15
  16. guzzimike

    guzzimike Long timer

    Joined:
    Aug 13, 2008
    Oddometer:
    1,405
    Location:
    Them Thar Hills WA Australia
    Fender is an aftermarket (Polisport?) for a KTM 450exc.
    The mounting bracket is made from a piece of plastic cutting board, (tough stuff that shit) I meant to paint it black but tried a fit up before painting and then couldn't be arsed taking it apart again.
    It is mounted by the 2 bolts (6mm) that hold the semi circular plastic bit to the bottom triple, spaced out with 20mmOD, 6mm ID x 15mm ally spacers (home made) and a replaced longer (60mm) horn bolt, again with spacer.
    This all gives spanner access to the 4 x 6mm bolts that mount the fender to the cutting board, again with spacers, you can see 'em in the pic.
    The long horn bolt is accessed through a hole drilled in the guard large enough for the socket spanner, it is locked by a nut above the horn.
    I hope all this makes sense, it's a lot harder to explain than to do.
    IT has just been across Oz on the dirt with no problems, in fact there is less crap comes off the front wheel into your face than with the stock guard.
    My design is not original, thanks go to Dan (WW Ronin) for the inspiration, you can find his detailed build on this forum.
    I don't like the Wunderlich "beak" either. (and the $$$!)
    #16
  17. runnin4melife

    runnin4melife Been here awhile

    Joined:
    Mar 23, 2012
    Oddometer:
    806
    Location:
    "No shit when I was back at Bragg!!!"
    Yeah it looked very similar to the setup I had seen before. I am rolling with the KTM 690 fender (which hopefully will be here soon). Since I am relocating the horn I plan on bringing it right up on the lower triple so I am hoping I do not need to make much if any form of spacers. If so I will probably make it out of CF. Waiting for now and will see once I get the fender in. Motorfiets has the 690 on his which looks great but he also has the KTM front suspension which makes hookup easy.
    #17
  18. runnin4melife

    runnin4melife Been here awhile

    Joined:
    Mar 23, 2012
    Oddometer:
    806
    Location:
    "No shit when I was back at Bragg!!!"
    As soon as I get the KTM fender in and fit it I will come up with the final design, if anyone has suggestions etc... please let me know, especially if you have attempted to do something similar. :evil
    #18
  19. Snowy

    Snowy Long timer

    Joined:
    Dec 2, 2008
    Oddometer:
    2,038
    G'day mate, I have a quick question for you. You had a 1200GS? If you were riding dirt roads (the sort of dirt roads you get in WA) and you were doing it 2 up with a load, would the 1200 be a better choice for the dirt?

    I figure if you've had both, and ridden both with decent loads on on those roads, then you'll probably come the closest to understanding the issues I have with riding fire trails 2 up.

    It'd be interesting to hear what you think. Sorry for the hi-jack.

    The high fender option is something I'm still planning for the F800. I have the alloy plate and a mud guard. I just lost the will power somewhere along the line.
    #19
  20. guzzimike

    guzzimike Long timer

    Joined:
    Aug 13, 2008
    Oddometer:
    1,405
    Location:
    Them Thar Hills WA Australia
    PM sent

    #20