HPN Paris Dakar replica

Discussion in 'Airheads' started by adventure950, Jul 19, 2011.

  1. hardwaregrrl

    hardwaregrrl ignore list

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    Wow!:eek1 That is some serious welding!!!! Thanks for keeping us along!:thumb
    #41
  2. adventure950

    adventure950 Anglo-Saxon

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    Bit of an up shot into the underneath of the side plates, A 'V' shape was cut into the leading edge of the original plates and the new plates and a welded seam put into this area this gives 6 mm of plating to the sides of the headstock, then the original inner plates are stitched to the down tubes on the front edge of the tubes. you can also see a bit of the saddle edges on the spine tube this goes right forward into the rear of the headstock along the edges of the spine tube. The spine tube is excellent quality however a lot of the link tubes used by bmw seem to be thinner than 3 mm and are not as strong as the main tubes.

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    #42
  3. Deadly99

    Deadly99 Fast and Far

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    And then......


    :lurk
    #43
  4. adventure950

    adventure950 Anglo-Saxon

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    been busy I am afraid but the oil cooler hangers done and a few other bits, it the swing arm next but you people just need to hang in there am afraid. forgot to take the camera down the workshop. Starting the wiring harness this week its like sorting out a monkeys nest
    #44
  5. adventure950

    adventure950 Anglo-Saxon

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    Bye the way I will be selling a used 43 litre tank, HPN tank fitting kit a HPN front bar to fit r80/100gs to allow the tank to be mounted and a pair of fairing side panels so the whole lot goes onto an R80/100gs looks like this picture when all done but the tank for sale is white none paintable the side panels are done in white primer, and the frontbar in black stove enamel. Make me an offer for the the lot plus postage. if anyones interested. Be available september time.

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    #45
  6. Beemerguru

    Beemerguru Beemerguru...G/S guy

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    Since you're lengthening the swing arm and extending the forks, you may want to consider repositioning the foot peg mounts lower for extra leg room and lower center of gravity when on the pegs.

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    #46
  7. Beemerguru

    Beemerguru Beemerguru...G/S guy

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    But then like all fab jobs..change one thing and something else needs to be tweaked..like the brake pedal..it gets heated and a little bend so it works properly.

    Attached Files:

    #47
  8. Airhead Wrangler

    Airhead Wrangler Adios Mexico

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    Mounting your shocks to the subframe?!?!? :eek1
    #48
  9. Beemerguru

    Beemerguru Beemerguru...G/S guy

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    Reinforced and mounted just like the original
    #49
  10. adventure950

    adventure950 Anglo-Saxon

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    Hi Mate I dont think I need to move the footpegs mounts down as I use lowered footpegs on the chassis already and the problem is as you say you start to invoke a lot more work for little gain, unless i had much longer legs then It may have been worth the while, But ta for the interest and your comments.

    Regarding the suspension mounts and the way you have done your bike - looks like you have done a lot of work -your bikes set up at the rear differs from the original Paris dakar bikes which are based on the 247E chassis Type (ie monoshock g/s, st and gs) and the suspension mounts when set up for twin shock are are on the mainframe not the sub frame. Below is a picture typical of the HPN PD set up.

    The sub frame in engineering terms is not really the ideal place to achieve good suspension Geometry or strength for a heavy off road bike. But like I say somewhere earlier in this thread we all go our own way to achieve what we want and I am sure your very happy with your own set up. What I am doing is maybe no good to the purist HPN rider, no problem to me as he /she would not be riding my bike - I am also restricted by a limited budget along with wishing to add some of my own designs into the bike and chassis,Thus it will be unique and my own design (with accepted a lot of HPN ideas and research slotted in to the design.

    Attached Files:

    #50
  11. adventure950

    adventure950 Anglo-Saxon

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    A few more pictures of the chassis coming along still a long way to go this one shows the oil cooler mounts in place doesOC on that frame meen oil cooler or orange county - when you look at that raked long front end makes you wonder.

    Attached Files:

    #51
  12. adventure950

    adventure950 Anglo-Saxon

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    And one of the neat alloy bobbins with rubber edge for the tank carrier the oil cooler can be seen in place.

    Attached Files:

    #52
  13. adventure950

    adventure950 Anglo-Saxon

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    this one is a dry run again of the tank, a spare engine and gearbox etc in place even pushed on some tyres to get some idea of the proportions. The oil cooler sits neatly between the tank but tucked in tight and out of the way.

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    #53
  14. adventure950

    adventure950 Anglo-Saxon

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    and from the other side, you can see the sub frame, swing arm and stand all need work to start now. I also have a big pile of wires, sockets relays and stuff waiting for the wiring harness which I am about to start next week. Been trying to work out some layout for the electrics at the moment.

    Attached Files:

    #54
  15. adventure950

    adventure950 Anglo-Saxon

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    The spine tube, now with spacers welded , drilled and tapped for the mounting of plates to carry all the electrics so when done they will be nice and neat.

    Attached Files:

    #55
  16. adventure950

    adventure950 Anglo-Saxon

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    A few more pics first one the battery box fabricated from 2 mm aluminium plate taking shape - needs to be welded on the bottom edges. The shock mounts are to be re modelled as these were on the frame when I bought it but were incorrect - but that is in the next stage of welding, also have made an error with the tank mounting points and they need to be moved up 38mm. pain but its to be redone.

    Attached Files:

    #56
  17. adventure950

    adventure950 Anglo-Saxon

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    Her you can see the plates bolted in place for hanging all of the electrics on, the front plate carries the two twin tower dyna coils, the large plate behind will carry the electronic ignition box, relays and fuse box. I have just started to do a first fit of the wiring to start building up a harness - its slow work.

    Attached Files:

    #57
  18. CordR

    CordR Been here awhile

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    Great work so far.

    I'm watching with interest as I have hopes to turn my 89 GSPD into a poor, poor man's HPN.


    Cord
    #58
  19. adventure950

    adventure950 Anglo-Saxon

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    Hi CordR even though this is a spare chassis, and I already have a donor bike with HPN tank, fairing rebuilt engine etc - Its still an expensive job, HPN for the Paris dakar chassis work, swing arm, sub frame and driveshaft cost about 2,500 uk pound, but then its all the other stuff suspension, tank fairing, exhausts any engine work different wheels and oh so expensive forks that start the tally running. I have a donor bike a r80gs for the engine and gearbox I am still running that at the moment, I also have a scrap r80 road bike i am using for fitting and setting up on the mock up chassis - you can see the engine and gearbox in the photos.
    Getting HPN to do the chassis would be easier and at least you get the name to add value to the bike. doing it this way is really long winded as everything is having to be made as one off pieces. I am lucky I have the time and my mate is doing the welding and some fabrication at a very low rate so a fraction of the cost of an HPN for the chassis work. The forks are HPN and second hand need rebuilt and new seals etc, the front wheel is hPn needs rebuilt as its old and well used, need new front disc, the shocks I chose wilbers but they were more than HPNs white power ones !!!! . at the back end the wheel is rebuilt twin shock so good, I have had to buy the brakes,cam, and bevel box. My gs will be broken and sold to finance the build on this bike. I could easily have bought a new yamaha 660 or similar for what will be the final cost of this build. Its frightening but now I have dipped my toe in the water I may as well get in and swim the lake. Eh!.
    #59
  20. Padmei

    Padmei enamoured

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    Yes but there will be people that would put up good money for a beautifully made 'new' old style HPN GS if you decided to sell it.
    Looking good.
    #60