In memory of Jim Adams - an R60/5 build diary

Discussion in 'Airheads' started by backdrifter, Aug 8, 2010.

  1. backdrifter

    backdrifter Wannabe rider

    Joined:
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    Parts are back from the powdercoater! :clap

    A huge thanks to HP Powdercoating, who an inmate referred me to. They did a great job - everything was properly masked, no threads have been sprayed, and everything looks fantastic. And it was very reasonably priced too.

    Before:

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    After:

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    With the subframe on:

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    So what's next? First, I need to clean up the work space, as I've let it get a bit cluttered.

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    Then, the goal for this week is to prepare all of the aluminum bits for blasting and cleaning. I have a friend that will let me borrow his blaster, I'm hoping to make it over there Thursday evening. In the mean-time, I first need to wash and scrub all the grease off and tape and otherwise prep everything for blasting. It's going to be long and tedious work. Lucking, I'm well prepared and have a sanctuary only feet from my work area :evil :slurp:

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  2. KLRUSERIOUS?

    KLRUSERIOUS? Farkle-whore

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    Papa would be proud! Can't believe I didn't see this thread earlier.

    Subscribed!
  3. trophymoto

    trophymoto MACDADDY!

    Joined:
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    455
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    S.C.
    [​IMG][/QUOTE]


    You are going to need help... I'll be right over!!
  4. backdrifter

    backdrifter Wannabe rider

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    Thanks for reading along!
  5. backdrifter

    backdrifter Wannabe rider

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    I'll gladly trade alcohol for help. I have no shortage of beer, but mechanical aptitude is another story altogether! :D
  6. backdrifter

    backdrifter Wannabe rider

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    I had a couple of relatively easy work weeks the past few weeks, which is why I was able to jump back in and start making progress. I'm a bit more strapped for time now, but thankfully I moved far enough along while I did have free time to get myself motivated again. Case in point: I woke up at 5:30 this morning to spend an hour or so getting a few things done. And plan to do it again tomorrow.

    Here's the stainless bolt kit I got from BMW Hucky. I'm very happy to have a complete new nut and bolt kit and to not have to worry about cleaning the old ones and sourcing new ones where needed. I know there is a heated debate about the usefulness of stainless as fasteners, but I work in industrial sales and have seen stainless fasteners used on far larger and more powerful equipment than my little R60. I have seen failures too, but I've found that if you use anti-seize and torque to the correct value, you'll be just fine. So that's what I intend to do.

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    The kit is very nice. It came in a box that made it look like it was going to be all loose pieces. I never opened it until yesterday. If I had, I could have saved myself some time during disassembly. I removed, bagged, and labeled every single nut and bolt from the bike. The pieces in the kit are so well grouped and labeled that I probably didn't need to. Oh well, better safe than sorry, right?

    So, this morning's goal was to remove the tires and disassemble the rims/hubs. Remembering lessons I've learned in the past, I decided to start on the rear rim and tire, figuring it would be the more difficult of the two.

    No problem!

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    Then on to the front one, which was a bear. Go figure! Not sure what it was, but the tire wouldn't give. The little tire that could:

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    Persistence prevailed:

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    I had planned on reusing the tires on the bike. They were a bit old, but they appeared to be in good shape. Today's inspection revealed this on the front tire:

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    Yep, some dry rot. Oh well, what the hell - what's a few hundred more dollars for some new shoes? :D

    The next step was to get the angle grinder out and cut the spokes, since I'm going to replace them with new stainless spokes anyways. I'd much rather do this job outside than get the garage dirtier than necessary, and unfortunately it is pouring rain this morning, so I called it quits.

    I'm hoping for dryer weather later today so I can finish the job. Then it's on to masking and cleaning everything to get ready for blasting later this week.
  7. backdrifter

    backdrifter Wannabe rider

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    The rain let up, so I went back out to finish the job. Gotta love angle grinders, this would have been an hour job (or more) if I had removed each spoke individually. Instead it took 15 minutes. One down:

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    On to the next:

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    I had a sheet lying under the rim so it wouldn't get scratched while rubbing against the concrete. It caught fire. :D

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    I put it out and kept going. Done:

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    And done:

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    I'm a visual kind of guy, so I decided I needed to tackle some kind of aesthetic project to make me feel good about the day. I decided to go for the lower triple clamp. I was happy with the results on the fork tubes, so I planned to use the same method - wire brush attachment on the drill, clean, and then some Rub N' Buff. Before (sorry for the sideways photo):

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    After the wire brush:

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    There were some spots that I couldn't reach with the drill or a hand wire brush, so I decided to reserve this for blasting too, and apply the Rub N' Buff afterwards.

    That's all for tonight. Time for a beer!
  8. KLRUSERIOUS?

    KLRUSERIOUS? Farkle-whore

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    Nice work! Keep them pics comin!
  9. backdrifter

    backdrifter Wannabe rider

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    Time for an update.

    I cleaned up the lower triple clamp and applied Rub N Buff. Looks brand new!

    Cleaned:

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    Rub N' Buffed:

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    Then I replaced the steering stem bearings. Getting the races out was a pain, but they finally came loose. I slathered the new bearings in this great stuff:

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    While pressing the inner race down onto the steering stem, I must've pushed in a wrong direction and suddenly I had an empty bearing cage and 21 little tapered rollers rolling all around my garage. I was discouraged, but determined to fix it.

    Tedious work:

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    This is going to require some moral support:

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    Got it back together and started assembling the triple clamps and forks.

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    I plan to clean or replace the triple clamp top nut. It looks pretty bad, I may need to replace it. I'm very happy with everything else though - it's starting to look pretty good!
  10. old2wheeler

    old2wheeler Former nÔÔb

    Joined:
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    Oddometer:
    720
    Location:
    La Veta, CO except for the wind, it'd be heaven
    "Pretty good."

    Uuummm, I'd give it an "approaching motorcycle porn!" rating. Beeeu-teee-ful! Yea, you've made it so purty, that nut will HAVE to go...

    :clap
  11. backdrifter

    backdrifter Wannabe rider

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    Thanks old2wheeler! Yeah, that old corroded nut will have to go, won't it? :D

    I should post some photos of the gauges too. I sent these to our very own Terry (Wirespokes) for some rejuvenation. Unfortunately I didn't remember to take a good "before" picture, but rest assured that they look a whole lot better now! Nearly new, actually. Great, great work and Terry was an absolute joy to deal with. I can't recommend him highly enough!

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    Thanks again, Terry!
  12. KLRUSERIOUS?

    KLRUSERIOUS? Farkle-whore

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  13. backdrifter

    backdrifter Wannabe rider

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    Thanks for the interest! Nope, I'm not trying to build suspense or anything like that. The last pictures were all relative close-ups because I was trying out my new 50mm camera lens and I didn't have enough room to back up and get the whole bike in the shot! :D

    I'll try to get a few more photos up in the next day or two. I just got swingarm bearings in the mail, so I hope to install the swingarm and shocks soon. Then it will almost look like a rolling chassis. Little by little!
  14. Dusty_Bottoms

    Dusty_Bottoms Adventurer Ordinaire

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    Location:
    Fort Collins, CO
    Looking sweet.
    Somehow Papa knew you were the only one that would do anything with her.
    How'd those olde guys get so smart?
  15. KLRUSERIOUS?

    KLRUSERIOUS? Farkle-whore

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    Updaaaaaaaaaaaaaaate!!!!
  16. backdrifter

    backdrifter Wannabe rider

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    Thanks for the inquiry, but unfortunately I don't have any updates just yet. I took a hiatus on the project to get through the money perils of Christmas and just haven't started up again. Thanks for the wake up call though - I need to get going! Spring is right around the corner and I want to be riding!
  17. KLRUSERIOUS?

    KLRUSERIOUS? Farkle-whore

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    Knock knock....who's there....spring time :D
  18. backdrifter

    backdrifter Wannabe rider

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    Damn if that isn't right! And guess who's not riding yet? Yep, you guessed it - ME!!!

    Oh well, I've given up on getting frustrated with myself. My motivation waxes and wanes. I know the project will get done eventually and I just ride the tide when the motivation is there. Speaking of, I decided I needed some kind of carat to dangle in front of myself to get that motivation going again. I decided a few weeks ago that I would get the body painted. I've been working with a local painter that I highly recommend. I pick up the pieces tonight, so expect the first proper update of this thread in nearly six months (pathetic, I know). Paint was certainly not the next logical step, but I think seeing the shiny bits will really motivate me to get back on track.

    I should add photos either tonight or tomorrow, so stay tuned.
  19. backdrifter

    backdrifter Wannabe rider

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    Pics as promised. Lots of them. The painter was a St. Louis area BMW fan named Larry. I highly recommend him and would be happy to put anyone interested in touch with him - just PM me.

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    I love this photo, it shows just how glass-like the finish really is:

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    Headlight bucket mocked up with gauges expertly restored by Terry (Wirespokes). Looks ready to ride!

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    Headlight ears:

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    One thing that I thought was really cool was that Larry masked and saved all of the initials from the original painters. He also added his own initials, which I thought was a really nice touch. Interestingly, all three pinstriped parts of my bike (front fender, rear fender, tank) were painted by different painters. Very interesting!

    The original initials on top, Larry's mark on the bottom:

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    A closer look:

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    I'm taking all the necessary parts to be re-chromed soon. Once I get the tank plates back all shiny and new, Larry will airbrush the black "wings" in them and then reinstall them for me (so I don't scratch the wonderful new paint).

    Now it's onto mechanical stuff. Next I need to change the timing chain, the main seal, and see what else I'm looking at.

    Little by little....
  20. azcycle

    azcycle Chihuahua Wrangler

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    Tucson, AZ
    Gorgeous!