My Winter Project (I must be nuts)

Discussion in 'Old's Cool' started by Cogswell, Dec 8, 2006.

  1. SteveBroskey

    SteveBroskey Teach me this knowledge

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    Mike, what made you decide to do a total overhaul vs. just getting it running?

    'Course experience might have something to do with it - I got a '72 Yamaha DT2 three months back and I'm still working on tearing it apart. (thread in old school)
    I'm just planning on getting it running first, and then taking stuff apart for a really good cleaning and tuning/rebuild.

    [I've gotten myself in trouble in the past where I dive into a project way too deep, then never get out; this is my first tear-apart-and-rebuild.]:loco
    #21
  2. Cogswell

    Cogswell Spudly Adventurer

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    It's all just a bunch of parts, knowing their orientation when putting it all back together helps a lot.

    :lol3

    Hopefully I'll see you at the rally, not completely done but rideable.

    Hammersley BMW and Max BMW both have online fiche.

    The decision for a total rebuild was that the bike was rough as a "COB"
    when I started. It did run, albeit a bit rough and the front brakes were locking up. Just take your time on yours, plan what needs to be done in what stages. I plan to clean things up as I go along on the reassembly.

    MIke
    #22
  3. camgregus

    camgregus riding gently now

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    :lurk
    #23
  4. kbasa

    kbasa Roubaix! Super Moderator

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    I'll be interested to see what you do with the timing chain cover. Mine looks a lot like yours and I keep going back and forth on whether to replace it entire, repaint it (in frame) to look acceptable or just live with it as it is.
    #24
  5. Cogswell

    Cogswell Spudly Adventurer

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    Yeah, I'm still pondering that as well. Repaint it or blast off the existing paint and leave it natural. The powdercoat guy I'm using is good about taping things off and not putting paint where it's not supposed to be. I probably don't really have it clean enough to evaluate it yet.

    Mike

    P.S. One of my riding friends says he knows you, Steve Hancock from up in the northeast. Ring a bell ?
    #25
  6. AntonLargiader

    AntonLargiader Long timer

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    Hey Mike!

    Nice project there. You're rocketing along with it; I'd be still just staring at it wondering what to do. When I started reading the thread I hoped you'd do a frame-off and was really glad to see the newly-powdercoated parts.

    What grit do you have for the flex-hone?

    Also, consider the 9.5 pistons. I just put them into an R100 and it feels really nice without any roughness. It's a good upgrade if the bike doesn't already have them.

    Getting the forks right is totally key to the ride and handling. Looks like you had them apart; be really sure that they slide easily after the brace is installed but before the springs go in.

    And keep the pictures coming!
    #26
  7. Solo Lobo

    Solo Lobo airhead or nothing

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    Hiya Mike,

    You do know that you shouldn't use a normal hone on the '81 and later cylinders, don't 'cha:deal The BMW shop I worked at had a "dingle-ball" hone for these...
    #27
  8. kbasa

    kbasa Roubaix! Super Moderator

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    I'm proud to call Steve one of my closest friends. Talk about a guy that can ride....

    His wife's a peach, too. This was at MotoGP a couple years ago. Ask him about it. You know Gene too, then. Another great guy.

    [​IMG]



    Sorry for the hijack.
    #28
  9. WR_guy

    WR_guy Been here awhile

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    Nice work Mike.

    Think It'll be done when I come down in June?

    -Rich
    #29
  10. Cogswell

    Cogswell Spudly Adventurer

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    Time for an update on progress and regress.

    Bad news first.

    If you look at the first pictures of the bike before I started you can see a blue sticker on the frame near the steering head.
    Seems the sticker wasn't fully removed during the frame clean-up and was powder coated over.
    I also made another discovery that the steering/fork stop was missing from the front of the frame.
    I made a phone call to the fine folks at Smiths Customs, Brandon and Josh.
    They told me to bring the frame back and they would make it right on their dime. (for the sticker)
    I fashioned a stop for the steering/forks and they are going to attach it to the frame.
    If you need any powder coating done I would Highly recommend you give these guys a shot at your business.
    They do great work, and stand behind what they do.

    I got the wheels back when I dropped off the frame. I was concerned
    about the wheels turning out too dark from the color sample but after seeing them finished I an happy with the result.
    One small detail on the wheels, seems there was a recall on the BMW snowflake front mag wheels. They would tend to crack and break after riding on rough surfaces. Thanks Crow. I now have a new front wheel on the way courtesy of BMW. It will need to be powder coated to match the rear.
    Hey, things like that are going to happen and it's just a minor delay. I don't really have any set time this bike must be finished.

    [​IMG]

    [​IMG]



    I also picked up some other goodies for the charging system to replace the diode board. ( a known weak link at this mileage)

    [​IMG]


    Other than that, I had a call from the machine shop that the heads are ready. Fresh valve job and cleaned.
    Need to borrow the press again to remove the steering head lower bearing and install the new one.
    I need to schedule some time on a glass bead cleaner for more parts cleaning.
    Spiegler brake lines and another box of gaskets etc are on Brown to arrive this week.

    May be I can have a roller by the end of the month !

    Mike
    #30
  11. Cogswell

    Cogswell Spudly Adventurer

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    I was kind of hoping I could enter it in the Cycle World rolling concours during the Honda Hoot.:evil

    Good to talk to you today Rich !

    Mike
    #31
  12. Cogswell

    Cogswell Spudly Adventurer

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    I called him when I heard about your incident last weekend, I knew he would want to know.
    I guess you'll have to post your repair progress in here.

    Hope you heal fast and straight.

    Mike
    #32
  13. Cogswell

    Cogswell Spudly Adventurer

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    Well I'll revive this from a lonely page 4 with a progress update. I have all the parts back from powdercoat along with the redone frame. The guy did a super job masking things off and plugging threaded holes. For anyone in or around the east Tn area I can recommend Smith's Customs in Louisville.
    Lots of time is being spent on time consuming projects like the brakes.

    [​IMG]



    BMW/Brembo has a really nice kit for the calipers. All the new rubber pieces are included along with new bolts. The pistons are a composite material so they cleaned up fine.

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    Above is the rear caliper, the fronts have the same internals and they all run the same size pad. I'm having to spend some time sorting through the brake line upgrade to stainless braided. While mounting the front wheel and calipers I noticed a clearance issue. When I got the bike the right front rotor was toast and the caliper rubber was melted. It appears the front rotor shims are not installed/were lost at some time in the past. I'll get some of those on the way with the next parts procurement.


    I had all the small bits on the handlebars powder coated as well as the front master cylinder.



    I did get the frame set up with the front end on it and started to route the wiring harness, thank Dog for high quality digital pictures !:lol3

    [​IMG]


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    I really dig the color on the wheels, it shows a bit better in these pictures than in previous ones.

    [​IMG]

    [​IMG]
    #33
  14. duckrider

    duckrider Been here awhile

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    This will be a great ride. Nice to see old iron back on the road. Also nice seeing someone doing it right. Good work!
    #34
  15. SteveBroskey

    SteveBroskey Teach me this knowledge

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    Yeah, yowza! You're really restoring the girl - I'm just trying to get my DT2 back in trail/road worthy condition looking nice; then I'm going to take it out and tear up some NY backwoods!
    #35
  16. Cogswell

    Cogswell Spudly Adventurer

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    Ok, I know it's been a while but work has been on the front burner for a while. The project has not been ignored. Most engine machine work, cleaning, and assembly has been done. I still have a couple of items to take to powder coat, bottom of the air box, and probably the engine front cover. It's really rough and I'll either try to match it to engine color or have them do it in black.

    [​IMG]

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    [​IMG]

    I have the wiring harness run and everything plugged back in at the fuse panel in the headlamp. Rear brakes are on and bled, front brakes have been a bit of a pain. When I got the bike there was an issue with the right side caliper inner half interfering with the rotor. I think I have that sorted by shimming the rotor out from the wheel.
    Body work painting is going to be started soon, I will probably meet with the painter this weekend. Other than that it's a little fitting here and a little more cleaning there, and a few oops I forgot to order that too's

    Mike
    #36
  17. datchew

    datchew Don't buy from Brad

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    looks great.

    Is that position and mount for the oil cooler OEM or did you modify it?

    I've seen alot of folks relocate the oil cooler on the gs's and that looks like it would be great if OEM equip is used.
    #37
  18. Cogswell

    Cogswell Spudly Adventurer

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    That's where it was when I took the bike apart. This was an "RT" with no body work on it when I bought it. No telling what was done prior to my ownership.
    I looked on the RT online fische and didn't see the oil cooler listed, suprised ?
    Let me know if you want better pics, it just clamps to the frame cross tube.

    Mike
    #38
  19. Caddy82rats

    Caddy82rats Long timer

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    Nice work !

    Its normal BMW place and cooler for RT RS, I've got the same at same place on my unfaired RS
    #39
  20. datchew

    datchew Don't buy from Brad

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    I would like some more pics if you don't mind.

    If nothing else, for comparing which relocation method for a gs is easier/cheaper.

    Thanks.
    #40