Overgrown Offroad Zombie

Discussion in 'Some Assembly Required' started by larryboy, Sep 18, 2011.

  1. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    15,459
    Location:
    On a set of 50,000 mile tires.
    If BMW destruction bothers you, stick to the hover and resist the click. :deal


    I picked up this 2001 1150GS in a trade and realized that needed upkeep was more than I could afford...conversion to something better was my only choice or so the voices told me.:dunno


    Start with this:

    [​IMG]


    Watch the flea market and find an XRR front end:

    [​IMG]


    Remove 149 pounds of crap to get to this:

    [​IMG]


    Find a CR500 frame on the 'list for $65, it's steel and uses the same head bearings and races as an XR650R:

    [​IMG]


    Cut a little bit at a time for mockup:

    [​IMG]


    Tell silly Lily to stop bothering me:

    [​IMG]


    Start making parts:

    [​IMG]

    [​IMG]


    Enjoy the look on my Father-n-laws face when he sees what I've done to this fine BMW:

    [​IMG]


    Start adding tube:

    [​IMG]


    Realized I put the fuel tank mounts in the wrong spot, back bone hits the tank...hmm, I better put it on it's feet before I get too crazy with the welder.

    [​IMG]


    That last picture was nine days into the build. I spent some time measuring and ordering parts between selling the 1150GS parts I don't need anymore. Figured out the tank mounting and some other stuff. Then I got the flu and lost 10 pounds, in recovery mode now...maybe some bike progress today.


    Stay tuned...a buddy is helping me figure out how to run a stand alone electronic ignition without the Motronic and I'm putting carburators on it too.

    I have to start test riding this thing by the end of October as my wife and I are riding it two-up in November all over Death Zombie Valley. :deal
    #1
  2. andyhol

    andyhol volcano rider

    Joined:
    Dec 28, 2008
    Oddometer:
    153
    Location:
    the Seven Seas
    weight as it stands? very very cool imho
    #2
  3. bk brkr baker

    bk brkr baker Long timer

    Joined:
    Jul 19, 2006
    Oddometer:
    6,022
    Location:
    The Bluegrass
    Watch out !
    Them propeller fellers are massing for an attack!:rofl
    #3
  4. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    15,459
    Location:
    On a set of 50,000 mile tires.
    I was at 430 before I started putting parts back on. I'll have to do a final teardown for paint and will weigh stuff as it goes back on.

    Edit: I'm hoping for 480 pounds ready to ride, with hard bags and mounts I'll probably end up at 500 pounds. 81 pounds lighter than stock.
    #4
  5. roadrage

    roadrage Long timer

    Joined:
    Feb 13, 2004
    Oddometer:
    1,022
    Location:
    San Joe's A, Ca
    Put the Harley wheels on it!!! :-)

    Cool hackage!
    #5
  6. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,826
    Location:
    Turning expensive metal into scrap
    Sweet, I like your style
    #6
  7. fatpony

    fatpony Dixiecrat

    Joined:
    Jan 23, 2005
    Oddometer:
    220
    Location:
    Flatistan NW aka Fl Panhandle
    YOU are my hero and an inspiration! Please continue. Thanks, Mike
    #7
  8. CamoGreg

    CamoGreg Can you see me?

    Joined:
    May 11, 2006
    Oddometer:
    5,381
    Location:
    Lewis & Clark Valley
    :lurk

    [​IMG]

    :lol3
    #8
  9. rallyman1978

    rallyman1978 Been here awhile

    Joined:
    Sep 1, 2008
    Oddometer:
    199
    Location:
    Worcester, UK
    :photog:lurk
    #9
  10. Wolfgang55

    Wolfgang55 Long timer

    Joined:
    Dec 24, 2006
    Oddometer:
    3,531
    Location:
    Next to Rio Bravo
    So the BMW 1150 was to costly to keep up on the maintenance.

    You keep the motor & put carbs on board.

    You do have a vision & I too want to see it run & stop.

    Good luck.
    #10
  11. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    15,459
    Location:
    On a set of 50,000 mile tires.
    Oh yeah, I traded the gauges for a rear GSA model rear wheel with a new TKC on it. Gonna have to pick up a fresh rear rotor as I let the rotor go with the wheel set I sold.


    [​IMG]
    #11
  12. Poolside

    Poolside Syndicated

    Joined:
    Apr 1, 2003
    Oddometer:
    11,887
    Location:
    Long Beach, CA
    The OE master bore diameter is 16mm and the slave is 24mm. Based on the 'engagement range' of the OE clutch I'd guess that a 10% smaller master bore diameter still might work. Say 14.5mm as a minimum diameter.

    But since Magura makes the OE BMW master, you might find a 16mm Magura part. If so, on the old and new clutch levers check the centerline distance between the clutch lever pin and the piston pin. For the same bore diameter, that dimension determines lever throw.

    <BR>
    #12
  13. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    15,459
    Location:
    On a set of 50,000 mile tires.

    I'm more of a bolt it on, bleed it and see if it works kind of guy. :wink: Clutch master is in stock, I have a couple of different ones I can try. Probably get to it after the new springs go in the forks and front end is complete.
    #13
  14. Poolside

    Poolside Syndicated

    Joined:
    Apr 1, 2003
    Oddometer:
    11,887
    Location:
    Long Beach, CA
    Yea, I am getting that feeling about you :lol3

    <BR>
    #14
  15. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    15,459
    Location:
    On a set of 50,000 mile tires.


    :freaky
    #15
  16. FLYING EYEBALL

    FLYING EYEBALL out of step

    Joined:
    Mar 18, 2008
    Oddometer:
    10,610
    Location:
    southeast of seattle
    Awesomeness!! :clap:clap:clap
    #16
  17. JimVonBaden

    JimVonBaden "Cool" Aid!

    Joined:
    Feb 11, 2005
    Oddometer:
    55,363
    Location:
    Alexandria, VA
    Interesting conversion so far. I wonder of the strength of the parts you are adding is enough considering the weight differences in the two bikes? I assume you intend to ride this off road a lot?

    Keep up the good work. Contrary to what some may think, not all BMW guys are purists.

    Jim :brow
    #17
  18. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,826
    Location:
    Turning expensive metal into scrap
    Ditto to what jim said. I considered a dirt bike front end for my build but ended up with a 950 due to braking concerns as well as being able to find springs heavy enough for the bike and its intended uses. My bike runs .64 springs and runs very well.

    With regards to brakes you may seriously want to consider a super moto setup. That was one consideration for me but I went with a known quantity after seing what that costs. I can tell you that hauling my 450# bike down from speed uses every bit of the dual brembos and could use more. Not sure what you intend to use thr bike for, but for street use id at least consider better brakes.

    Kudos for a bitchin project when finished
    #18
  19. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    15,459
    Location:
    On a set of 50,000 mile tires.
    It's hard to notice the supermoto huge front disc that is on there when it's surrounded by such a huge motorcycle, but it's there.

    Rode a buddies Super Enduro and it felt fine with a similar size front rotor.

    The plan is to get this thing together ASAP as good as I can do it with the amount of cash I have right now, take our trip to Death Valley, then tear into any issues that exposes. I'll have seven months before we ride the Divide with it.

    I had a KLR that weighed in at 420 pounds on a certified scale and it had wimpy forks and brakes. I'm light years ahead of that with brake/fork size...ya just gotta know your limitations and don't over ride the machine for the conditions.


    Edit; Oh yeah, the 950SE uses .48 springs on the front for stock and that felt really good to me on a bike that weighs nearly the same as this project, so I ordered .49 springs for this thing and will go with 20w Harley fork oil.
    #19
  20. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    15,459
    Location:
    On a set of 50,000 mile tires.
    Got the springs yesterday, need to get some fork oil.


    Parts inbound:

    Two TM40-6 carburators...:wink:

    Highway Dirtbike Ultimate guards. :evil

    Buell headlights with an HID conversion. :norton

    Ignition box from Germany, top secret, details later. :augie

    Two Doubletake mirrors from Neduro. :pain


    Time to get my butt into the carholio. :deal
    #20