AIRHEAD TECH DAY BUILD

Discussion in 'Airheads' started by Scott in Missouri, May 23, 2019.

  1. Scott in Missouri

    Scott in Missouri Been here awhile

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    The Missouri Airheads recently completed three-year project. Well, we’re not really that slow and there’s a story. Three years ago a member brought a great running 1977 R75 in and the club totally disassembled it. Each component was carefully removed, inspected and all wiring and bolts were marked, bagged and tagged. But no matter how you say it, the club successfully transformed a perfect running 36k mile Airhead into a Basket Case. It took three years and the bike found a new owner, but from start to finish the “Tech Day” Airhead was finally completed in time for the Rolling Rally to the BMW National Rally. From a Bing rebuild and tuning, final paint polishing to the complete custom rebuild- A special thanks to Euromotoelectrics.com for supporting the effort as well as all the friends and members for the group effort.

    The idea was to rebuild the bike as a vintage Airhead and improve the brakes, wiring and comfort. The bike had to have great, usable luggage for Airhead events. Along the build I was fortunate to find two additional R65s that were basically abandoned years ago and of course...no titles. I will end up with three bikes again, but each will have a specific purpose. This bike is the "Bagger", but I have already started aligning the parts for an 80s GS style build. This will basically be all of the worst stuff that is left over from the other two...long front end...spoke wheels and the like. The last bike will most likely be a Hot Rod that will be comfortable enough to ride into town or bike night. Although these bikes were basket cases or abandoned, all the good parts will be used and the stock stuff stored in the shop or given to Airhead club members as needed.

    ***WARNING***
    If you are a BMW Traditionalist...this thread is not for you. I chop up bikes, parts and used multiple Honda and Harley parts on this build. Multiple BMWs (three) were used as donor bikes to make this bike. I'm talking low mile, vintage bikes...If you are opposed to this, please look somewhere else. The Internet is a big place...Best wishes.
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    #1
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  2. Scott in Missouri

    Scott in Missouri Been here awhile

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    The lines were all wrong for me. I wanted the bike to be traditional, but cleaned up here and there. It was a challenge to refine the bulky look.
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    #2
  3. Scott in Missouri

    Scott in Missouri Been here awhile

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    This area was always going to hit the tank so I snipped off about 1/4" and it fits great now with padding.

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    #3
  4. Scott in Missouri

    Scott in Missouri Been here awhile

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    View attachment 1694482 View attachment 1694481 View attachment 1694478 A lot of seat pics....it was terrible big and a lot of trimming was needed to get it smaller and usable. The easiest thing is to toss the original seat since they are too tall, too wide and too heavy. I trimmed it everywhere I could because the hing action and fit of the seat pan are actually cool.

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  5. Scott in Missouri

    Scott in Missouri Been here awhile

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    These super magnets hold a pistol anywhere you mount them. IMG_1877.JPG IMG_1875.JPG IMG_1876.JPG
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  6. Scott in Missouri

    Scott in Missouri Been here awhile

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    After looking at the Panniers on my Africa Twin I thought it would be cool to have them on this bike and be able to quick release from one bike to the other without unpacking....So I ordered a new set of KLR racks and cut them up as a donor. A key item when mounting the bags was to mount the exhaust even though the engine was out. This was to ensure the panniers had enough clearance with the mufflers. IMG_9185.JPG IMG_9291.JPG IMG_9305.JPG IMG_9435.JPG
    #6
  7. Scott in Missouri

    Scott in Missouri Been here awhile

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  8. Scott in Missouri

    Scott in Missouri Been here awhile

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    Tail light from a 32 Ford
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  9. Scott in Missouri

    Scott in Missouri Been here awhile

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    Like many old battery trays, this one was corroded and the top plate was missing. After turning new threads on a piece of round steel the two rods were welded back in and powder coated. The top plate was replaced with a small piece of aluminum. I used elastic nuts on this and the battery fits very snug.
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    #9
  10. Scott in Missouri

    Scott in Missouri Been here awhile

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    I wanted a top rack to fit in the middle but it hit the sides...I had to trim it up a bit since it was hitting the panniers. It was off an Africa Twin. Spare (free) parts is the name of the game when working on old BMWs. Replacement / Original parts are very expensive.
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    #10
  11. Scott in Missouri

    Scott in Missouri Been here awhile

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    A little trimming was needed to take about an inch off each side of the top plate. I tried to duplicate the angles and holes of the original design and then just very carefully drill, cut and file for a factory look.
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    #11
  12. Scott in Missouri

    Scott in Missouri Been here awhile

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    Some cutting and filing and it fit fine. The plan was to make the plate fit in between the panniers and also be about level so large bags and camping gear can strap across the entire top on a big trip.
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    #12
  13. Scott in Missouri

    Scott in Missouri Been here awhile

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    Then needed a mount that made it level and centered. A wire template gets the angles about right and then just use the wire pattern when heating the steel and bending. I didn't want the rack to sit too tall. Since it will be run without the panniers, it still needed to look good and have nice lines.
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  14. Scott in Missouri

    Scott in Missouri Been here awhile

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    Time to make a dash for the GPS/Speedo and warning lights. An old scrap of aluminum, a bender, a drill and a bit of imagination is all that is needed. You need to do a lot of measuring and sit on the bike to make sure the dash clears everything and is at the right angle when seated. Your neck / eye line and the sunlight angle need to be right on a long trip.
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    #14
  15. Scott in Missouri

    Scott in Missouri Been here awhile

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    Not going to talk about engines a lot sice that's covered all over, but it has one. IMG_1500.JPG IMG_1505.JPG IMG_1995.JPG
    #15
  16. Scott in Missouri

    Scott in Missouri Been here awhile

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    Once it was all together I road the bugs out of it....lots of dirt roads and lots of fun. IMG_0346.JPG IMG_0347.JPG IMG_0348.JPG IMG_0349.JPG
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  17. Scott in Missouri

    Scott in Missouri Been here awhile

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    Then...tore it all apart to paint and powder coat everything.
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    #17
  18. Scott in Missouri

    Scott in Missouri Been here awhile

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    Paint and finish work. Trimmed the rear fender out a bit. IMG_1594.JPG IMG_1588.JPG IMG_1600.JPG IMG_1608.JPG
    #18
  19. Scott in Missouri

    Scott in Missouri Been here awhile

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    Powder coat and paint.
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  20. Scott in Missouri

    Scott in Missouri Been here awhile

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    Finish work...A stainless steel bolt kit and lots of stuff from EME- Euromotoelectrics is my go-to place-Great folks. We reassembled the bike at the same Tech Day location it was disassembled three years ago. Lots of fun with friends in the Airheads. We stripped a head stud and that had to be repaired and also the Bings needed a rebuild and balance.
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    #20
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