Here We Go Again - Yet Another BMW R1150GS Adventure/Ural Sidecar Renovation

Discussion in 'Hacks' started by mikepa, Feb 5, 2020.

  1. mikepa

    mikepa SideCzarist Supporter

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    An interlude . . . .

    Massive spring cleaning, mission accomplished. Now sanitary and ready for a final brake system install and wiring up the tub. Celebrated with a hefty MadHatten double!

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  2. Flyin' Monkeys

    Flyin' Monkeys Wicked Witch Airlines Supporter

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    A shop THAT clean and organized, is the Sign of a Sick Mind :zilla
  3. mikepa

    mikepa SideCzarist Supporter

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    Hey, I resemble that remark! You shudda' seen it for the last three weeks.
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  4. Bobmws

    Bobmws Curmudgeon At Large

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    That's just not right..... :jjen
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  5. rg sw wa.

    rg sw wa. Long timer Supporter

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    Mike, please don’t post pics like that again, once is enough. I am now going to have nightmares maybe for the rest of my life after going into my garage / shop.
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  6. Miggins1

    Miggins1 Been here awhile Supporter

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    I daren't post a picture of my garage - it might see you off Mike!
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  7. mikepa

    mikepa SideCzarist Supporter

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    OK, after a brief hiatus from wiring, with an orderly shop (after weeks of crap everywhere, can't find the tool I'm looking for, and where did I put that part), it's back to our regular programming.

    Yes, I know, you've seen the photos previously, but these are the real deal, the final product, wiring on the the tub is now honestly, truly 100% complete, so here's what the final result looks like:

    From left to right: the stock fuse/relay box, now minus the ABS relay. Next, the Blue Sea Systems fuse block, fully populated, with one spare available. Next, the cover for the Blue Sea panel. Finally, the terminal block which branches the load relay trigger, R/H turn signals, relay trigger for the auxiliary driving lights, front running light, rear tail light and brake light for the bike and sidecar:

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    Close-up of the fused power distribution block:

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    Close of with the cover in place:

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    Close-up of the tail terminal block, now with the harness for the sidecar wired up:

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    And with that done, time to cut a big hole in the sidecar for the wiring connector. Made a quick template in hope of only having to cut the hole only once <g>:

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    Ready to start the final phase of not only the total re-wire of all accessory circuits, but the entire refit itself. It's all downhill from here (I hope):

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  8. mikepa

    mikepa SideCzarist Supporter

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    Finally able to button-up the bike today. Was finally able to remove the black tape the criminal former owner taped over the flashing ABS lights (as I yanked the entire ABS system to include all the plumbing), go the new brake flushed and bled. Installed the fuel tank. She started up, and we were able to do a throttle body sync, the last remaining service task! It's starting to look like an adventure rig again!:

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  9. Flyin' Monkeys

    Flyin' Monkeys Wicked Witch Airlines Supporter

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    O M G...I found a flaw......alert the sidecar Po-Lease.....I found a flaw :fpalm

    Mike, in this picture, look at the Tie-Wrap in the one o'clock position of the picture, the Tie-Wrap that is on the upper frame rail, or technically on the right side upper frame, and see that this one specific Tie-Wrap needs to be rotated 180 degrees, so that the "tang" of the Tie-Wrap is not UP, but is located DOWN, like all the other Tie-Wraps are.

    Makes a big difference when working on vehicles, as one could snag the back of their hand on the "tang", and scrap the skin.

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    And, while this 2nd thing is not a "flaw", may I suggest that you fab a "cover" to go over that "tail terminal block", much the same as there is a cover on the Blue Sea terminal block ?
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  10. mikepa

    mikepa SideCzarist Supporter

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    OM-Effing-G! Missed that one, thanks for heading off a potential ER visit! And on the 2nd, though 12V systems are far less sensitive to shorts due to moisture, and water is non-conductive, others have suggested the same (and thanks for the recommendation!) so I am going to modify the clear cover from a Pelican Microcase, photos to come!

    Before (hopefully you noticed the stainless steel tang):

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    After (practice safe cable-tying) :

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    Attached Files:

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  11. masegraves

    masegraves Adventurer Supporter

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  12. mikepa

    mikepa SideCzarist Supporter

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    OK Gang, are we happy now? Re-purposed the cover of a Pelican Mico case to make a rain cover for the tail terminal strip. I'll sleep better at night!:

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  13. mikepa

    mikepa SideCzarist Supporter

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    Sidecar harness and disconnect installed. Not pretty, but brutally functional. Connector has a strong clamp on the jacket, and I sealed it against water intrusion by packing it in butyl bedding compound, it's probably waterproof as a result:

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  14. norton(kel)

    norton(kel) He’s my President! Supporter

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    Mike, are you cutting your cable ties? If you twist them off rather then cut them, there is no sharp edge:-)
    rg sw wa. likes this.
  15. mikepa

    mikepa SideCzarist Supporter

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    Answer (and yes, it's adjustable for proper tensioning before trimming the tail):

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    I use Thomas & Betts UV-stabilized cable-ties with a stainless locking tang:

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    Unlike Home Depot cable-ties, they don't have teeth so can be precisely tensioned and significantly stronger:

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    They're molded from nylon (polyamide). Twisting the tail off is not optimal. It takes about six turns, and as nylon is a tough material, it elongates and doesn't break like cheaper cable-ties:

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    Why? It's how I was trained. I also use torque wenches :

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  16. wilfred

    wilfred juvenile delinquent Super Supporter Supporter

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    A beautiful resurrection, the bike looks familiar. It's in better hands.
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  17. rg sw wa.

    rg sw wa. Long timer Supporter

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    :clap
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  18. mikepa

    mikepa SideCzarist Supporter

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    Finally, starting wiring inside the tub! Wire spools in the trunk lead through external connector:

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    Here's what it looks like from the other side (in the trunk):

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    Shop may have received a good spring cleaning, but the immediate work area is always a mess of stuff:

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  19. brstar

    brstar Long timer

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    Love the T handle on the plug.
    Such a simple solution to a common annoying problem. Like disconnecting a trailer in the dark on a cold night with mud and grit effectively locking the connection up tight.
    Which is how the feelings are with a little knuckle abuse as it finally lets go.
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  20. norton(kel)

    norton(kel) He’s my President! Supporter

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    Thanks Mike for the tie info! Nice torque wrench’s !!
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