R80g/s rebuild - some pics as I go along....

bakerlonglegs · Aug 28, 2007

Hello you fellows,
As the airhead comes together I thought I'd bore one and all with some photos....

This is how it started back in March, via the Proff delivery service.... :rob

I had intended to bimble around on it for the summer and then do the 'winter project' thing. Then it failed its MOT (badly

) and I found a bunch of this:

.....so decided to do the 'summer project' thing instead, hell why not? Which was fine, as the weather has been rubbish.

So out came the spanners, and we started doing some of this:

....and found more of this:

Decided to rebuild this:

The bike has been stood for some time, so I chickened out of the big stuff, and took the engine and gearbox for rebuilding to a BMW airhead specialist. The final list included, amongst other things:
- valves and guides
- 5th gear
- main seal
- clutch
- 2nd hand barrel (corroded nicasil (sp?) coating)
- timing chain and adjuster
- rings

All this stuff went for blasting and powder coat:

Frame needed a repair first to get rid of this gopping side stand mount:

For a while I had nothing in the garage while everything was with other peeps getting worked on, then bit-by-bit it started coming back.....

Ooooooohhhhh yes......

And now the rebuild starts....

Current state, otherwise known as 'expensive wheelbarrow'

Most difficult jobs so far:
- taking apart: getting those dang engine mounts out (thank you Proff and Rob)
- rebuilding: re-attaching the driveshaft to the gearbox and refitting the gaiter

More pics to follow as the build continues....

:beerjug:

DrAlf · Aug 28, 2007

Great post. Really well documented. Look forward to reading more

Voyager · Aug 28, 2007

Very, Very nice :thumb2

It will be a credit to you when its finished.

But you won't want to get it dirty :blast

I look forward to seeing it develop.

(I recently replaced all the wiring on my 100GS with pukka BMW looms . . Now that's expensive ! Are you doing this too ?).

Bob.

Colt · Aug 28, 2007

well you have been £busy.
you missed the bit where i found you my rare block connector to help keep the bike on the road and the rebuild costs down :augie

well it will look good when its finished. :clap

GS Weissbeer · Aug 29, 2007

Very nice work :thumb2

Especially the "new" wheels :clap

Trippy · Aug 29, 2007

Really good post and looking forward to seeing the work progress.

(RIP) Proff · Aug 29, 2007

You are going to be so proud when it's finished :thumb2

You are doing a great Job :bow

I look forward to seeing the finished bike very soon :thumb2

BTW Glad to see you have the PROPER Tyres on her now :augie

It's really made me feel Chuffed all over :rob

Flipfly · Aug 29, 2007

Is it done yet!!!!!! :augie

Nice job, I've got another you can do when that ones finished :augie

Kenny · Aug 29, 2007

Trippy said:
Really good post and looking forward to seeing the work progress.

You'll be next Trippy

Lovely project Mr longlegs

Rob Farmer · Aug 29, 2007

Kenny said:
You'll be next Trippy

Lovely project Mr longlegs

Actually I'll be next...Photographs of a gearbox rebuild anyone

Great to see her coming back together again. You will have the bug after this

Trippy · Aug 29, 2007

I hope not, the girl who sold me mine said that it had an engine rebuild 6000km ago in 1998 and as far as I can see it all looks ok.

But I bought it to do abit of tinkering

Flipfly · Aug 29, 2007

Come on Mr gangly, you've had all day, where are the pics of it finished

bakerlonglegs · Aug 29, 2007

It's my first project - thanks for all the words of encouragement :thumb2

Now I've started putting it all back together it does feel I've turned a corner. There was time, when it was all in bits, I thought 'crikey, how am I going to construct a working motorsickle from this lot' :confused:

Voyager said:
But you won't want to get it dirty

(I recently replaced all the wiring on my 100GS with pukka BMW looms . . Now that's expensive ! Are you doing this too ?).

Bob.

Oh yes I will! Plan is some beginners off-road runs at GS weekends - I was looking at the latest pics from the EM off-road run thinking that'll be me soon enough.....

It won't be concours when it's done, but that was never the plan anyway as I intend to properly use it.

I am replacing the wiring loom. I can check the receipt but I think the main loom was £120-ish from Motorworks. Then there's various sub-looms like the rear lights/indicators, etc.

colt said:
well you have been £busy.
you missed the bit where i found you my rare block connector to help keep the bike on the road and the rebuild costs down
well it will look good when its finished.

Dang! Sorry Colt, I forgot to give you a name check. Ta for the address by PM, I still have the part you sent and will return it.

While on the subject of ' :blast

I forgots', a big thank you to Rob for the loan of the tools :bow

. I will get them back to you.

Flipfly said:
Come on Mr gangly, you've had all day, where are the pics of it finished

'Gis a chance!!

Kenny · Aug 29, 2007

bakerlonglegs said:
'Gis a chance!!

Another 41 minutes have passed :augie

Trippy · Aug 29, 2007

bakerlonglegs said:
Oh yes I will! Plan is some beginners off-road runs at GS weekends

Best we have a retro day on the Plain late in Sept for some of the gentlemen of the Airhead section.

Rob Farmer · Aug 29, 2007

Trippy said:
Best we have a retro day on the Plain late in Sept for some of the gentlemen of the Airhead section.

Last time I was there was followed by 7 weeks of pain

newguy · Aug 30, 2007

/Hijack on
wow, pls tell me what you used to polish your parts.
When my bike failed it took a while for me to get it back to my garage. When I washed the bike the mud seemed to have left some spots that dont want to come off.
/Hijack off

Everything is so shiny

Flipfly · Aug 30, 2007

Is it done yet?????

I think the polish is media blasting and can't be done at home :thedummy

Come on, the suspense is killing me

bakerlonglegs · Aug 31, 2007

newguy said:
/Hijack on
wow, pls tell me what you used to polish your parts.
When my bike failed it took a while for me to get it back to my garage. When I washed the bike the mud seemed to have left some spots that dont want to come off.
/Hijack off

Everything is so shiny

/cheat mode on
The shiny wheel rims and spokes are actually new. The wheel hubs were blasted clean. Same with the timing chain case. The frame has been blasted, then powder coated satin black. A lot of fixings were beyond repair and have been replaced with stainless. The fork legs were badly pitted so were ground and re-chromed. The fork sliders, like the frame, were blasted and powder coated.
There are various bits I am cleaning up in the garage (bevel box, exhaust, etc.) and they are being cleaned with wire wool and WD40. It doesn't leave a shiny-shiny look, more of a gun-metal finish if you know what I mean, but I like it. More pics in a few days!
HTH
/cheat mode off

MickDB1 · Aug 31, 2007

Great bit of restoration up to now sir!! :clap

Always seems a shame to risk buggering um up first time out, just take it steady
I will, if wanted, show any of the conserned Airhead folk a few more of my route list
different degrees of difficulty can be accomodated from "Is that it" up to the "what the fooook am I doin up this trail". I would like the group to be a max of around 6 or 7
almost anytime but preferably mid week
I live in Derbyshire :thumb2

Mick

R80g/s rebuild - some pics as I go along....

Relative numpty

Well-known member

Well-known member

Well-known member

GS Weissbeer

Guest

Trippy

Guest

25 Mar 1949 - 10 Nov 2016

Well-known member

Trustworthy Scouser AND

Well-known member

Trippy

Guest

Well-known member

Relative numpty

Trustworthy Scouser AND

Trippy

Guest

Well-known member

Registered user

Well-known member

Relative numpty

Well-known member

Similar threads