New year, new project bike

Mad Hatter

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This project was inspired by a GS airhead owned by Tetley of this parish, which was originally built by Mikeyboy albeit in a different colour scheme. I saw a photo of it on the forum and thought it looked great. That little event coincided with Mikey advertising that he had a spare engine and gearbox awaiting rebuild at an attractive price and the rest is history…….

A deal was done with Mikey he got stared on the engine and gearbox while I went searching for a frame and suspension etc. A siebenrock 1000cc kit was procured, with Mikey machining bigger squish bands in the heads to suit. A low 1st and high 5th gear were also sourced for the gearbox.

A late night alcohol infused eBay session saw a frame being ordered from James Sherlock. This turned out to be the wrong one though (twinshock), but Sherlock very kindly accepted it back and another frame was sourced from Motorworks (the moral of this story kids is don’t press buy now when you’re pissed). The correct frame was sent to Mikey who had it braced a la SWT and powder coated in santorini blue.

Meantime I found a pair of almost new KTM 690 forks in the states at a bargain price and was able to bring them home as hand luggage on the back of a business trip to the states. A rear shock was also commissioned from Wilbers and I was able to collect that from their factory and bring it home on the back of the 1150GS at the end of a bike trip to the Harz mountains.

Next on the list was a pair of wheels. I bought a brand new ktm690 hub for the front and a used 4 bolt paralever hub for the rear, luckily with hardly any wear on it. These were sent to Doug Richardson who laced them to a 21” front and an 18” rear with heavy duty stainless spokes. Doug did an excellent job and was brilliant to deal with.

Mikey meantime dug out a decent paralever swingarm, bevel box and drive shaft, all of which he refurbished.

While this was ongoing Roy Martin at BilletBikeBits made me a set of yokes to fit the KTM front end to the GS frame. Roy was brilliant to deal with as well and made a cracking job of them

Photo’s to follow. This one is Tetley’s bike which inspired the project in the first place
 

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Here’s a few photo’s of the major parts
 

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After finishing a full refurb of the mechanical parts Mikeyboy did a loose assembly of the rolling chassis so I could put it in the van and drive it home
 

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There then followed a slight delay while I serviced a couple of my other bikes and sourced a whole load of minor parts needed to complete the build (no donor bike to start with remember, just a bare frame, motor, gearbox and final drive)

An arm and a leg later on parts and I’m now ready to get on with it. The first job was to put it on the ramp and pull the suspension off so I could service the forks and fit heavier springs. I also pulled the swingarm off to fit a brand new driveshaft and the new Wilbers shock instead of the original WP item. If anyone needs a used shock or driveshaft let me know.

This is how things look at present
 

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This is the old shock which originally came off my Basic. Doesn’t leak but preload adjusters absolutely mullered by some previous owner with more muscles than brains :blast
 
This time with the photo:augie
 

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Following with interest - and looking forward to seeing how this projects goes. I've got a set of wheels with Doug at the moment - agree, a really nice guy to deal with.

Also agree with your views on booze and ebay - 11 years ago today I flew to to Portugal to collect a T4 camper van that that I had placed a last second drunken bid on and shockingly won.

Good luck with the project:thumb
 
Accidentally won a camper van:D:D

Todays job was finishing the fork service and refitting the front end, complete with shiny new brake caliper
 

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Great thread will follow with interest. Anything Maketboy is associated with usually has a Walt Disney ending! More dripple and pictures please!!
 
Tonight’s progress was fitting the disc to the wheel and the wheel back on the bike, simple but satisfying :beerjug:
 

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Stuck waiting for the new prop shaft to arrive now so I can reassemble the back end. Filling in time by rebuilding a pair of carbs for the bike. Mikeyboy had already rebuilt a pair for me, but they were off an an early bike. I managed to blag a younger pair off eBay so I’m going to fit them instead. They have come up really well just using carb cleaner in the ultrasonic bath. If anyone wants the pair that Mikey refurbished give me a shout
 

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Pleased with how these have come up
 

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Both carbs finished and the new driveshaft has arrived. Next job - reassemble the back end
 

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New driveshaft, swingarm and bevel back in
 

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Ready for this to be fitted next :D:D
 

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Busy day today, firstly rebuilding the back end. New Wilbers shock and everything assembled with new OEM bolts
 

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Just about enough clearance with 18” rear and standard rim offset
 

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Followed by 8mm sump plate
 

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