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

[bakerlonglegs]

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....

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....

 

[DrAlf]

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

 

[Voyager]

Very, Very nice

It will be a credit to you when its finished.

But you won't want to get it dirty

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]

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.

 

[GS Weissbeer]

Very nice work

Especially the "new" wheels

 

[Trippy]

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

 

[(RIP) Proff]

You are going to be so proud when it's finished
You are doing a great Job
I look forward to seeing the finished bike very soon
BTW Glad to see you have the PROPER Tyres on her now

It's really made me feel Chuffed all over

 

[Flipfly]

Is it done yet!!!!!!

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

 

[Kenny]

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

You'll be next Trippy

Lovely project Mr longlegs

 

[Rob Farmer]

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]

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]

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

 

[bakerlonglegs]

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

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.

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 ' I forgots', a big thank you to Rob for the loan of the tools . I will get them back to you.

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

'Gis a chance!!

 

[Kenny]

'Gis a chance!!

Another 41 minutes have passed

 

[Trippy]

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]

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]

/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]

Is it done yet?????

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

Come on, the suspense is killing me

 

[bakerlonglegs]

/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]

Great bit of restoration up to now sir!!

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

Mick