The making of a Rahier Dakar Replica

[PROTON1]

Trial fitting of HPN Tank with Marlboro Decor on Project Bike

Hi there Airheads. I acquired the Marlboro/PLAYBOY HPN Tank from Nick CT (this used to be the Sycomoto Tank) and trial fitted it on the project Bike. Have not yet giving up the chances to find an original Tank, or in absence thereoff (as finding oil in Belgium would be easier...) the MOTO FORMS Replica Tank. However the project is to continue and hence will use this Tank. And swap later if the real thing or the MOTO FORMS Replica turns up. Next step before dismantling of the Bike is searching a suitable seat (as close as possible to the 85 Bike) . But must watch the seat height as already with this cannot feel soil under feet with this extreme ride height. Yes, I hear you think...so could'nt Rahier...Then will make a Twin Exhaust ressembling the 85 Bike. Then all will be taken apart and everything refirbished and/or remanufactured. The Engine will be done by Mr 2 Valve Junkie himself, Mat Beekers of BMW Boxertoko in Holland. Just a 1000cc but with light forged pistons, a 320 camshaft and enduralast alternator. Maybe a Silent Hectic Twinspark, will see. Here a picture with the Tank trial fitted. More pictures on www.gs-airheads.be , section ALBUM, then click the making of a Rahier Replica.

 

[sycomoto]

If your interested

Hi there Airheads. I acquired the Marlboro/PLAYBOY HPN Tank from Nick CT (this used to be the Sycomoto Tank) and trial fitted it on the project Bike. Have not yet giving up the chances to find an original Tank, or in absence thereoff (as finding oil in Belgium would be easier...) the MOTO FORMS Replica Tank. However the project is to continue and hence will use this Tank. And swap later if the real thing or the MOTO FORMS Replica turns up. Next step before dismantling of the Bike is searching a suitable seat (as close as possible to the 85 Bike) . But must watch the seat height as already with this cannot feel soil under feet with this extreme ride height. Yes, I hear you think...so could'nt Rahier...Then will make a Twin Exhaust ressembling the 85 Bike. Then all will be taken apart and everything refirbished and/or remanufactured. The Engine will be done by Mr 2 Valve Junkie himself, Mat Beekers of BMW Boxertoko in Holland. Just a 1000cc but with light forged pistons, a 320 camshaft and enduralast alternator. Maybe a Silent Hectic Twinspark, will see. Here a picture with the Tank trial fitted.More pictures on www.gs-airheads.be , section ALBUM, thenclick the making of a Rahier Replica.

I,ve got a few bits n bobs that may help the build things like the leather tool box that was fitted to the rear mudguard.

 

[PROTON1]

indeed interested

Hi Sycomoto, I trial fitted "your Tank" , acquired through Nick CT, now I must look for close matching Seat (might need to buy it at HPN...). Yest I am interested in whatever you could offer me. But please sent (offer) by a Private Message. Sycomoto what would be the best Option for a close matching Black Twin Exhaust ? Any ideas ? I will take the Bike apart for rebuild only after having trialfitted a close matching black twin exhaust. Also sent me your phone number through private msg, then can give you a ring. Thank you for your help Sycomoto , much appreciated.

 

[PROTON1]

Leftovers

Hi there Airheads. I acquired the Marlboro/PLAYBOY HPN Tank from Nick CT (this used to be the Sycomoto Tank) and trial fitted it on the project Bike. Have not yet giving up the chances to find an original Tank, or in absence thereoff (as finding oil in Belgium would be easier...) the MOTO FORMS Replica Tank. However the project is to continue and hence will use this Tank. And swap later if the real thing or the MOTO FORMS Replica turns up. Next step before dismantling of the Bike is searching a suitable seat (as close as possible to the 85 Bike) . But must watch the seat height as already with this cannot feel soil under feet with this extreme ride height. Yes, I hear you think...so could'nt Rahier...Then will make a Twin Exhaust ressembling the 85 Bike. Then all will be taken apart and everything refirbished and/or remanufactured. The Engine will be done by Mr 2 Valve Junkie himself, Mat Beekers of BMW Boxertoko in Holland. Just a 1000cc but with light forged pistons, a 320 camshaft and enduralast alternator. Maybe a Silent Hectic Twinspark, will see. Here a picture with the Tank trial fitted.More pictures on www.gs-airheads.be , section ALBUM, thenclick the making of a Rahier Replica.[/QUOTE

I,ve got a few bits n bobs that may help the build things like the leather tool box that was fitted to the rear mudguard.

Hi Sycomoto, what leftovers can you offer me ?
I finished breakdown of the donor bike, now the real work will start.

 

[PROTON1]

Restoration started

By clicling on this link:
https://picasaweb.google.com/117484...feat=directlink#slideshow/5654174366444724994
You can follow the restoration progress. At present the bike is totally disassembled in bits and the painstaking restoration and or replacement of parts started. Virtually every weekend, pictures of the progress will be added. The aim is to get the bike ready as a rolling chassis by Xmas. By February, the bike should be back complete. But finances have to be spread.

At present following parts have been procured:
- HPN Nylon Tank , originally painted in 1985 Decor by Sycomoto
- Original HPN -Acerbis Front mask with K100 Headlight and original HPN Mask frame for Marzocchi M1 Headstock
- Original 4.5 Liter HPN underseat Tank (required bracket on rear frame to hang the tank) - Very rare part nowadays...
- HPN Tools wallet for Tank
- HPN Sump extension and flat bashplate.
- Bike Standard sent to Herr Halbfeld from HPN for remanufacturing to original spec.
- Extended sidestand on order with HPN (to mount to standard crashbars) - was never fitted on a Dakar machine but handy for normal use of bike...
- New HPN Brake Disc for Brembo Hub
- New GS Steering handle (stock R100GS)
- Refurbishment kit for Dual Piston front brake.
- Refurbishment kit for the Marzocchi M1
- Rear wheel respoked, TKC 130-18 Tire fitted
- New seat on order with German specialist Saddlemaker. Sorry, but lower seat as the original...either that or need to extend leggs...
At present working on frame mods and shotblasting of parts...i.e. the dirty work.

 

[PROTON1]

Assembly Started

on this link you can see some further pictures added as assembly started:
https://picasaweb.google.com/117484...feat=directlink#slideshow/5654174366444724994
At present waiting for the mudguards, Rear Frame and HPN Headcowl being painted in Fluo Marlboro Rosso. Recently acquired some parts from Syco. Also waiting for the HPN Main Stand welded by Alfred Halbfeld of HPN himself. With some luck by 1.1.12 the bike might be back on wheels...

 

[PROTON1]

Assembly progress...

on this link you can see some further pictures added as assembly progressed:
https://picasaweb.google.com/117484...feat=directlink#slideshow/5654174366444724994

The last hurdles are the Twin Exhausts (which still need to be made), fitting the R80G/S carbs to R100RS Heads (for more torque) and to design a custom dash resembling the 1985 Marlboro Penthouse BMW Dakar. Guess in a few days the Tank will be on...

The engine: Pretty Stock except 1000CC Barrels, light short Pistons, 320° "EnduroCam" , R100RS Heads of 70 BHP Motor. So all in all should give 75-76 BHP...When the lottery is ever won will modify into 1043 HPN. With G/S carbs this is nevertheless a coctail for Torquey engine.

Made mistake with the Tyres, these are TKC, but now it appears the rear is a 18/120. 120 is too narrow, a 140 easily passess, so both tyres will be replaced by larger ones?
On this picture the Sump is not fitted. Will be the HPN Flat Sumpp. Presently being machined so that A Temp Sensor can be fitted.
Observe the Steep angle of the swing. The rear wheel kan move 310mm and the Twin Spring Öhlins cope very easily. This Bike really rides on Springs. The Marzocchi M1 in the Front is the 300mm Stroker.
Black area between rear Springs is the HPN Underseat Tank. It can take 4.5 liter of juice.

 

[sycomoto]

nice job

on this link you can see some further pictures added as assembly progressed:
https://picasaweb.google.com/117484...feat=directlink#slideshow/5654174366444724994

The last hurdles are the Twin Exhausts (which still need to be made), fitting the R80G/S carbs to R100RS Heads (for more torque) and to design a custom dash resembling the 1985 Marlboro Penthouse BMW Dakar. Guess in a few days the Tank will be on...

The engine: Pretty Stock except 1000CC Barrels, light short Pistons, 320° "EnduroCam" , R100RS Heads of 70 BHP Motor. So all in all should give 75-76 BHP...When the lottery is ever won will modify into 1043 HPN. With G/S carbs this is nevertheless a coctail for Torquey engine.

Made mistake with the Tyres, these are TKC, but now it appears the rear is a 18/120. 120 is too narrow, a 140 easily passess, so both tyres will be replaced by larger ones?
On this picture the Sump is not fitted. Will be the HPN Flat Sumpp. Presently being machined so that A Temp Sensor can be fitted.
Observe the Steep angle of the swing. The rear wheel kan move 310mm and the Twin Spring Öhlins cope very easily. This Bike really rides on Springs. The Marzocchi M1 in the Front is the 300mm Stroker.
Black area between rear Springs is the HPN Underseat Tank. It can take 4.5 liter of juice.

looking stunning danny. sweet job. can you do a quick pic with the tank and seat in place just so i can see how that tank i did looks against the rest of you supper work. I recon yours and camille next to each other in august will looks stunning

 

[PROTON1]

Camile and Emile

Syco, as the mecanic from Gaston Rahier , Emile, is still alive (did I posted that picture of Emile at the grave of Gaston, did I ?) I call the 85 Replica now Emile. So what we need to do is to park Camile and Emile next to each other during the August Tenting do... that will be nice display... Maybe can get a truck of Sand poored out to get a suitable scenery.... or you join me this summer on the Morocco-Algeria Sahara tour, just to find out that what little Gaston could, we 2 tall blokes can...food foor thought Simon ?

The Tank is at the Sprayboot today, to get a fat coat of transparent 2 Pack, then will put the Tank on and maybe will roll the Bike out for a picture...hopefully this weekend...Still need to sort out the Twin pipes, and some other bits 'n' pieces, but in 1 month from now, hope the work will be 95% done. I am reasonably pleased with the result. Its a Replica, but in many aspects its close to the real thing, and lots of exotic pieces on this Bike...Syco, in August you can drive Emile, not many will be allowed, but you are one of them !

 

[sycomoto]

Thanks mate

Syco, as the mecanic from Gaston Rahier , Emile, is still alive (did I posted that picture of Emile at the grave of Gaston, did I ?) I call the 85 Replica now Emile. So what we need to do is to park Camile and Emile next to each other during the August Tenting do... that will be nice display... Maybe can get a truck of Sand poored out to get a suitable scenery.... or you join me this summer on the Morocco-Algeria Sahara tour, just to find out that what little Gaston could, we 2 tall blokes can...food foor thought Simon ?

The Tank is at the Sprayboot today, to get a fat coat of transparent 2 Pack, then will put the Tank on and maybe will roll the Bike out for a picture...hopefully this weekend...Still need to sort out the Twin pipes, and some other bits 'n' pieces, but in 1 month from now, hope the work will be 95% done. I am reasonably pleased with the result. Its a Replica, but in many aspects its close to the real thing, and lots of exotic pieces on this Bike...Syco, in August you can drive Emile, not many will be allowed, but you are one of them !

And I'll return the favour with a go on camille it's nearly as personal as wife swapping this

 

[Fanum]

And I'll return the favour with a go on camille it's nearly as personal as wife swapping this

Photos will be needed.

Of both

 

[sycomoto]

Yeh right

Photos will be needed.

Of both

Bike or wife

 

[PROTON1]

And I'll return the favour with a go on camille it's nearly as personal as wife swapping this

Syco, as requested here a pickie of "struggle and strife" with the Tank fitted, more pics in the above Link. It all fits very neatly together... now running around puzzled what do do with the pipes, its like a woman considering what type of breast implant

 

[PROTON1]

trying to figure exhaust out

what about blackening the BK MOTO pipes and get these on ? Can anybody suggest another solution ?

 

[sycomoto]

That looks nice

what about blackening the BK MOTO pipes and get these on ? Can anybody suggest another solution ?

The tanks not bad either

 

[Fantoluca]

Exhaust

what about blackening the BK MOTO pipes and get these on ? Can anybody suggest another solution ?

I would ask you if you have installed pipe of r 100 rs and silencers of bk moto
you can send me more photos of exhaust at this e-mail:
[email protected]
Very thanks and regards Luca.

 

[PROTON1]

Header pipes and BK Moto exhausts

I would ask you if you have installed pipe of r 100 rs and silencers of bk moto
you can send me more photos of exhaust at this e-mail:
[email protected]
Very thanks and regards Luca.

Luca, the Header Pipes are R80/7 types. It is not possible to use GS Headers as this bike is based on a R80/7 frame. The header pipe diameters are 38mm. The BK Moto pipes do NOT fit directly on these headers. An intermediate section has to be made. I still need to have these made, thereafter I could sent you pictures if you want them. Ciao Danny

 

[Fantoluca]

exhaust

Luca, the Header Pipes are R80/7 types. It is not possible to use GS Headers as this bike is based on a R80/7 frame. The header pipe diameters are 38mm. The BK Moto pipes do NOT fit directly on these headers. An intermediate section has to be made. I still need to have these made, thereafter I could sent you pictures if you want them. Ciao Danny

Ok very thanks

 

[PROTON1]

Bike near ready

Please try following link to a Photo Album:
https://picasaweb.google.com/117484...feat=directlink#slideshow/5718650438285280594

further visit: www.gs-airheads.be

Will soon post a picture of the finished bike on this Forum

 

[PROTON1]

Ok very thanks

now you can see pics at:
https://picasaweb.google.com/117484...feat=directlink#slideshow/5718650438285280594