Looks SUPERB Danny 
The making of a Rahier Dakar Replica
- Thread starter PROTON1
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Work of art 
PROTON1
Registered user
Not quite finished...
Kenny, its not quite finished as yet. Well the carbs are now on and soon will fit the front and rear (perfect replicas) of the original Startnumber (101) and the Sponsering decalls. A specialist is making them...
The Propshaft makes a bit of an excessive steep angle with the bike in rest (the UJ nearly scores the front bell house of the propshaft-tunnel). During ride and with load the Angle is OK, unless when the bike would take a jump... The bike is also much too high (for me small bloke
). So the Öhlins struts are fantastic and look a million, but are 390mm centre hole to centre hole, so against my liking will fit either Billstein or WP struts of 370mm
Wheels also taken off, go for wider tires as with these TKCs bike does look a bit thin on its feet...
Further, its only nitty gritty work left here and there. A few more weeks...then will be on the road with it, not many like this in Belgium I guess...
, guess guys with 1200GS "CadCam Bikes" will not know what they see...or would they ?
Work of art
Kenny, its not quite finished as yet. Well the carbs are now on and soon will fit the front and rear (perfect replicas) of the original Startnumber (101) and the Sponsering decalls. A specialist is making them...
The Propshaft makes a bit of an excessive steep angle with the bike in rest (the UJ nearly scores the front bell house of the propshaft-tunnel). During ride and with load the Angle is OK, unless when the bike would take a jump... The bike is also much too high (for me small bloke
). So the Öhlins struts are fantastic and look a million, but are 390mm centre hole to centre hole, so against my liking will fit either Billstein or WP struts of 370mmWheels also taken off, go for wider tires as with these TKCs bike does look a bit thin on its feet...
Further, its only nitty gritty work left here and there. A few more weeks...then will be on the road with it, not many like this in Belgium I guess...
, guess guys with 1200GS "CadCam Bikes" will not know what they see...or would they ?
Danny your bike is truly a wonder of the modern world 
If I were you I would make some cardboard silencer models and try and get as low and close to the knuckle as possible - then stand back and see/admire
I like to see the exit of the silencers horizontal and if possible slightly outwardly so for me I would have a cranked exit like this one I knocked up in windows "Paint"
If you adopt this style I would be honoured to have the
"Exhaust by DB1 design" = only joking
See image below and please dont be offended if you think I am vandalizing your bike
If I were you I would make some cardboard silencer models and try and get as low and close to the knuckle as possible - then stand back and see/admire
I like to see the exit of the silencers horizontal and if possible slightly outwardly so for me I would have a cranked exit like this one I knocked up in windows "Paint"
If you adopt this style I would be honoured to have the
"Exhaust by DB1 design" = only joking
See image below and please dont be offended if you think I am vandalizing your bike
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PROTON1
Registered user
No , no offence, I got pipedreams for a while. But I think you better look at the pictures in the Album on www.gs-airheads.be "The making of a Rahier replica". Ywill see both exhausts are a bit outwardy. When the bike is 100% finished, I plan to take the complete exhaust line off, make possibly a little tweak, and have it completely blackened. Its all in Stainless...Danny your bike is truly a wonder of the modern world
If I were you I would make some cardboard silencer models and try and get as low and close to the knuckle as possible - then stand back and see/admire
I like to see the exit of the silencers horizontal and if possible slightly outwardly so for me I would have a cranked exit like this one I knocked up in windows "Paint"
If you adopt this style I would be honoured to have the
"Exhaust by DB1 design" = only joking
See image below and please dont be offended if you think I am vandalizing your bike
But before that will focus on the last issues.
PROTON1
Registered user
MickDB1, here a picture where the twin exhaust and the angle the pipes make are visible.
Pipes run parallel with reinforcement bracket of rear frame. But for better pics look at the Album.
https://picasaweb.google.com/117484...feat=directlink#slideshow/5718650438285280594
Pipes run parallel with reinforcement bracket of rear frame. But for better pics look at the Album.
https://picasaweb.google.com/117484...feat=directlink#slideshow/5718650438285280594
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Deleted account 231002001
Registered user
Nice work.
PROTON1
Registered user
Rahier Replica Job parts bin
On the PDR101 Marlboro Playboy of Gaston Rahier (made by HPN GmBH in Seibersdorf), not many parts were original BMW. In a similar way, on the Replica Bike Project, not many parts are original BMW either.
Hereby a summary of the “Parts Bin”. Many parts are identical with the PDR101 of Rahier. For these parts that are different on the PDR101 of Gaston Rahier, I highlighted these (different on the Rahier Bike) in red colour.
• Frame: R100/7 based with double tube backbone top frame, reinforcements to Headstock Tube, Top frame split and bottom frame members. Lots of special parts welded to this frame, including peg brackets… Rahiers’ bike got a 2 cm lifted engine at the front frame to counteract the propshaft angle with rear wheel from the ground as Rahier was notorious for his motorcross style long jumps…The Bikes of Loiseaux and Hau (Rahier Teammates) did not got a lifted engine at front.• Rear Frame: Special handmade frame, welded by Alfred Halbfeld of HPN
• Central Stand: Special HPN handmade (on the Rahier Bike this was often taken off to reduce weight, in fact it was not on in the race…)
• Side Stand: R100GS extended jiffy (by A. Halbfeld of HPN) – on the Rahier Bike the side stand arrangement was different (only Rahier got one, not Loiseaux, not Hau) and could be taken off in 3 seconds.
• Headlamp and HPN Fairing carrier Bracket: Designed by HPN, with fixations for Marzocchi M1 Fork.
• Headlamp Dakar Rallye Fairing: HPN (produced under License by Acerbis Italia)
• Windscreen: Original windscreen from BMW K100
• Headlight: Original headlight from K100 (with special bracket, used without the metal light cowl)
• Front Mudguard: Acerbis Baja
• Rear Mudguard: HPN (produced under licence by HPN)
• Main Tank: HPN Nylon Tank (on original Rahier Bike was a Kevlar Tank, Kevlar copy of French designed 1984 Aluminium tank)
• Tank Decals: Airbrushed (to perfection) on Rahier bike were stickers.
• Underseat Tank: HPN (made under license by Acerbis) – on Rahier bike was painted white.
• Seat: Special design, based on a shortened Denfeld seatpan.
• Instruments: R100GS Speedo (on Rahier type used is unknown), Oil Temp Gauge and Mirage Fighterjet Kompass (in addition to Rahier bike have fitted: R80G/S Rev counter and R100RT Voltmeter)
• Wiring Loom (based on R80G/S but heavily modified)- On Rahier bike there was no cable loom, just some essential wiring.
• Traficators: Stock BMW 80ties (there were no traficators on Rahier machine)
• Rear Parcel Shelve: R80G/S (there was no parcel shelve on the Rahier machine)
• Front Fork: Marzocchi M1 Competition, Yokes Marzocchi competition.
• Front Wheel Hub: Brembo competition
• Front Wheel rim: 21inch from R80G/S
• Front brake: Brembo Dual Piston brake
• Front Brake Disc: HPN Floating (is obviously made for HPN by a specialist, but source is unknown)
• Front steer: Copy of late 70ties KTM crossbar (Rahier got light Aluminium crossbar)
• Front handles: BMW R100/7 (on Rahier bike were stock Magura, due to no electrical controls)
• Rear Wheel: Standard BMW R100/7 , 17 and 18 inch (with Japanese wheelrim, same on Rahier bike)
• Rear Differential: R100/7 (with changed gearing ratio)
• Dual Swingarm: IMPEC CADRE CONCEPT Square box swing (110mm longer then R100/7) made in France for Arceuil Motor (on Rahier Bike was a copy of this Swingarm, welded by HPN). The IMPEC CADRE CONCEPT Swingarm was designed by a French specialist Firm upon demand of Arceuil Motors (French BMW Importer). Many aspects of the bike were in fact developed by BMW Arceuil Motor in France, long before HPN got involved.
• Propshaft: IMPEC CADRE CONCEPT with special junction and non standard BMW Universal Joint !!! (On Rahier bike was HPN made)
• Shocks: ÖHLINS Competition Twinspring shocks (on Rahier bike WP competition Twinspring shocks)
• Motor: R80/R100 core, with SR1000 pistons and shortened lightened pistons, giving exactly 1000cc. R100RS Heads with large Valves. 320° Cam fitted. Further all other parts standard BMW. Hall effect Ignition. R100GS carbs. (on Rahier Bike motor was HPN with short conrods, big bire shortened cylinders, special shaped piston heads giving 1043cc, Unknown Cam, lightened crankshaft, lightened drivetrain for valves….etc was the prototype of the later HPN Motor)
• Airfilter: Stock BMW (on Rahier Bike HPN, with special filter, grating for desert sand)
• Gearbox: Standard R100, no gear ratio changes (on Rahier Bike: gear ratios were changed and gears were lightened)
• Exhausts: Front Manifold: Stainless by BOXUP Germany, joints are special handmade, Pipes are BK Moto TÜV approved. (On Rahier bike: handmade by HPN from manifold to Can, very loud pipes to scare camels…)
• Tires: Conti TKC (on Rahier Bike Michelin Dessert – Front tire not suitable for highway use)
• Tank Case: HPN
• Rear Case: HPN
• And of course many other parts…
On the PDR101 Marlboro Playboy of Gaston Rahier (made by HPN GmBH in Seibersdorf), not many parts were original BMW. In a similar way, on the Replica Bike Project, not many parts are original BMW either.
Hereby a summary of the “Parts Bin”. Many parts are identical with the PDR101 of Rahier. For these parts that are different on the PDR101 of Gaston Rahier, I highlighted these (different on the Rahier Bike) in red colour.
• Frame: R100/7 based with double tube backbone top frame, reinforcements to Headstock Tube, Top frame split and bottom frame members. Lots of special parts welded to this frame, including peg brackets… Rahiers’ bike got a 2 cm lifted engine at the front frame to counteract the propshaft angle with rear wheel from the ground as Rahier was notorious for his motorcross style long jumps…The Bikes of Loiseaux and Hau (Rahier Teammates) did not got a lifted engine at front.• Rear Frame: Special handmade frame, welded by Alfred Halbfeld of HPN
• Central Stand: Special HPN handmade (on the Rahier Bike this was often taken off to reduce weight, in fact it was not on in the race…)
• Side Stand: R100GS extended jiffy (by A. Halbfeld of HPN) – on the Rahier Bike the side stand arrangement was different (only Rahier got one, not Loiseaux, not Hau) and could be taken off in 3 seconds.
• Headlamp and HPN Fairing carrier Bracket: Designed by HPN, with fixations for Marzocchi M1 Fork.
• Headlamp Dakar Rallye Fairing: HPN (produced under License by Acerbis Italia)
• Windscreen: Original windscreen from BMW K100
• Headlight: Original headlight from K100 (with special bracket, used without the metal light cowl)
• Front Mudguard: Acerbis Baja
• Rear Mudguard: HPN (produced under licence by HPN)
• Main Tank: HPN Nylon Tank (on original Rahier Bike was a Kevlar Tank, Kevlar copy of French designed 1984 Aluminium tank)
• Tank Decals: Airbrushed (to perfection) on Rahier bike were stickers.
• Underseat Tank: HPN (made under license by Acerbis) – on Rahier bike was painted white.
• Seat: Special design, based on a shortened Denfeld seatpan.
• Instruments: R100GS Speedo (on Rahier type used is unknown), Oil Temp Gauge and Mirage Fighterjet Kompass (in addition to Rahier bike have fitted: R80G/S Rev counter and R100RT Voltmeter)
• Wiring Loom (based on R80G/S but heavily modified)- On Rahier bike there was no cable loom, just some essential wiring.
• Traficators: Stock BMW 80ties (there were no traficators on Rahier machine)
• Rear Parcel Shelve: R80G/S (there was no parcel shelve on the Rahier machine)
• Front Fork: Marzocchi M1 Competition, Yokes Marzocchi competition.
• Front Wheel Hub: Brembo competition
• Front Wheel rim: 21inch from R80G/S
• Front brake: Brembo Dual Piston brake
• Front Brake Disc: HPN Floating (is obviously made for HPN by a specialist, but source is unknown)
• Front steer: Copy of late 70ties KTM crossbar (Rahier got light Aluminium crossbar)
• Front handles: BMW R100/7 (on Rahier bike were stock Magura, due to no electrical controls)
• Rear Wheel: Standard BMW R100/7 , 17 and 18 inch (with Japanese wheelrim, same on Rahier bike)
• Rear Differential: R100/7 (with changed gearing ratio)
• Dual Swingarm: IMPEC CADRE CONCEPT Square box swing (110mm longer then R100/7) made in France for Arceuil Motor (on Rahier Bike was a copy of this Swingarm, welded by HPN). The IMPEC CADRE CONCEPT Swingarm was designed by a French specialist Firm upon demand of Arceuil Motors (French BMW Importer). Many aspects of the bike were in fact developed by BMW Arceuil Motor in France, long before HPN got involved.
• Propshaft: IMPEC CADRE CONCEPT with special junction and non standard BMW Universal Joint !!! (On Rahier bike was HPN made)
• Shocks: ÖHLINS Competition Twinspring shocks (on Rahier bike WP competition Twinspring shocks)
• Motor: R80/R100 core, with SR1000 pistons and shortened lightened pistons, giving exactly 1000cc. R100RS Heads with large Valves. 320° Cam fitted. Further all other parts standard BMW. Hall effect Ignition. R100GS carbs. (on Rahier Bike motor was HPN with short conrods, big bire shortened cylinders, special shaped piston heads giving 1043cc, Unknown Cam, lightened crankshaft, lightened drivetrain for valves….etc was the prototype of the later HPN Motor)
• Airfilter: Stock BMW (on Rahier Bike HPN, with special filter, grating for desert sand)
• Gearbox: Standard R100, no gear ratio changes (on Rahier Bike: gear ratios were changed and gears were lightened)
• Exhausts: Front Manifold: Stainless by BOXUP Germany, joints are special handmade, Pipes are BK Moto TÜV approved. (On Rahier bike: handmade by HPN from manifold to Can, very loud pipes to scare camels…)
• Tires: Conti TKC (on Rahier Bike Michelin Dessert – Front tire not suitable for highway use)
• Tank Case: HPN
• Rear Case: HPN
• And of course many other parts…
absolutely gorgeous. id give my r1200gs, wife and cat for one of those
PROTON1
Registered user
swap
Dancanovas, please sent picture of struggle and strife wife, maybe we can discuss a swap...
PROTON1
Registered user
The full story
If you want to read the full story of this Replica build, check the link below. Most of the text is in English (some in Dutch or German), but lots of pictures...
http://www.atfreeforum.com/gsairheads/viewtopic.php?t=54&mforum=gsairheads
If you want to read the full story of this Replica build, check the link below. Most of the text is in English (some in Dutch or German), but lots of pictures...
http://www.atfreeforum.com/gsairheads/viewtopic.php?t=54&mforum=gsairheads
Last edited:
awesome thanks for sharing
PROTON1
Registered user
PROTON1
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PROTON1
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PROTON1
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absolutely stunning
PROTON1
Registered user
Mirage Compass fitted
see photo at the end of this thread:
http://www.atfreeforum.com/gsairhea...ays=0&postorder=asc&start=0&mforum=gsairheads
see photo at the end of this thread:
http://www.atfreeforum.com/gsairhea...ays=0&postorder=asc&start=0&mforum=gsairheads
she really is. im playing the lottery now and if I win ill be sending a big cheque 
