MOTOBRICK.COM
TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => Project Custom Motobricks => Topic started by: Mike Flores on August 19, 2016, 06:49:25 PM
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Hello everyone,
I thought I’d share my project with all of you since I’ve learned so much from this forum. I’m about 9 months into this project, but have really ramped it up over the past couple of months.
It all started when I picked up someone else’s half assed project K100. It had some nice components, but nearly everything done on it
was pretty hack / unsafe / and just plain wrong. I had a pretty clear vision for what I wanted out of my K100 build, and thought I might be
able to fix what was wrong with the bike and still meet that goal. As I got into the bike a bit, I realized that it just wasn’t going to happen and
that I’d need a new donor bike.
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b785e8d1758e022c26652a/1471645164709/IMG_1986.JPG?format=1500w)
The stem on the golden GSXR front end was too long, resulting in the entire front end rocking back and forth if you applied the front brakes (death trap unsafe). The rear of the frame had been left open to the elements after it was chopped. The seat is laughable. The exhaust was nice, but in rough shape. The wheels and tires were good. It actually ran pretty strong despite all this. However, after some investigation I realized the bike had way more miles on it than I was comfortable with, so I set out to find a lower mile K100 donor. I found just what I was looking for in a paperwork free K100, and set about merging the bikes. I was planning to keep the wheels, exhaust, and titled frame. Almost everything else would be sold off to help fund the build.
I found a good deal on a newer GSXR 1000 front end, and ordered up some custom triple trees and stem from Cognito Moto along with new tapered bearings to mount it onto the K100 frame (and a bunch of other parts). I also picked up some rearsets from BSK Speedworks.
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b783718419c278536de14d/1471644533468/IMG_2620.JPG?format=1000w)
Here it is mocked up:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b7839915d5dbf599f3fbe0/1471644571921/FullSizeRender.jpg?format=2500w)
I wanted to re-work the rear of the frame, but it took a while for me to gain access to my friend’s shop so I could use his fabrication tools due to scheduling. We both had some time around the holidays, and set to work. I’d be cutting off the rear of the frame, as well as all the other tabs and mounts that I didn’t need. Because I was removing so much of the frame, including the shock mount, I needed to build a frame jig to make sure the frame didn’t get twisted up during welding. It also helped me locate the new shock mounts into exactly the same place. Here’s some pics of the frame fabrication:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b783b115d5dbf599f3fc94/1471644599368/IMG_3185.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b783c615d5dbf599f3fd5a/1471644618840/IMG_3184.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b783d515d5dbf599f3fded/1471644633362/IMG_3188.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b783e015d5dbf599f3fe55/1471644644271/IMG_3194.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b783e915d5dbf599f3feb9/1471644652572/IMG_3195.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b783fe15d5dbf599f3ffa2/1471644675691/IMG_3200.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b7841e15d5dbf599f400eb/1471644704839/IMG_3214.JPG?format=1000w)
My good friend Phil broke out his 35mm film camera and took some photos of me working on it:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b7842b15d5dbf599f4016a/1471644723825/IMG_3365.JPG?format=2500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b7843a15d5dbf599f401e4/1471644737239/IMG_3369.JPG?format=2500w)
I wanted to integrate my LED Taillight/Turns strip into the frame, so I cut a channel out of a piece of rectangular tubing and welded it into the rear part of the frame:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b7844603596e6c59ac4a6d/1471644745751/IMG_3205.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b7845315d5dbf599f402b6/1471644758851/IMG_3206.JPG?format=1500w)
Frame Fab done. I reused the fuel tank mounts, as well as the mounts for the relay box.
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b7846115d5dbf599f40336/1471644774442/IMG_3209.JPG?format=1500w)
Mocked up:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b7847815d5dbf599f403e0/1471644795184/IMG_3211.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b7848415d5dbf599f40472/1471644808868/IMG_3218.JPG?format=1000w)
Now to work out a design for the rear cowl. My plan is to hide the L Jetronic ECU under the cowl, so it was made to fit that size. I also wanted to retain some squareness and angularity of the engine and stock fuel tank:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b7849b15d5dbf599f40560/1471644830953/IMG_4158.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b784ab15d5dbf599f40650/1471644849724/IMG_4159.JPG?format=1500w)
I got in touch with Cliff Meyer at Meyerbuilt Metal Works, who builds the cowls and LED integrated frame tails for Cognito Moto, and convinced him to make my cowl for me. I sent him my cardboard templates, and he whipped this badboy out for me:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b784c115d5dbf599f40717/1471644869544/IMG_4835.JPG?format=1500w)
It didn’t fit perfectly, but I didn’t expect it to considering I sent him a jigsaw puzzle of cardboard. Dimensionally it was perfect though, and it just needed a little massaging to fit perfectly. There’s an awesome DIY moto garage here in LA called Lucky Wheels that’s opened up, and they have a nice fab shop setup that I have been able to take advantage of. I’ve done the rest of my fab work and anything else I can’t do at home there.
Cowl fitted up perfectly:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b784e7cd0f68daca4c527e/1471644908831/IMG_5098.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b784f9cd0f68daca4c532b/1471644926578/IMG_5099.JPG?format=1500w)
Part of utilizing the old Triumph front wheel I had with the new ’13 GSXR 1000 front end required machining the hub down on each side to accommodate the wider Speed Triple rotors I was using. I also needed caliper spacers made, and axle spacers. I was able to get help from an old friend from my off-road racing days to help out with that. Here’s the front end all buttoned up:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b78537d1758e022c265f21/1471644987029/IMG_5077.JPG?format=1500w)
Now time to tab the frame for the new seat/cowl:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b78546d1758e022c265fc2/1471645002355/IMG_5104.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b78553ebbd1a60cf6e80a0/1471645015264/IMG_5106.JPG?format=1500w)
Speed nuts just prior to being riveted in place:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b78561ebbd1a60cf6e8111/1471645028804/IMG_5111.JPG?format=1500w)
ECU support plate:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b78571ebbd1a60cf6e81ac/1471645045973/IMG_5120.JPG?format=1500w)
Everything bolted in place:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b78582ebbd1a60cf6e8236/1471645062420/IMG_5125.JPG?format=1500w)
Here’s the actual seat pan that will get upholstered and then riveted to the cowl/seat:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b78591ebbd1a60cf6e82a8/1471645077070/IMG_5220.JPG?format=1500w)
Seat upholstered, and mocked up, other progress:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b785a1ebbd1a60cf6e8317/1471645092810/IMG_5243.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b785afebbd1a60cf6e83a0/1471645106865/IMG_5364.JPG?format=1500w)
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b785baebbd1a60cf6e83de/1471645118150/IMG_5365.JPG?format=1500w)
Time to relax for now with my favorite Bourbon:
(http://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/57b78605d1758e022c2666e0/1471645198997/IMG_5402.JPG?format=1500w)
Getting into the fun part, wiring up the electronics. I’ll make another post here when I have some more time detailing the electronics and wiring portion that I have done so far.
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Looks great so far! Love the integrated tail light, that's going to look really good. Impressive fabrication skills. Good luck and keep us posted on your progress,
Mark
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Are the indicators part of the tail light? Or will there be extra indicators in addition to the tail light?
What are the details / specs of the tail light?
well done on the work. It looks well organised.
regards
Guy
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Are the indicators part of the tail light? Or will there be extra indicators in addition to the tail light?
What are the details / specs of the tail light?
See this post (http://www.motobrick.com/index.php/topic,8771.msg68824.html#msg68824)
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Mike,
Congrats on getting Honorable Mention at the Deus Bike Buildoff. Your K100 looks very sharp and professionally finished. Please share some pics with the community when you get a chance. :2thumbup: :clap:
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looks good, did you measure the length difference between the yellow forks and the black ones, from what year are those yellow forks, I know you mentioned the black ones from 2013. The reason I asked I have 2003/04 GSXR1000 forks and stems that I'd like to use for the front end.
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I haven't really had time to put together a post detailing the wiring portion of the build, but suffice it to say it wouldn't have been possible without rbm's guidance or his TGPI 4.0 board. I promise I'll come back with some more later. Here are a couple photos from the Deus BBO event captured by their resident photographer Nevin...
(http://cdn.deuscustoms.com/wp-content/uploads/2016/09/VENICE-BBO2016winners-2764.jpg)
(http://cdn.deuscustoms.com/wp-content/uploads/2016/09/VENICE-BBO2016winners-07370.jpg)
I'm a cinematographer by trade, and plan on taking some really nice photos sometime in the near future. I also need to finish a few details on the bike before it's actually completed. (ceramic coating the exhaust, etc).
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I'm a cinematographer by trade, and plan on taking some really nice photos sometime in the near future.
Action shots from a drone's perspective, too, of course. What I'd like to see is some detailed photos of what the alternator, starter and the back of the rider's jacket look like after the bike travels 50 miles on a wet highway. :giggles
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I was a cinematographer in my former life back in the UK as well - hence the name... though I guess the word Film in there dates me lol
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Mike great Job! Love the front end of this bike as well as the tail light / frame integration. Looking forward to seeing some more pics when you've got the finishing touches done:)
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looks good, did you measure the length difference between the yellow forks and the black ones, from what year are those yellow forks, I know you mentioned the black ones from 2013. The reason I asked I have 2003/04 GSXR1000 forks and stems that I'd like to use for the front end.
I never bothered measuring the yellow forks because I knew I wasn't going to keep them. The yellow (gold forks) were from an '04-'05 GSXR 600/750. However, this chart has everything you'll need to know if you're trying to swap over a GSXR front end:
(http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/Fork-Conversion-Details.jpg)
(http://www.triumphrat.net/memberalbums/data/504/242.jpg)
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Took some proper photos of my completed build:
(https://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/5871e81037c5811e54ccac1c/1483859986143/DSC05837.jpg?format=750w)
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Beautiful! Perfect frame modification. Love the lines. :2thumbup:
I must say I'm jealous of your small license plates and being able to place them there.
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Congrats on finishing the build - the bike looks awesome! Love the clean rear wheel, it really stands out with your frame modifications. Really nice work. Hope you can post a few more pics when time permits - that is a fantastic shot!
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Here's a few more photos:
(https://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/58729ea3b8a79b5c39e87095/1483906733537/DSC05811.jpg?format=2500w)
(https://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/58729eb8d482e9490a2a277c/1483906754603/DSC05857.jpg?format=2500w)
(https://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/58729fd72e69cf407977b663/1483907067821/IMG_7409.JPG?format=2500w)
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Absolutely awesome.
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Wow that last picture in particular is amazing! Well done - beatiful bike and beatiful pics. Thanks for sharing those,
Mark
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How does the lower front end affect handling?
Damn.. I had almost managed to convince myself to not spend money on a front swap... (Yet) But seeing how great your bike look with that GSXR front got me prowling eBay and junkyard sites again. :eek:
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How does the lower front end affect handling?
With the lowered front end, and the increased length rear shock it handles like a sport bike instead of an upright sport touring bike. Turning radius is drastically increased (you'll look like a rookie everytime you go to park the bike). However, it handles really great up in the canyon roads (after some suspension tuning). I can easily keep up with my fast friend on his Thruxton R, though I'll get dropped by the modern liter bikes.
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Best build to date. Super job!
Sent from my iPad using Tapatalk
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It turned out super nice! I'm starting to look around for a rear shock for my project, how do you like that fox shock? Which model is it?
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It turned out super nice! I'm starting to look around for a rear shock for my project, how do you like that fox shock? Which model is it?
I love my Fox shock, however it's a completely custom one-off that was built utilizing an RC2 Podium shock (I have an old friend fairly high up at Fox). Because it isn't really available, I'd probably go with an Ohlins unit.
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You know, I just didn't think that tail would work as I was going through the build pics, but dang, it works quite well!!!
Very creative being able to pull off such a unique design. It is so awesome! Nice fab skills :2thumbup:
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I love my Fox shock, however it's a completely custom one-off that was built utilizing an RC2 Podium shock (I have an old friend fairly high up at Fox). Because it isn't really available, I'd probably go with an Ohlins unit.
Furnimoto,
I spent quite a long time looking for a rear shock with a piggyback reservoir. There's not many options out there for K-Bikes. Ohlins does not make one with K-Bike specs. Unit Garage out of EU does sell one made for them (see link). Wilbers custom make one for all of the K-bike models (see link). Finally, I did procure a Fox RC2 Podium shock by working with ATVgalaxy and a Fox customer service rep. The key is to make sure the spring weigh range will support the K-Bike you're building. It's not the same as what Mike was able to get, but it's to my satisfaction. You can see pics from my post.
http://www.unitgarage.com/ohlins_suspension_1
https://www.wilbers-shop.de/index.php?mfid=150&lang=1&cur=3
http://atvgalaxy.com/index.php/
http://www.motobrick.com/index.php/topic,8956.0.html
Good luck,
Duc
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BSK Speedworks will sell you an Ohlin's shock made to spec for the K100 and your weight and riding style:
http://www.bskspeedworks.co.uk/ohlins-rear-shocks.html (http://www.bskspeedworks.co.uk/ohlins-rear-shocks.html)
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You can see pics from my post.
Duc, I saw that you were rocking the fox shock on the fist of fury a while back, that's why I thought that, between you and Mike both using fox, there might have been a shock specified for bricks. Thanks for the links, I've been eying that unit garage exhaust for a while as my project is some kind of scrambler thing.
Also, thanks Mike for the bsk link, I think that ohlins might be a good choice. I'm going to keep researching for a bit. By the way your exhaust looks really nice, did you fabricate that merge collector?
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Duc, I saw that you were rocking the fox shock on the fist of fury a while back, that's why I thought that, between you and Mike both using fox, there might have been a shock specified for bricks. Thanks for the links, I've been eying that unit garage exhaust for a while as my project is some kind of scrambler thing.
Also, thanks Mike for the bsk link, I think that ohlins might be a good choice. I'm going to keep researching for a bit. By the way your exhaust looks really nice, did you fabricate that merge collector?
Furnimoto,
Check this site out. It has K-Bike exhaust and parts that may fit your build. They have K100 4-1 collector.
http://cafe4racer.eu/en/
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Mike,
Congrats on your bike being featured at bikebrewers.com!
http://bikebrewers.com/bmw-k100-cafe-racer/
Duc
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Mike guess who's bike I just saw featured on Bike EXIF!! Congrats man that's super cool. Enjoy the bike:)
Mark
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Thanks Markus77! I actually submitted it to Bike Exif, so it wasn't a surprise for me... but I feel very honored that they found it worthy of posting. I've always been a huge fan of Bike Exif, so it means a lot to me personally. I love how much love/hate there is for the K bikes, especially there, haha.
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Congratulations for the articles. Well deserved. Bike looks stunning. Great photos too!
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Congratulations, Mike. Being selected by Bike EXIF with world-wide competition, your bike deserves tremendous respect. That you built it in a DIY garage, makes your achievement more impressive. You may be responsible for starting a wave of K bike buyers descending on the market! :2thumbup:
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Hey I'm working on one myself. Where did you relocate your computer to?
Sent from my Nexus 6P using Tapatalk
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Hey I'm working on one myself. Where did you relocate your computer to?
Sent from my Nexus 6P using Tapatalk
It's under the cowl.
Sent from my iPhone using Tapatalk
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This showed up in my youtube recommended videos today
https://www.youtube.com/watch?v=Ne6I8bTXxmA
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Well, last night I got hit on the bike by a car that ran a red light. Happened about 1/4 mile from home, after a 300 mile ride out to the desert and back. Thanks to some cat like reflexes and fully armored leather gear, all I've got to show for it is a nice bruise on my leg... however my bike needs some work.
Everything is fixable, but I'm going to need some help finding some parts that I need to replace and am hoping there might be someone on here that can help me out by selling me what I need. Also, I've been invited to the Handbuilt Show in Austin, TX in April so I'm on a timeline to get it back to 100% before the show.[size=78%] [/size]
[/size]I need:[size=78%]
A good condition fuel tank (just the tank, don't need fuel pump, fuel cap, fuel level gauge) - I'm going to strip the paint and do the brushed finish, so it just can't be dented anywhere.
I also need a good condition valve/cam cover - paint and color doesn't matter as it will be powdercoated, it just can't have road rash.
If you have or know where I can find either of these parts it would help me out a lot. I'm checking eBay as well, but thought I'd ask here first.
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How bad is the tank? You might take it around to a few paintless dent repair shops to get it straightened out. Depending on the damage, they can do some pretty nice work.
There are several tanks on eBay, and since you don't have a fairing(do you?) I would think almost anything should work as long as it isn't a very early one.
Are the repairs being paid for by the jerk who hit you? If so, if you haven't already, get him to give you the money to buy a new one. Then buy off eBay. Same thing for the valve cover with mounting bolts and all the seals. What about the grips? Control levers? Mirrors? The difference can finance another project bike.
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Sorry to hear what happened! Saw the bike on your Instagram. Definitely a bummer to see the motogadget components also somewhat took a hit. If you do make out here to Austin in April make sure to let me know. I know of a few good places to ride out here in the hill country.
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Are the repairs being paid for by the jerk who hit you? If so, if you haven't already, get him to give you the money to buy a new one. Then buy off eBay.
Then there's that brand new OEM factory primered but unpainted tank sitting in my shop ... :yes Shipping would be a killer.
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Aw man, this is awful! Im so glad that you're okay and that the bike has minor damage. Looks like you've been riding it quite a bit.
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Glad to see you are alright sorry about the bike. I've had to drop my bike to avoid a red light runner while turning right, she went between two stopped cars at speed. The car behind me hit his horn, I hit the front brake hard and dumped the bike, she missed my front wheel by inches. She slowed down, then floored it, by the time I got the bike up again, and pursued her but she was long gone. Did your idiot stop and did he get booked.
Regards Martin.
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Sorry to hear about this Mike - obviously the important thing is that you're okay but I'm sure you're pretty pissed about the damage to that beautiful bike! Hopefully you can find the parts you need quickly and hope you get it back on the road soon.
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That sucks. Glad to hear you're okay though.
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Yes, the guy that hit me stopped and we exchanged insurance info. A witness that confirmed the guy ran the red light and hit me also stopped and gave me his info. The police were called, but here in CA if neither party is injured or under the influence the police don't come out and fill a report out, it's all handled through the insurance companies. Because the guy know's he's at fault, he's offered to pay me cash to fix the bike rather than go through insurance, which is fine by me... I'd rather not have an insurance company total my bike out.
I'm genuinely not the litigious type, and since I'm not really injured I don't mind handling it that way. But if the guy backs out... I know some good attorneys.
I've been more banged up by off's on a mountainbike, so I'm just considering myself very lucky. I'm more disappointed than pissed about the bike, but I'm going to take the opportunity to make the bike better than it was before.
Out of curiosity Ed, how much would you want for that tank you have in your shop?
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Mike,
Try contacting Mark. He has a K100 parts bike that he's using for his project. I've gotten a couple of parts from him. He's in Washington State, so shipping would be much cheaper to CA. I will be at the Handbuilt show, so I hope to see your bike there. Good luck!
http://www.motobrick.com/index.php/topic,8675.0.html
Duc
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Out of curiosity Ed, how much would you want for that tank you have in your shop?
New tank is ~$1500 at RealOEM.com. I could let it go for $600 ...
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We seem to now have three major problems with car drivers, red light runners, tail gating and mobile phone users. All three are deadly. I hope you manage to get your bike up and running better than ever.
Regards Martin.
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Through some careful ebay searching, I've managed to find all the parts I'll need to get my bike back to 100% and for a decent amount less than I initially thought. All parts are ordered, so just waiting for the packages to arrive at this point. I ended up with two fuel tanks that appear to be in perfect condition thanks to some overzealous ebay "best offers" - but maybe I'll keep the other one for the next K100 build I do.
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That's great. Another build? Just curious knowing what you know now. What would you change?
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That's great. Another build? Just curious knowing what you know now. What would you change?
Honestly, the major difference between mine and the next one will probably just be the way the cowl and tail section of the frame is designed (maybe round the edges a bit more) and that I'll TIG weld the entire frame next time. I also hope to get my aluminum skills up to snuff so that I can make my own cowl. In time I'd like to do the paralever K1100 swap on this bike, and also build a half fairing out of aluminum.
It's probably more likely that I add these parts to this bike before building a completely new one. It's just that I still love the K Bikes, and now that I can tackle the wiring and most of the maintenance jobs with confidence it just makes sense to build another one.
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Yes good plan. As soon as I rode my K for the first time the other day, I knew there was something special about them.
Raising the bar on yourself is what it's all about. I look forward to seeing your next build. I think I'm going to build an R100 next.
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I'm pretty close to having the bike completely repaired and back together, just in time for the Handbuilt show next week in Austin, TX. I figured I'd take this opportunity to share a few more pieces that went into the build, and show a little more than I did when I built it the first time.
Here's my spal e-fan replacement and the bracket I made for it. I ended up using a fairly thick piece of aluminum sheet so that I had the room to counter-sink the holes and have the bolts tighten down flush to the bracket, so as not to risk bolt heads getting into the radiator fins.
(https://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/58ee9ae7be6594f0ff4d0833/1492032276896/IMG_8673.JPG?format=1000w)
Here are the new engine cases back from powdercoat. those smaller pieces are the brackets I cut out of aluminum to mount my Ducati carbon front fender.
(https://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/58ee9b0c2e69cf7898e9ea5c/1492032322125/IMG_8699.JPG?format=1000w)
I had to do the fin polishing myself. I am definitely not a pro at this, but I'm satisfied with the results:
(https://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/58ee9b35197aea0b0daed9ad/1492032334579/IMG_8702.JPG?format=1000w)
Here's my newer lighter battery tray and smaller Shorai. Also note I made a new shorter ground cable, along with another ground cable that I run directly from the negative terminal on the battery to the stock frame ground location under the fuel tank. A fully powdercoated frame doesn't ground very well on it's own.
(https://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/58ee9ae7e4fcb501940aa894/1492032271050/IMG_8603.JPG?format=1000w)
You might notice that my fuel tank rubber bushings are out a bit wider... in my rush to get a good tank and fast I made the error of buying both a K1100 tank, and a K75 tank (listed mistakingly as a K100 tank on ebay). The K1100 tank fits after I tapped the frame lugs and put bolts into them to widen to the proper length. Loctite wasn't cutting it, so I used some jb weld as threadlocker and put a couple dabs to keep the bushings at the extremities. This seemed like a better option than cutting/griding/welding on my freshly powdercoated frame.
(https://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/58ee9b0cebbd1aeb69c878b5/1492032313497/IMG_8674.JPG?format=1000w)
How my bike looks at the moment. The ultra black was cured as of last night, so I just need to install the throttle cable, clutch cable, fill with fluids, and fire it up. Also need to zip tie the wiring to the frame. All told, I hope to be riding it tomorrow.
(https://static1.squarespace.com/static/525a388fe4b06e05e7cd3437/57b7833dc534a554d7a7734b/58ee9b41f5e231091c29b6a7/1492032331131/IMG_8740.JPG?format=1500w)
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Great update! What model is the fan?
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What'd you use to polish the fins? Can't tell if they were masked off before the powder coating or if you took it off somehow after?
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Great update! What model is the fan?
It's the Spal 6.5" Puller fan, as documented by others here on the forum. I did switch the connector it came with to an AMP superseal connector. It can be purchased here: http://www.universalpartsinc.com/shopping/productDetails.aspx?i=749937&c=0
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What'd you use to polish the fins? Can't tell if they were masked off before the powder coating or if you took it off somehow after?
They were not masked off for powdercoating, the entire covers were powdercoated and then I used an air grinder with a sanding flap wheel (180 grit I beleive) to carefully grind off the powdercoat on just the fins. This is how it was done by the polishing shop the powdercoaters used during my initial build, I just had to do it myself this time around due to time contraints. I used a couple layers of blue painters tape, and then a layer of electrical tape to protect the area immediately adjacent to the fins in case I messed up... but luckily it wasn't an issue. I just had to take my time and be very careful.
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Mike
You have a template for the fan mounting plate? And what thickness of aluminum plate did you use?
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Mike
You have a template for the fan mounting plate? And what thickness of aluminum plate did you use?
Sent from my iPad using Tapatalk Pro
I did not make a template, I just traced the old fan on the aluminum sheet with a sharpie, and whittled away at it from there (with a plasma cutter). If memory serves, it's 0.250" aluminum. Way thicker than it needed to be other than allowing for clean mounting with countersunk bolts.
Sent from my iPhone using Tapatalk
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Mike, I love what you've done with your brick. Any updates?
I'll be doing an 06/07 gsx-r600/750 swap soon on my '92 K100RS. I realize that you had to replace the stem but did you have to replace the triple clamps also? Or did you only replace them because you wanted to? I'll be getting a stem and bearings from Cognito moto too.
Sent from my iPhone using Tapatalk
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Mike, I love what you've done with your brick. Any updates?
I'll be doing an 06/07 gsx-r600/750 swap soon on my '92 K100RS. I realize that you had to replace the stem but did you have to replace the triple clamps also? Or did you only replace them because you wanted to? I'll be getting a stem and bearings from Cognito moto too.
I got the bike back together, and everything seems to be great so far. Even after the improvements, the bike looks pretty much just as it was.
I replaced the triple clamps because I wanted to, not because I needed to. I think you'll be fine with the new stem (and bearings) and stock gsxr triple trees.
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I got the bike back together, and everything seems to be great so far. Even after the improvements, the bike looks pretty much just as it was.
I replaced the triple clamps because I wanted to, not because I needed to. I think you'll be fine with the new stem (and bearings) and stock gsxr triple trees.
Thanks for the quick reply, Mike! And thanks for the info. I do like the look of the triple clamp you used better than the stock gixxer one (especially since it says Suzuki on it) so I may just bite the bullet and get one.
I know you said your turn radius is much bigger now with the strap-ons. Do you think using 1" or 2" rise strap-ons would help with that? Or is it not because of the strap-ons?
Sent from my iPhone using Tapatalk
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I know you said your turn radius is much bigger now with the strap-ons. Do you think using 1" or 2" rise strap-ons would help with that? Or is it not because of the strap-ons?
The increase in turning radius is marginally due to the clip ons, and mostly because of the new fork tubes having less an offset from the steering stem as compared to the stock front end.
In short, when you swap to a front end from a sportbike, you're going to end up with a sportbike turning radius.
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The increase in turning radius is marginally due to the clip ons, and mostly because of the new fork tubes having less an offset from the steering stem as compared to the stock front end.
In short, when you swap to a front end from a sportbike, you're going to end up with a sportbike turning radius.
That makes sense. Thx again!
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Hello Mike,
Well done on your build and your bike is one of the best k100 I have seen so far. I want to ask you about the front fork, what did you use to make it fit properly and what parts are needed from cognitomoto. com.
Thanks
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Hello Mike,
Well done on your build and your bike is one of the best k100 I have seen so far. I want to ask you about the front fork, what did you use to make it fit properly and what parts are needed from cognitomoto. com.
Thanks
Thank you.
Cognito Moto is making it very easy for fork conversions at this point, basically this is what you need:
https://cognitomoto.com/collections/fork-conversion-parts/products/gsx-r-fixed-offset-triple-tree-conversion-30mm-45mm-50mm-55mm-60mm
That's the complete kit that will give you everything you need, you just need to input your fork make/model/year, and decide which offset you want (it's going to depend on the year/make/model of forks you get - specifically the fork tube length and how that affects rake/trail).
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Great looking bike, love the rear cowel.
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true craftsman great work and bike :2thumbup:
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Thank you.
Cognito Moto is making it very easy for fork conversions at this point, basically this is what you need:
https://cognitomoto.com/collections/fork-conversion-parts/products/gsx-r-fixed-offset-triple-tree-conversion-30mm-45mm-50mm-55mm-60mm (https://cognitomoto.com/collections/fork-conversion-parts/products/gsx-r-fixed-offset-triple-tree-conversion-30mm-45mm-50mm-55mm-60mm)
That's the complete kit that will give you everything you need, you just need to input your fork make/model/year, and decide which offset you want (it's going to depend on the year/make/model of forks you get - specifically the fork tube length and how that affects rake/trail).
Hi Mike,
great build!!! what offset did you go with for the stem?
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I am wondering if these forks have extensions or did Mike accept the front end being lower then stock? Cause as far as I know these GSXR fork are a lot shorter then the stock ones.
I am starting with a K100 rebuild and was wondering if I can accept the frond end being lower.
thanks, M
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I am wondering if these forks have extensions or did Mike accept the front end being lower then stock? Cause as far as I know these GSXR fork are a lot shorter then the stock ones.
I am starting with a K100 rebuild and was wondering if I can accept the frond end being lower.
thanks, M
I accepted the front end being much lower than stock, and I also put a longer shock setup in the rear.
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thanks for the reply Mike. I am doing the same wheel change as you are but I have a fully rebuild triumph sprint ST fork laying here so I am thinking of installing that. Kinda like the triumph calliper on a BMW :bmwsmile
This front fork is 29.5 inch and if I am not mistaken yours is 28.6 inch. Standard is 31.8 inch.
Do you have any idea what the rake and trail is on your bike?
How is the steer handling with the gsxr forks?
If any problems rise and I can always install a step down top yoke.
thx, M
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thanks for the reply Mike. I am doing the same wheel change as you are but I have a fully rebuild triumph sprint ST fork laying here so I am thinking of installing that. Kinda like the triumph calliper on a BMW :bmwsmile
This front fork is 29.5 inch and if I am not mistaken yours is 28.6 inch. Standard is 31.8 inch.
Do you have any idea what the rake and trail is on your bike?
How is the steer handling with the gsxr forks?
If any problems rise and I can always install a step down top yoke.
thx, M
I didn't log the rake and trail details when I built the bike, but the trail is definitely shorter than stock, leading to...
The steering handling is much "faster" or "quicker" or more responsive than stock. It handles very much the way a sportbike does, although I wouldn't describe it as twitchy, just more "flickable."
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my daily driver is a triumph speed triple 1050 so I know how that you mean with flickable. looking forward to having a BMW with the same attitude
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Mike,
Unless I missed it somewhere in this thread but is this a 16V or 8V K100?
Just asking cause I lended a K1200RS rear wheel from a friend to see it will fit the K100 8V but it seems the offset is not what it should be and also fitting a tyre on this 5" rim will get realy close to the swingarm.
thx, M
It's an 8V K100. The wheel centerline is slightly left of center, and the tire does come pretty close to the swingarm, but in roughly 4,500 miles of riding it hasn't been a problem for me.
My rear tire is a Pirelli Angel GT 170/60/17
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Whoa, I have no idea what went wrong with the forum software that allowed me to post from your account. weird!
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that is indeed pretty weird posting from my account. What dimension of rear tyre did you fit on it?
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that is indeed pretty weird posting from my account. What dimension of rear tyre did you fit on it?
I posted that information in the last post... from your account
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didn't see that. Forget to read my own post completely ;-)
thanks for the info.
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A friend of mine lent me a 2014 speed triple for a few weeks - what a bike. I really miss it now it has gone!
It and the my K bike show exactly why one bike is not enough.
The BMW is a much better bike for me and my wife to tour on etc but the Triumph is hard to beat for a blast on some twisties.
In a couple of weeks the same friend is lending me a Triumph Thunderbird for a month or so That will be interesting, I have never ridden a cruiser type bike and have never really liked them but that may just be anti-HD bias, we will see.
I have also been thinking about trying to find a more modern bike to have as a sports tourer but it seems they do not really exist anymore in the same way as bikes like the K bike from back in the day. Most tourers seems to be the adventure types like the GS 1200. I am sure they are great bikes but at my height simply not really an option for me and anyway I like the sports part of the sports tourer package a bit more than I think the GS would provide.
I know there are Beemers like the R1200RS but that does not look very pillion friendly whereas the LT versions look totally touring orientated.
Hence the need for two (or three or four) bikes I guess!
BTW I do yearn for a K75S so maybe that will be the next K in the stable. :riding:
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Hi Mike,
Inspirational build! Mind if I ask a few questions to help with a build I'm starting?
1. Did your K1100 tank have the grommet hole for plastics? Wondering if you were able to just trim it off and if you had any concerns about damaging the tank as a result.
2. Is the tank simply bare aluminum? What was your finishing process there?
3. I noticed the hole for the wire for the rear light through the frame. Where does it come out of at the front?
Thanks for the insight!
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1. Did your K1100 tank have the grommet hole for plastics? Wondering if you were able to just trim it off and if you had any concerns about damaging the tank as a result.
2. Is the tank simply bare aluminum? What was your finishing process there?
3. I noticed the hole for the wire for the rear light through the frame. Where does it come out of at the front?
Thank you.
1. Yes, I trimmed it off. No concerns for damaging the tank, although I did take great care to not cut into the tank or split the welds.
2. Yes, it's bare aluminum. I used a burnishing tool to apply the brushed finish.
3. The 'front' exit hole for the wire is on the inside of the frame rail, underneath the cowl.
Hope that helps.
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Super helpful, thanks. A few follow ups:
Did you trim the tank with just a cut off wheel?
How did you remove the old paint? Soda blast? Paint stripper? Did you have to seal it in any way to maintain the finish afterwards? Clear coat or maybe just wax? Or maybe not necessary with the brushed look.
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Super helpful, thanks. A few follow ups:
Did you trim the tank with just a cut off wheel?
How did you remove the old paint? Soda blast? Paint stripper? Did you have to seal it in any way to maintain the finish afterwards? Clear coat or maybe just wax? Or maybe not necessary with the brushed look.
Yes, just a cut off wheel and a sanding pad on an angle grinder.
Paint was removed using paint stripper.
I have not sealed the tank in any way. The aluminum has oxidized over time and is a bit more dull, but I'm fine with that.
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Excellent, thanks.
On to wiring - your wiring looks super clean! Did you redo everything or replace everything or a mix of the two? There's a lot going on and I'm a little intimidated by it to be honest with you. So any advice you have would be great!
Oh... and I love the little shorty muffler you have. Where did you source that?
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Excellent, thanks.
On to wiring - your wiring looks super clean! Did you redo everything or replace everything or a mix of the two? There's a lot going on and I'm a little intimidated by it to be honest with you. So any advice you have would be great!
Oh... and I love the little shorty muffler you have. Where did you source that?
It's a mix of the two. I utilized the stock wiring harness wherever possible, but replaced connectors with AMP superseal connectors. I did have to make new wiring for some of the aftermarket parts, but it wasn't much. https://www.corsa-technic.com/index.php is a great source for connectors, wire, etc.
The muffler is from Cone Engineering.
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Excellent, thanks for the tips on the connectors and the mufflers!
Did the stock harness allow you to place the ECU that far back in the seat? Or was that facilitated by having the BEP 3.0 vs. the lunchbox?
Also, is your exhaust painted, powder coated, or ceramic coated?
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Excellent, thanks for the tips on the connectors and the mufflers!
Did the stock harness allow you to place the ECU that far back in the seat? Or was that facilitated by having the BEP 3.0 vs. the lunchbox?
Also, is your exhaust painted, powder coated, or ceramic coated?
I was able to place the ECU in the cowl with the stock harness, but just barely. I don't have the BEP or Lunchbox, I'm using rbm's board.
My exhaust is ceramic coated. I tried painting it first, and it started flaking off after a couple rides.