The New And Improved Unofficial R65 Forum V2

Technical Discussion => Restoration Progress Logs => Topic started by: marcmax on March 10, 2013, 10:25:20 AM

Title: Time for a make-over
Post by: marcmax on March 10, 2013, 10:25:20 AM
I have been collecting bits and pieces for a little over a year to change the look of my R65LS. I finally think I have everything and the weather is cooperating so it is time to make the transformation.

Mechanically everything is fine, maintenance is up to date and she is running fine. It's just time for the old girl to get some new clothes.
Title: Re: Time for a make-over
Post by: marcmax on March 10, 2013, 10:29:28 AM
Might try this exhaust but I am afraid it will be just too loud to be enjoyable. I had a set of LS mufflers that had rotted completely through is so many places they were unusable. I cut off the end caps, cut out the rotten silencer and turned them into a pair of short megaphone style pipes (with a small baffle inside).
Title: Re: Time for a make-over
Post by: montmil on March 10, 2013, 10:57:17 AM
Whoa! Very nice selection of pieces parts. Credit card a melted lump of plastic? ::)

How do you plan on mating the vintage speedo to the R65's speedo drive ratios? Or is the headlight assembly a modern repop. Liking the yellow lens.

What's your plan for the bags and wind screen? Perhaps a sporty Cafe Commuter.

You gotta get busy... Springtime riding weather is about to hit Jawjia.

Keep those photos flowing. [smiley=beer.gif]
Title: Re: Time for a make-over
Post by: marcmax on March 10, 2013, 11:22:51 AM
Thanks Monte. It actually wasn't that expensive when you space all the purchases over a long enough period of time. I think the most expensive part was the paint. It is a three part Cadillac pearl white. It really looks good out in the sun. Everything else was picked up battered and abused at flea markets or motorcycle swap meets. It just takes time. I don't add the cost of my bringing all the pieces back to life since I enjoy it but if I charged myself for labor it would have been cheaper to buy a Ferrari.  ;D

The headlight shell is from a '59 Puch Twingle modified to take a standard 7" headlight and trim ring. The yellow lens is a transparent yellow paint (Duplicolor Metalcast) painted on the inside of the lens before assembly. The more coats the deeper the yellow gets. The original LS ignition switch is mounted in the shell with a folding key.

The speedometer is a repop from India. The vendor was easy to work with and very accommodating. I explained what I needed and he tweaked the ratio of the speedo before sending it. I connected the BMW speedo cable, wire tied it to the bars and went out to check it against my gps. It reads about 4-5 mph under the actual speed but I can live with that.
Title: Re: Time for a make-over
Post by: montmil on March 10, 2013, 01:40:55 PM
Nicely played, Marcmax.

I'm familiar with the Cadillac Pearl White as that was the color of Pretty Wife's last DTS. Her latest has a paint that changes hues depending on sky and sunlight conditions. I call her Cadillac Woman, but infrequently to her face... ya know.

I have the Indian speedo website bookmarked. They offer a number of intriguing products including tractor gauges for those so inclined to restore "farm implements" like our Airheads.

I may be able to find the photos I snapped at last year's Barber swap meet. A couple Puch/Sears Allstate twingles for sale. In the mid-50s, that was one of my rides! Well, actually all I did was sit on them at the big Sears Roebuck store in Dallas. But I did put many adventurous miles on them in my young mind. ;D

I'm a lifetime subscriber to your philosophy of buying used and doing a resto. Most all my bikes have like-new looking but gently used items on 'em. My '86 Cabriolet, too.

Get after it. Charlie Mike! [smiley=thumbsup.gif]
Title: Re: Time for a make-over
Post by: CaptainSlow on March 11, 2013, 07:38:48 AM
Like the colour, LOVE that headlight! This will be a rebuild to watch - please keep posting updates & pics  :)
Title: Re: Time for a make-over
Post by: montmil on March 11, 2013, 09:17:38 AM
Spotted in the Swap Meet during the 2012 Barber Vintage Days, these Puch-Allstate 250cc "Twingles" brought back many pleasant memories. Note the headlights; as soon-to-be-seen on the Marcmax BMW R65.

This deep red museum-quality resto was absolutely immaculate. No price was posted on the bike. I was afraid to ask. These bikes were but a few hundred bucks back in the 50's. To put the price in perspective, the mortgage, taxes and insurance on our new home in North Dallas was a cool $100.00 monthly.

A runner in fine condition. More like the ones I saw rockin' the roads in Dallas.


Very unique Trials version available in Europe only. Now too rare and nice to ride off road.

Title: Re: Time for a make-over
Post by: marcmax on March 11, 2013, 04:08:57 PM
One piece done. Many more to go.
Title: Re: Time for a make-over
Post by: Dave 2 on March 13, 2013, 09:35:01 AM
I love your new exhaust and I look forward to seeing how it will all come out. Nice pics monte. D2
Title: Re: Time for a make-over
Post by: marcmax on March 23, 2013, 11:32:00 AM
Finally got a chance to get some work done of the changes. My daughter has been home from school for spring break and I didn't want to ignore her and hang out in the garage. Now things can get moving again.

I am in the process of doing all the rewiring to accommodate the changes. I am also making changes I have been putting off, replacing the fuses with weatherproof ATM style fuse holders and adding a resistor to the charging circuit.

Still couldn't resist a trial fitting of the new body parts.

Title: Re: Time for a make-over
Post by: CaptainSlow on March 23, 2013, 12:56:19 PM
Thats quite a change - like it  [smiley=thumbsup.gif] (I love white bikes)
Title: Re: Time for a make-over
Post by: marcmax on March 27, 2013, 09:06:08 PM
Made up a little plug-in fuse assembly to replace the oem ceramic fuse/box with weatherproof ATM fuses. The nice thing about it is all the oem connectors plug right up to it.
Title: Re: Time for a make-over
Post by: montmil on March 28, 2013, 08:57:34 AM
Very sano way to handle the new fuse install. May want to alter my ATMs install -steal your plan.

With all those new, sexy hard parts on the R65, I might consider naming her The Trophy Wife.  ;)
Title: Re: Time for a make-over
Post by: soliecirc on March 29, 2013, 12:47:44 AM
That headlight/speedo set up is great. Nice work!
Title: Re: Time for a make-over
Post by: disco51 on April 28, 2013, 08:48:08 AM
Nice looking mods...
Did you cut down a stock front fender or source it from somewhere else?
Liking the white
Title: Re: Time for a make-over
Post by: marcmax on April 28, 2013, 09:44:31 AM
The front fender is stock, just cut down. I used thin masking tape to try out different outlines until I got one I like the profile before cutting. The stock mounting holes in the fender/fork brace held the cut down fender to far away from the wheel. I ended up cutting about 3/4" from the ends of the fender mount and drilling new holes for the mount/ I purposely made them slightly oversized so that once I mounted the fender I had some leeway in moving the fender up/down, fore/aft to get it positioned where I wanted it before tightening in place.
Title: Re: Time for a make-over
Post by: Ironhead2 on May 20, 2013, 07:23:13 PM
That headlight/speedo set up is great. Nice work!
+1 love that headlight combo
Title: Re: Time for a make-over
Post by: marcmax on May 20, 2013, 08:19:16 PM
Thanks! I live right on the Florida/Georgia border and checked in GA about the legality. I was told that GA code states you can not have blue or red lights visible from the front of a vehicle but white, yellow and amber is acceptable. All it says about the headlight is height and aiming but nothing about color. I have ridden past local, county and state law enforcement and they said nothing.

I was in Florida this weekend at Riding Into History (entered the Concours d'Elegance - no luck) but was right next to the guys from Dime City Cycles. I asked them about yellow headlights and was told they had all been stopped by FL State Patrol for having yellow headlights.

I will ride it and see what happens, so far nothing.
Title: Re: Time for a make-over
Post by: marcmax on July 30, 2014, 01:21:09 PM
Finally got around to replacing my starter cover. I was originally going to just remove the airbox and use a blocking plate. I didn't quite like the cut-off, angular look it left at the rear of the engine. Instead I went with a fiberglass cover that follows the lines of the engine and covers both the starter and the old airbox opening.

The problem was that the original starter cover had the BMW name badge cast into it. The fiberglass cover is smooth and ended up making the engine look like a big lump of aluminium.

I ended up making a silicone cast of the BMW badge, casting expoxy replicas, painting them and using 3M automotive adhesive to mount them to the starter cover. Gives it a more OEM look in my opinion.

Opinions and comments welcomed.
Title: Re: Time for a make-over
Post by: NathanR65 on July 31, 2014, 05:25:56 AM
Looking good! Love the bmw logos on the cover is that from boxercafe? That was the one thing I didn't like about the cover but you have made it look oem well done. Do you have enough space under the cowl to fit the battery?
Title: Re: Time for a make-over
Post by: marcmax on July 31, 2014, 06:12:14 PM
Hi Nathan. Thanks for the kind words. That is one of the starter covers from Boxercafe. I was a little nervous of it being fiberglass and not wanting the smooth, glossy look. It is well made and does have a smooth glossy finish. I followed a tip suggested by our own RevLight and sprayed it from a slight distance with a high build primer. That paint spatter gave it a texture that looks remarkably like cast aluminium. Once sprayed with a cast aluminium engine paint it definitely looks the part.

As for the battery under the cowl I didn't want to put the extra weight that high up in the frame. When I built the seat cowl (steel) I built it on a stock seat pan so it still hinges on the stock seat hinges. I cut a latching trap door in the seat pan and now have a storage area under the cowl for my tool kit and even enough room for some rain gear.

I was intending to mount the battery under the gearbox but didn't want to give up my centerstand. Instead I stitched a leather bag over the original battery holder and "hid" the battery in place.
Title: Re: Time for a make-over
Post by: steve hawkins on August 01, 2014, 02:56:26 AM
What a great idea for the BMW Logos.  Both Tony and I have similar covers fitted.  And not only do you lose the logo, but what is left is a strip of casting that is a different colour from the rest, as it was covered by the old top cover.  It is not even a regular.  I was going to leave it in the hope that it would eventually blend in.  But I hope you don't mind if I copy your idea.

That is a tidy bit of pipe wrap as well.


Rev. Light
Title: Re: Time for a make-over
Post by: marcmax on August 01, 2014, 02:47:35 PM
I tried everything I could think of to clean that strip of casting to that had been covered and never could get it to match. I used it as a guide for where to mount the logos as it showed just were the old top cover had been.

Just as an FYI the logo is slightly different on the left side from the right side. I didn't notice it until it came time to mount the new BMW logos. The BMW is just slightly biased toward the front edge of the logo. Also since the top cover does not sit exactly level when mounted on the engine but the logo is, there is a slight angle to the ends of the piece. It is only a few degrees difference. I only molded the left side and made two pieces from the mold. When I attached it to the right side there is a slight gap where the front edge meets the timing case casting. Also on the right side the BMW is now slightly biased toward the rear edge. Not enough for most people to notice but I know it is there.

I am flattered that you want to use my idea. Since joining this forum my direction on my R65 has changed based on seeing pics of your bikes.

A good friend told me to get the narrowest width wrap to do the pipes. Most wrap is designed for larger diameter automotive exhausts. This was only 1" wide. I also soaked it in a bucket of water before wrapping to allow it to follow the contours more easily. The first day or two after wrapping I would come to a corner and be enveloped in a cloud of steam. Got some interesting looks.
Title: Re: Time for a make-over
Post by: Adrian on August 12, 2014, 09:43:39 PM
Great looking bike and good story - loved the pictures  ;D
Title: Re: Time for a make-over
Post by: r80rt on August 26, 2014, 06:56:26 AM