The New And Improved Unofficial R65 Forum V2

Technical Discussion => Restoration Progress Logs => Topic started by: NathanR65 on July 07, 2014, 02:22:28 AM

Title: My R65 Cafe Build
Post by: NathanR65 on July 07, 2014, 02:22:28 AM
Hi everyone!
This is my first post and also my first build so I thought I would share a few photos of my progress so far and a little info on my plan for the build.

Today i stripped the bike down to bare frame just need to get the damn swing arm out of the frame! I have grinded off the battery mounts and will delete the center stand also.
So far I have a rebuild kit for my carbs, new seals and gaskets for engine, new shaft bolts for rebuild (throw old ones out), new brush kit for alternator, tarozzi low rise clip ons, boxer metal rear set, cowl and seat pan on the way. New headlight mounts, acewell digital tacho/speedo, indicators, rear light and grips. Airbox delete kit with pod filters and choke pulls. I have also already rebuilt the forks and added new gators.

Plan to powder coat rims and paint frame satin black, engine to be painted cast aluminum with satin black highlights, not sure on colour theme for tank and cowl and fenders.
I am soda blasting my carbs and a few other bits tomorrow so i will post again with some updates. Any ideas/tips for my build appreciated!
Title: Re: My R65 Cafe Build
Post by: NathanR65 on July 07, 2014, 02:23:46 AM
Some pics from today
Title: Re: My R65 Cafe Build
Post by: NathanR65 on July 08, 2014, 08:08:58 AM
Started soda blasting tonight. Carbs come up pretty good I think
Title: Re: My R65 Cafe Build
Post by: arvo92 on July 08, 2014, 12:22:46 PM
That soda blasting is pretty cool. I have looked into it myself but unluckily I do not have a compressor. The results are pretty impressive taking into account the starting point. Good luck, I think they will look cool once they are polished up and back on the bike.
Title: Re: My R65 Cafe Build
Post by: ShutterPilot on July 08, 2014, 02:58:23 PM
My '81 was also "born" in 10/'80.
Great job - keep it up and keep us posted!
Title: Re: My R65 Cafe Build
Post by: montmil on July 08, 2014, 07:26:02 PM
Confirm for us that your engine lift straps did not bear on the pushrod tubes.
Title: Re: My R65 Cafe Build
Post by: NathanR65 on July 08, 2014, 11:57:28 PM
I lifted the engine using the straps tied around the bottom of the heads not on the tubes.I also had a jack underneath to take most of the weight.
Title: Re: My R65 Cafe Build
Post by: tc80211 on July 10, 2014, 08:43:13 AM
Looking good!
Title: Re: My R65 Cafe Build
Post by: montmil on July 11, 2014, 09:55:15 AM
Quote
I lifted the engine using the straps tied around the bottom of the heads not on the tubes.I also had a jack underneath to take most of the weight.

That would be a bit better. Your photos show the lift straps at the bottom of the cylinder jugs rather than the bottom of the heads as you stated. Depending on how far you plan to take the engine, it would be much easier to replace the pushrod tube's rubber grommets while the engine is removed from the chassis.
Title: Re: My R65 Cafe Build
Post by: NathanR65 on July 13, 2014, 01:57:55 AM
I'm replacing all gaskets including the boots on the pushrods as well as wheel bearings, steering head bearings etc. here's a pic of my clamps I took to work and had bearing heated up to remove from bottom  and I deleted the bar mounts on the top clamp just need to give it a polish. Powder coating frame, rims and a few other bits this week!
Title: Re: My R65 Cafe Build
Post by: NathanR65 on July 13, 2014, 11:47:21 PM
Hit it with some wet and dry
Title: Re: My R65 Cafe Build
Post by: NathanR65 on July 14, 2014, 12:49:03 AM
Made my own driveshaft socket at work on a wheel grinder
Title: Re: My R65 Cafe Build
Post by: NathanR65 on July 15, 2014, 10:47:38 PM
Test fitting of the cowl and seat pan before sending the frame off
Title: Re: My R65 Cafe Build
Post by: dav on July 17, 2014, 08:51:28 AM
Nice work mate, love your work bench was the missus at work ;)
Title: Re: My R65 Cafe Build
Post by: NathanR65 on July 26, 2014, 06:10:32 AM
While I'm waiting for the frame and other bits at the powder coater I have been busy with cleaning and painting and have changed over most nuts and bolts to Allen head stainless for the rebuild.
Title: Re: My R65 Cafe Build
Post by: montmil on July 26, 2014, 08:50:53 AM
Looking sharp. [smiley=thumbup.gif]

Regarding your -and other owners- change out of hardware to SS cap screws or other nut n' bolt materials; many of the BMW hardware bits have specific length, non-threaded shanks. These shanks are designed to be load bearing. Replacing them with hardware which has threads within the loaded area is not a good idea. The products so bonded can move a bit during operations due to the less than specified tolerances.

Engine, brake and chassis -all have some bolts or screws that must be load bearing. Performance and safety may be degraded by incorrect hardware. Be sure. Be safe.
Title: Re: My R65 Cafe Build
Post by: clonmore1 on July 27, 2014, 04:35:00 PM
Good advice Monte, I am now at the point of nut/bolt selection in the re-assembly and will be taking no chances!
Title: Re: My R65 Cafe Build
Post by: NathanR65 on July 28, 2014, 04:36:04 AM
Did the tube seals and o rings on the heads today. used a couple of skewers to compress the rings worked a charm. Cleaned up the heads and checked the bores etc
Title: Re: My R65 Cafe Build
Post by: NathanR65 on August 09, 2014, 03:16:35 PM
I've finally received my frame and various other bits back from the powdercoaters and quite happy with the results. Will touch up the bmw logo on the top cover with some silver paint. Now I can start the rebuild!
Title: Re: My R65 Cafe Build
Post by: Tony Smith on August 09, 2014, 06:22:57 PM
this may be completely un-needed advice, in which case I apologize for wasting your time but I remembered something in the course of assembling my own heads yesterday that has been a cause of grief for many.
 
Your rocker shafts need to go on such that the punch marked end is upper most in order that the oil feed via the upper studs can lubricate the needle rollers.

If your engine has not run for some time, you should move the rocker shaft down about half the length of the rollers and oil them up so that they are adequately pre-lubed, it is also a good idea to ensure that the oil feed is working as soon as possible after first start.

And, if like me, you have a momentary lapse of concentration whilst applying the start up lubrication and end up with needle rollers all over your work bench. A clean plastic lid  with a small quantity of lithium grease smeared in it is the go - after you wash the rollers in solvent put them on the grease smeared lid and work them round a bit, you only need a hint of grease on the rollers and they will stay in lace as you laboriously put them all back in the race.
 
To anyone wondering, you have the right number of rollers in the bearing when there is a little bit more than one roller's worth of space left, in other words you could put one more in, but not two - that is the way they are designed.
Title: Re: My R65 Cafe Build
Post by: NathanR65 on August 09, 2014, 08:00:25 PM
I followed a youtube video by chris harris for replacing pushrod tube seals and setting valves torquing heads and adjusting rocker arms etc. Didn't remove the rocker shafts so oil is still present and checked this by measuring the play in the rockers once tensioned by pushing up and down on the rocker to see the oil squeeze out at the top and bottom. But thanks for the advice
Title: Re: My R65 Cafe Build
Post by: Adrian on August 12, 2014, 09:20:35 PM
Hi there mate - this is a great looking project - loved the photos. Its coming together really well. I look forward to seeing the project finished  ;)
Title: Re: My R65 Cafe Build
Post by: NathanR65 on August 15, 2014, 06:23:28 AM
Hi Adrian thanks for the kind words, I have a bit of an update today after a bit too much pondering I started the rebuild! Slow going for me as I wanted to make sure I was setting everything correctly but it almost looks like a bike again instead of a box of parts. To everyone on here that is following I would like to say thank you as it has given me a bit of a boost.
Title: Re: My R65 Cafe Build
Post by: NathanR65 on August 22, 2014, 06:27:39 AM
Currently wiring up my acewell speedo and fitting all the electrical components starting to come along !
Title: Re: My R65 Cafe Build
Post by: dav on August 24, 2014, 07:15:10 PM
Looking forward to the end result mate, great job.
Title: Re: My R65 Cafe Build
Post by: Luca on August 25, 2014, 08:29:08 AM
Plenty of folks would still be sitting around looking at a naked frame and drinking beer!  Putting even little bits back on is a huge step forward.  I like the rear turn signals.

That garage looks mighty comfy  ;)
Title: Re: My R65 Cafe Build
Post by: steve hawkins on August 26, 2014, 02:40:21 AM
You might find the handling a little too lively now that you have pushed the fork tubes up through the top yoke by that much.  You will have shortened your rake and trail.

It might be better to mount those clip-ons under the yoke and have the tops of you fork stations flush with the top surface of your top yoke, unless you have done something with your fork internals.

Let us know how you get on.

Cheers

Rev. Light
Title: Re: My R65 Cafe Build
Post by: montmil on August 26, 2014, 07:51:27 AM
[smiley=tekst-toppie.gif]
Quote
You might find the handling a little too lively now that you have pushed the fork tubes up through the top yoke by that much.  You will have shortened your rake and trail.

May have the steering responses of a trials bike. Should be fun at speed.
Title: Re: My R65 Cafe Build
Post by: Superhoholu on September 17, 2014, 03:09:28 AM
Hello buddy,

I saw you got a different fuel tank on your R65. I have a 1980 model R65 (dual shock version), but just canīt "plug n play" fuel tanks from other models, like R75 o R80

How did you manage to fit it there? Did you do any MOD for the tank?
Title: Re: My R65 Cafe Build
Post by: NathanR65 on September 22, 2014, 09:56:33 PM
Hi Dong,
As far as I am aware my tank is the original tank for my R65. Its got a bail type mount which locks around the backbone tube and is not bolted in as such. All my relays and plugs etc sit neatly underneath.
Title: Re: My R65 Cafe Build
Post by: NathanR65 on September 22, 2014, 09:59:03 PM
Also a bit of an update, bike is pretty much sorted. I am now just waiting on my seat to come back from the upholsterer. Once I have that back I will take some pics of the finished bike and you will be able to see my colour theme that I went with  ;)
Title: Re: My R65 Cafe Build
Post by: montmil on September 23, 2014, 04:28:15 PM
Permit me to re-address the issue of replacing OEM nuts n' bolts with stainless.

Always use an aluminum-based anti-sieze compound on each and every threaded bit. Don't even think about a temporary install as the nut n' bolt will most likely gall and be ruined.

Also, due to the lubrication provided by the anti-seize, reduce the torque wrench readings by 15%.