BMW R80 restoration

[therapy]

yuck! I see what you mean, but as you say, a sympathetic vapour blast will have it looking lovely again.

nick

 

[Ancientmariner]

So pulled heads off and bores are good. Will all be good once new rings are in and all washed and ready to reassemble with new seals.

 

[Ian M]

I have seen a few very nice BMV boxer cafe racer type builds and they do look rather good. I am sure this one will too.
I also saw a bobber version and that worked surprisingly good on the eyes.

 

[Ancientmariner]

So thought I'd get back into it and removed the head stock bearings today. Actually took about 30 mins once I'd started. Cut length of bar and ground to size, welded in and then knocked out with hammer and brass bar.
Hopefully take the frame to be blasted tomorrow.

Also cleaned.up the piston crowns and just ordered new piston rings.

 

[johnm93]

1989 model Nick (I checked the V5 today).

So strated a small but of stripping today which turned into an 85% strip.
The old girls had a hard life but a nut and bolt rebuild will be a new lease of life. I plan to:
1. Remove, strip, OH and rebuild engine.
2. Clean and vapour blast all that can be and have painting, powder coating and plating done as required.
3. New wheels (wire spoke).
4. Ohlins front forks and rear mono.
5. All bearings and seals to replace.
6. Strip and rebuild shaft drive.
7. Brakes full strip and rebuild, new discs.
8. Bend/weld new rear sub frame.
9. Make new seat.
10. Strip and repaint tank.
11. Build battery housing and handle bars.
12. OH anything else not listed.

So more than I expected done today.

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Kit bashing in 1:1 scale - what could go wrong, eh...?

 

[Ancientmariner]

So have got a bit more done.

Removed clutch and flywheel today. Clutch bolts were either M7, imperial or corroded M6. Couldn't be bothered faffing about so drilled out and retapped mate.
Came off easy enough, fabricated simple tool to lock fly wheel and then removed that as well.

Can shaft sprocket off and cam shaft out, got to get crank shaft sprocket off next. Have to say I love the Rothenberger blow torch. Put pullers on, tighten up as hard as it will go, heat and wait for the pop as it comes off.

Looking forward to once it it 100% bits and I can start an actual rebuild.

 

[adt70hk]

Nice to see some proper corrosion rather than our modelling version!

 

[Ancientmariner]

Cam shaft and crank shaft out. Cam followers are in tatters. Not unexpected after what if assume is 89000 miles but oddly the cam shaft is A1 almost. I would guess it's had a new cam shaft at some stage, though why you would put that in and not replace the cam followers I don't know.
Cank seems ok, removing the sump and oil pump today and then clean and get the rest blasted before hopefully some rebuilding.

 

[therapy]

Those followers have certainly taken a beating. Nice to see the progect making progress.

Nick

 

[Ancientmariner]

So washed and started blasting......

 

[Tim Marlow]

Coming along mate. Amazing the change bead blasting makes. Better than new

 

[Ancientmariner]

Yeah it's come out really well. Need to strip and rebuild gear box but at least it's clean now.
Just doing last 2 cylinder heads and rocker covers and the block and it's all done.

That's using 2 different machines, but both with glass media.

 

[therapy]

Excellent! They've really come up nicely...

Nick

 

[Ancientmariner]

Block....

 

[tigersteve]

Looking Really Nice !!

 

[JR]

Unbelievable finish, take my hat off to you, your very skilled indeed James.

 

[Ancientmariner]

So got most bits for engine rebuild ready (excluding gearbox which needs to be done) apart from a new set of cam followers which are eye wateringly expensive.
Think doing away with the air box type filter for direct inlets onto heads will look good.

 

[PaulinKendal]

Um, are you dispensing with the carbs as well as the airbox? Could make for a very lean mix!
Seriously, this is amazing - I wish I could do this sort of thing.

 

[Ancientmariner]

Um, are you dispensing with the carbs as well as the airbox? Could make for a very lean mix!
Seriously, this is amazing - I wish I could do this sort of thing.

Ha ha not quite, carbs are in a lot of bits currently

 

[Ancientmariner]

Finally rebuilding. Slow and steady but got a bit done today.....