Got my new wheel from Woody's!

[tenni128]

I've mostly been going throught the electrical while I had some other parts on order. Ran new cables to the battery, (another shout to EME...had them in hand 3 days after ordering) cleaned points and whatnot. The stock headlamp ears fit; I had to shorten them 3/4" or so to fit between the K100 trees and remove the rubber bushings to account for the thicker forks. I found a k75 top clamp that doesn't have the ugly rubber bar mounts...I'm going to use the same setup for the /5 gauge-tach combo unit that I had fabbed up for the original /6 front end. The local BMW dealer found the bulb holders and bulbs for the /5 gauge, I still have to wire it up but the needles work and the ratios are right. Made hard lines to connect the calipers to a brass T; the original flex line runs to the rebuilt M/C from the same spot on the left side. I've gotten really lucky on a box of random /6 spares I got from flea-bay a while back...things like a MC rebuild kit, braided lines, extra relays and stuff like that that would've cost a ton I ended up with for not much money, and I'll resell alot of the stuff I won't need. I plan on bleeding the brakes, filling the forks and bounce checking the front end tonight. I'm cursing myself for sure, but I'm going to go ahead and say that I *should* be back on the road by week's end. Ha.

[tenni128]

.

[Nourish]

I just went out and slipped some standard Headlamp ears over some K75 stanchions and they are hardly a snug fit. I was thinking that the Mono R65 uses with these headlamp ears and their stanchions are less than 3mm down in diameter than the K's - so would their headlamp rubbers fit ? - just a thought. Regarding the indicator brackets - if you're using the standard ones fitting under the headlamp ears how are stopping them from moving as they locate on the roll pins in the R's lower Tree as standard. I would like to mount the indicators through the headlamp bolts but I can't think where else to put the ignition switch. Cheers for now

[tenni128]

After work tonight I'll take another look. I know when I pulled the rubber grommets out of the ears they slid over the K100 forks; that was all I was looking to see at the time, figuring I'd come up with some sort of grommet when the time came. That R65 idea might be the ticket. My initial idea was a couple layers of 3M clear rubber stuff (it's like 5-10 mil thick) that I use for headlight lens protection, but I hadn't put much thought into that yet. R/ the indicators, I will do what's needed to make it look as stock as possible. Past that tentative "goal" I have no idea how it'll end up having to be located. I did notice that as a possible issue...

[richard t]

I'm glad to see that I am not the only airhead that keeps a claw hammer handy.

. I can't find the damn hammer.

I ain't buying that, my wife made a remark the other day about how junky my shop was, and how neat Brad and Ken kept their shops.

Richard T
just can't win

[tenni128]

After a rough day at work, most of what got done involved filling re-built fork tubes with their oil while simultaneously draining a glass bottle of it's wine.
Still, there was progress. I measured the indicator mounts; they are the exact diameter of the K100 tubes: 41.6mm, so that's good enough for me. To locate them, I'll drill a hole for another roll pin just behind(relative to the tube) the pinch bolts on either side of the lower clamp and add a notch on the indicator mounts to match. Thanks for putting that on my radar, Nourish. As with every project (or at least the ones I get into) it's the little things that soak the big time...I spent two hours dealing with the steering stop. The K100RS trees *barely* grab the stop on my R90's frame. Not enough to make me comfortable, anyway, so I cut a few pieces of 1/8th inch steel, drilled and plug-welded them in place to increase the purchase of the stop. Anybody who does this for a living, with the attendant equipment, probably would have spent ten minutes on this, but for me it was two hours. Those threaded bosses on the lower clamp serve no purpose for me. I've been considering cutting them off and working them away with a grinder, but I think that will depend on how bad they bother me once it's all together. Maybe I'll keep them to mount...umm...something to.

[tenni128]

Well, finished up the last of the detail work needed for this front end swap. All that's left to figure out is the fender mounting and wiring up the /5 speedo/tach unit.

BMWfrontsmall1.jpg (205.38 KiB) Viewed 1217 times

The stock headlight mounts fit over the 42mm forks. They needed to be shortened about 1/4 inch, and the top grommet had to be ground down thinner to fit. I ended up having to remove a bit of metal on the stock indicator mounts to get them to lay flush on the K100 lower clamp, and located them with a roll pin like the stock setup, just clocked further back due to the pinch bolts being different.

BMWfrontsmall2.jpg (170.25 KiB) Viewed 1217 times

The stock K100 upper clamp had a nasty looking rubber mounted bar setup, so I found a K75 clamp that looks a lot cleaner. I'm considering drilling out the threads, and putting longer studs in the stock R90 bar clamps to use those nice smooth aluminum clamps.

BMWfrontsmall3.jpg (178.58 KiB) Viewed 1217 times

So, it's mostly back together. I still have to bleed the brakes, pick up the rest of the bulb holders for the gauge unit from the BMW dealer, finish the tune-up, and figure out the turn signals that went intermittant on me before all this started. Still, I think it passes for a way to get good dual discs and still maintain a rather stock appearance. Plus, I've got the thicker forks, bigger axle with sealed bearings, and a real set of fork clamps that aren't sheetmetal.