lol thanks guys

and yes Blakey I have seen those posts about green frames ...in fb ...bevel heaven  and so many pages

cheers

the soda blasting has created a whole new challenge to get it back to shiney stuff ….giggles

Charlie - if you can find someone who does vapour-blasting, that would solve the problem. I've had three engines vapour-blasted from scratch i.e. just the grease and shite removed from bare alloy (no good if they're painted).



The good thing about the finish, particularly on a sump, is that vapour-blasting actually closes up the pits and pores preventing corrosion from getting easily restarted and stopping crap from sticking so easily.

great result Dai

don't know the resources in this country town yet , but will keep looking

One you get it all perfectly cleaned and assembled you should entomb it in a large clear acrylic block so that it can't even get dusty.

spent a good few hours on those parts today


what do you think ?









given the option for soda blasting , and finned bits , I would have to say ,  maybe not again ???

Looks pretty good Charlie!

You're going to have to start wearing sunglasses when working on that motor.

just on the off chance

I have to change the serial number on the sump , so that my serial number here in aussie is registered 

does any one have the right stamps for this , loan or buy …..  just need  the number "7" and the number "0"

Some good advice Charlie, don't change the serial number it can lead to disastrous consequences if it is picked up.

engine covers update , made satin some 2 years  ago , took out some sandcast marks and a bit brighter now , there are still some legacy deep marks in the crank cover (typical stuff with fairings and rubber mating against the aluminium , drop events etc )
still some polishing to do , ...after its assembled , will do

should fit in well with the updated sump eh ?

shims for valves arrived today ..woohoo ...so decided to do a bit more work



cut off old and hardened rubber from the cover bolts and installed new








reassembled the timing gear and rolled it over a couple of times ...all ok and valve clearances are good to go






so then replaced the timing cover and cam cover ….with a sneak peak at the theme i'm hoping to achieve









yeah ok …..for all you northern hemisphere types (who cant read upside down )   right side up, by photo manipulation



what do you think ...looking the goods ….yes ?

next the output shaft sump etc

sump and output shaft back together






couple of screws to do up on the water pump , but heres the idea any how

I truly appreciate your efforts towards cleanliness being next to godliness, Chaz. I, on the other hand, leave perhaps too much of yesterday's devilish grease and oil while I impatiently see how it all fits together.

brought old Gerty to her new home today  by visiting brisvegas again

thanks to Matt , the old girl started straight up , after removing a battery tender attached by Matt

thanks heaps Mate !!!

Gertys new home ...plush to say the least …"oh the serenity "



also acquired some bolts for gearbox to bell housing (enough for 2x applications ) from my favorite bolt shop

I showed the attendant pics of their stock supplied by them and installed to the motor that I have been working on ,  and she instantly recognised the  k100 head , which she also has , installed to a mini project she is working on ...great affinity indeed .. she was impressed  to say the least .

also some new head - steering bearings arrived , ( jap brand at least ) so the project moves along

Charlie, out of curiosity, did you replace those awful Torx bolts with capheads when you bolted the bellhousing back on? What the hell were BMW thinking of when they did that?

hiya Dai .. yes cap head bolts into the bell housing will be allen heads




today spent a few hours  with smithy , repairing a frame bridge crack , now rewelded with some steel support



and replaced the steering head bearings , the lower yolk bearing being particularly hard to remove .


now with new jap bearings fitted , this bit ready to go




a bit of fiddling about repairing paint defects and injuries (from rough handling , bumps etc )  will happen this week , followed by a good layer or two clear coat , should have the frame ready for taking parts next week

will give me time to refinish the bell housing and fit it back up with a later version of the sprage clutch

Reckon that silver against red is gunna have a classical look to it, Chazza. I don't know your ultimate direction, but if using an RS fairing, what colour have you chosen for the panels?

just a reminder , something like this mate

bit of bump and tickle to the bell housing late this afternoon





still upside down ...alas …  brush finish only ...so far

too much ? or should I polish it also ????

thoughts please ?

Polishing eh?

I had a fat-tank 860 Ducati and made the fatal mistake (young and stupid) of poishing the cases so they just about glowed in the dark.

Boy, did I make a rod for my back!

I had to keep them polished as they just looked crappy otherwise!

Good luck with whatever you decide.

I dunno much about finishes, never been my forte, but after all this elbowing, would a shot of clear keep it lookin like lickin?

yeah your right guys

the sump oil pump etc is clear coated . likely the top of the motor also
side panels , cam cover, timing cover and crank cover will be Cornubia waxed as they are easy to get to  and suffer from exposure issues ,so easy to keep  wiping it over

effort this morning has the bell housing  taken from brush - scotch bright finish ,  to polished , not a great deal of appearance difference to the camera , but smooth as a babys bum

clear coat to go on later

thanks for the replys ….appreciate the opinion

It's amazing the different paths people take. I applaud your genuine effort as the real deal. This K11 I bought a coupla years, the basket case, well the bloke spray painted everything black. He musta used a spray gun coz it's a thick, durable layer. Trub is the wanker sprayed over the rubber boot on the Paralever, hose clamps, even wheel weights. 

Spray Job Special.

Only trouble Charlie is once it's finished you wont want to ride it, because it's soooo pretty.
Regards Martin.

dang , I feel your pain


we do have a pretty good paint stripper out here , poly stripper , which is miles better than many other brands at removing tough paint

if using some other product be aware that if unsuccessful first application  there is no way back , it hardens the paint a great deal and nothing less than sanding etc will remove it , just a heads up

eager to see what becomes of the old basket case …  a great deal younger than my attempt

MartinW wrote:Only trouble Charlie is once it's finished you wont want to ride it, because it's soooo pretty.
Regards Martin.

I don't think ill have any trouble with that martin ...giggles , after all it could turn into a very shiney "Rat Bike "

Charlie NOOOOOOOOOOO ARHHHHHH.

bell housing fitted up , and clutch basket inserted to check if the newer type seal is making the right contact

ill tighten this baby up tomorrow and move onto refurbishing a gearbox bearings and seals (and other stuff)

got to make a stand for the engine , and transmission line in the coming days also

Hallo Mcharlie99 wrote: … boxing day cleanup of gasket area and pistons ,diready for the head I cleaned up back in july , 86 model with the different seats below



should be all buttoned up a little later today sometime

Hello #charlie99 !
Well done and nice, is your kitchen as clean , haha.

A German fried would very much like to know how you have cleaned this part.
He rebuilds a lot K bike but doesn’t get it as clean.
Would be great if you could explain !!!


Cheers :-)

charlie99

charlie99

hmm , not hard to do chocolate

first off valves were removed to start with

ports were cleaned up with a Dremel tool  reshaping the short curve radius as to reduce any sharp corners with a sanding barrel type thing

valves were cleaned up on the face and rear using a wire brush on a drill

hemispheres of the combustion chamber were cleaned up with wet and dry paper , finished with the Dremel type tool and wire brush

head surface was refinished with a standard stone used for sharpening knives etc ….when brand new they are particularly flat and make for a good grinding stone , all by hand

careful not to make any big differences in the surface , uniformity is paramount

valves were them lapped to the seats with grinding paste ,  

it took quite a while to get it to look like that



hope that helps

Your description of the process gives the impression it's all in a relaxed Sunday arvo, when in fact it's a heap of time - and patience - required to achieve those results. Well done, Mr Semi-Retired. I'll wager the stack of tinnies in the corner can tell the tale.

charlie99 wrote:hmm , not hard to do chocolate …

Thanks Charlie, that helps.

Cheers

first coat of clear coat on the frame , late in the afternoon , nearly night time

and some other bits getting the Charlie treatment

thanks to smithy for the extra parts  (oops overlooked a couple of bits needed ) 

flipped the motor right way up and started on induction system
 


rubbers matched to the ports



some grubby - modified tbs



and thinking about the top rubbers clamps ….hmm .. the Suzuki thin types with screws perhaps ???

threw some bits on the frame , just to see what it looks like , and really to start assembling the wiring loom , with the mods that I will be using








mostly will be unseen  once fairings , panels , tank etc are installed

It's bringing back memories of my first new bike a Ducati. Bought from Pratts in Melbourne delivered by a BMW with a flat cargo chair. Could of been an omen of my future.

Regards Martin.

Hi Charlie, if your rubbers are in good condition and supple. I have found that tie wraps will do the job, of course on a faired bike you will want to be extra careful checking for leaks before covering them up

5mm tiewraps... now that is a good idea if the rubber hasn't gone hard. If you can get them on from the inside that will definately improve the look of the bike in that area.


























- just as long as they're not white ones.

um translation please

tie wraps ?  would we know them as zip ties


or a pic would be good

Yes Charlie. Correctly translated.

robmack wrote:Yes Charlie.  Correctly translated.

thanks mate

interesting how we have different terminology at times …..  but just by asking ….resolved !!

given the heat and uv and obvious unknown age of cable ties - zip ties before installation ...ill be looking for something of a longer lasting solution , but a good thought at least ,,,thanks for the suggestions

cheers

Charlie Bunnings have packets of stainless cables ties.
Regards Martin.

hmm nice option martin

ill think on that one for sure

MartinW wrote:Charlie Bunnings have packets of stainless cables ties.
Regards Martin.

But are they white or black? 😉

Bill

Colour can be changed with the aid of marker or paint pens. So pink is a distinct possibility if you want.
Regards Martin.

One of the problems with zip ties in stainless is the width of the tie. It's generally too wide for the ridge provided on the bushing and won't sit quite properly. The Suzuki band clamps are the correct diameter and width and fit much better. You'd have to check the ties you have available to you to see whether they fit.

MartinW wrote:Colour can be changed with the aid of marker or paint pens. So pink is a distinct possibility if you want.
Regards Martin.

Pink it is. Looking forward to seeing that, Charlie. 

Bill

Rob I haven't checked them out lately but I believe they can be had in a couple of widths. I was going to substitute the OEM ties for stainless. After a bit of cogitation I concluded that they would be a pain to remove on the side of the road if needed.
Regards Martin.

more top end works

oops … bloomin old and hardened rubber , too easy to do

 but found another



getting there

panel damage ...such a pain !!! ...happened whilst moving in plastic storage containers …. not enough packing and too many things in the same box  … the lower panels came off worse ...but blemishes and scratches abound .


oh well... time for a fresh coat of paint and finally  clear coat in a few days