K1100RS by wooboodoo

[billday]

Many a happy hour I've passed in the fasteners department at Lowe's. Thanks for bringing back the memories. And thank you for documenting and sharing this impressive build.

[The Mighty Gryphon]

My process for gear position switches is to first remove every bit of the old potting compound from around the wires and the switch's cover.  After I clean it thoroughly with brake cleaner to get rid of any grease or oil I mix up some quick set epoxy and repot the wires and cover. 

After an overnight to fully cure the epoxy, I pull the switch apart and clean all the internal bits.  When I put it back together I put dielectric grease on the mating surfaces of the switch halves to help keep water out. 

Reinstall the switch with stainless socket head Allen screws.  They're easier to get out than the OEM screws.

[wooboodoo]

Many a happy hour I've passed in the fasteners department at Lowe's. Thanks for bringing back the memories. And thank you for documenting and sharing this impressive build.

I’m glad to hear that I boinged back your good memories and thank you for good words about my work I’m happy to hear that you like it. :)

[wooboodoo]

My process for gear position switches is to first remove every bit of the old potting compound from around the wires and the switch's cover.  After I clean it thoroughly with brake cleaner to get rid of any grease or oil I mix up some quick set epoxy and repot the wires and cover. 

After an overnight to fully cure the epoxy, I pull the switch apart and clean all the internal bits.  When I put it back together I put dielectric grease on the mating surfaces of the switch halves to help keep water out. 

Reinstall the switch with stainless socket head Allen screws.  They're easier to get out than the OEM screws.

Thank you for sharing all detailed info, it definetly gonna help me to work on this switch restoration.

[wooboodoo]

So, last weekend I basically spent on sand blasting and painting, it was productive 2 days ;)


 IMG_4361 by wooboodoo, on Flickr

IMG_4363 by wooboodoo, on Flickr



Soaking in the acetone...


IMG_4346 by wooboodoo, on Flickr

IMG_4347 by wooboodoo, on Flickr


As I mentioned before I found the way to use cerakote C type on the front cover (baking longer in lower temperature).


IMG_4340 by wooboodoo, on Flickr

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I have to admit that the final product exceeded my expectations, I'm so happy !!! :)


IMG_4364 by wooboodoo, on Flickr

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I hope that tomorrow I will start putting together my K ...

[thestza]

man... some awesome work here. super impressive

[wooboodoo]

man... some awesome work here. super impressive

Thank you very much ! :)

[wooboodoo]

I thought that I'm done with the sandblasting at least for now, but it looks like I was wrong...
Stand was in very bad condition visually and mechanically so I had to take care of it.

IMG_4379 by wooboodoo, on Flickr

IMG_4381 by wooboodoo, on Flickr



After blasting, cerakoting and baking.


IMG_4445 by wooboodoo, on Flickr



First of the mechanical issue was missing/gone orings and lock ring on one of the sleeve so I had to restore these.



IMG_4467 by wooboodoo, on Flickr

IMG_4468 by wooboodoo, on Flickr



Second issue was cracked side stand aluminum bushing... Thankfully I had some aluminum materials laying around and I could copy that busing in no time.



IMG_4454 by wooboodoo, on Flickr

IMG_4456 by wooboodoo, on Flickr

IMG_4473 by wooboodoo, on Flickr

IMG_4474 by wooboodoo, on Flickr

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Time for assembling and final product...


IMG_4470 by wooboodoo, on Flickr

IMG_4480 by wooboodoo, on Flickr

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IMG_4483 by wooboodoo, on Flickr



Now time for some pleasure lol, I gave a good bath for the intake manifolds and replaced old rubber flattened gaskets with new silicone orings.


 IMG_4441 by wooboodoo, on Flickr

IMG_4446 by wooboodoo, on Flickr



Then I decided to replace the monkey nuts, brand new are so tight I thought that the old ones are ok but I think I was wrong.


IMG_4488 by wooboodoo, on Flickr

Here's the pic of the old ones just to compare...

IMG_4031 by wooboodoo, on Flickr
 


Silicone - checked , bolts - checked, torque wrench - ready... first cover back on the engine lol !!! :)


IMG_4489 by wooboodoo, on Flickr

IMG_4496 by wooboodoo, on Flickr

 
I'm almost there haha ;)

IMG_4501 by wooboodoo, on Flickr

[daveson]

 Good job!

[wooboodoo]

Good job!

Thank you ! ;)

[wooboodoo]

I had to finally take care of the final drive, Looks like I had a leaking pinion seal...

IMG_4517 by wooboodoo, on Flickr

IMG_4518 by wooboodoo, on Flickr



It wasn't easy to take it apart... I damaged the threaded ring a little bit.


IMG_4584 by wooboodoo, on Flickr



Cleaned and ready to go...


IMG_4594 by wooboodoo, on Flickr



New seal and compression ring.


IMG_4582 by wooboodoo, on Flickr

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Some compound...


IMG_4596 by wooboodoo, on Flickr


And done !

IMG_4599 by wooboodoo, on Flickr


Then I had to take care of paint, I decided to give a try for Eastwood ceramic engine paint and I like it so far.


IMG_4561 by wooboodoo, on Flickr


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IMG_4654 by wooboodoo, on Flickr


I painted whole swing arm of course ;) and yes... I took off the frame for powdercoating I couldn't sleep still thinking about it, that project cost me too much work to leave it painted with regular paint I wanted something more durable so i took the frame to the city. At the same time I realized that everything black except the alternator is not best idea so I painted it as well ;) Since I was in "painting mode" I sandblasted the fuel rail and painted it using the same eastwood paint, they say that it's chemical resistant so I'll test it lol


IMG_4672 by wooboodoo, on Flickr

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The guys @ thepowdertouch (https://www.instagram.com/thepowdertouch/) took care of my frame, finish black matte of course... they did amazing job, I'm very happy now ;) 


frame by wooboodoo, on Flickr

frame1 by wooboodoo, on Flickr


It took awhile but the result is satisfying :) Every weekend I'm closer ! by the way, in meantime I changed the spring from blue to titanum  lol

IMG_4749 by wooboodoo, on Flickr

IMG_4750 by wooboodoo, on Flickr

[TommyT]

That engine looks great!

How easy is it to spray that paint? Do you use it straight out of the can?

[caveman]

Thanks for keeping us up to speed with your build! It is looking great so far and looking forward to seeing more as you go forward!

[wooboodoo]

That engine looks great!

How easy is it to spray that paint? Do you use it straight out of the can?

Thank you Tommy,
The engine covers are painted with cerakote H series then baked in the electric oven at 300*F for one hour. It’s two component paint and depend the surface you want to paint you have two options for best results, for smaller (difficult) parts you can use an airbrush and for bigger touch up spray gun (my preference). All info you can find here https://www.cerakote.com/finishes/?tab=coatings&cat=HSERIES but if you have any questions feel free to contact me. ;)

[wooboodoo]

Thanks for keeping us up to speed with your build! It is looking great so far and looking forward to seeing more as you go forward!

Caveman thank you very much, I’m glad to hear that you like my job I’ll try my best to keep this thread updated ;)

[TommyT]

Thank you Tommy,
The engine covers are painted with cerakote H series then baked in the electric oven at 300*F for one hour. It’s two component paint and depend the surface you want to paint you have two options for best results, for smaller (difficult) parts you can use an airbrush and for bigger touch up spray gun (my preference). All info you can find here https://www.cerakote.com/finishes/?tab=coatings&cat=HSERIES but if you have any questions feel free to contact me. ;)

How did you like the Eastwood stuff?

[wooboodoo]

How did you like the Eastwood stuff?

It looks very legit, covers nicely and dries quickly. However, its too early to say how durable it is. Wish I got it earlier so I could paint the gearbox and engine block it seems to be a better paint than 2K in spray can.

[wooboodoo]

Guys ! If any of you planning to fix the gear position switch I have some hint... I was looking for something small and round in the garage and I found roll of teflon tape, yes the cheapest one, it seats on the K1100RS switch just perfect I think the K100 and K75 switches are the same. All you need to do is notch for wire, I used round file.

Clean the rest of the oem (probably cracked already) protection from the back of the switch using small flat screw driver... Secure the switch (I screwed it to the wood) push in the cable a little bit so epoxy can hold the vinyl sleeve as well.


IMG_4665 by wooboodoo, on Flickr


Install the roll on the switch and fill it with good quality epoxy glue.


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 After few hours using razor blade do the notch vertically on the roll (careful, not too deep) using pliers break the plastic roll then using metal saw blade cut excess of the epoxy (I left about 1/4") A little bit sand paper for smother finish after cutting and done !


IMG_4668 by wooboodoo, on Flickr

IMG_4669 by wooboodoo, on Flickr

[billday]

Nice. After that, I hope no one here ever sees what mine looks like (a blob).

[wooboodoo]

Nice. After that, I hope no one here ever sees what mine looks like (a blob).

Haha is hard to see it thankfully ;) by the way its suck that we have to remove the swing arm to work on this switch.

[talvare]

This was looking like a great build. What happened ? Sure would like to see an update.

Ted

[wooboodoo]

This was looking like a great build. What happened ? Sure would like to see an update.

Ted

Hi Ted,
Project is almost done but I was a little bit busy to update this thread but I’ll be more than happy to continue updating seeing that you’ll like to see it! 🙂

[talvare]

Yes, I'd definitely like to see your progress. Looks like a first class build. Judging by the parts you are fabricating, it appears that you have CNC capability.

Ted

[wooboodoo]

Ok then lets continue the journey...
I think the next step was to design the triple tree clamp, I badly wanted some "pocket" for separate gear indicator and motogadget motoscope pro display so Adam (the owner of DIXER PARTS) took care of me and cut excellent clamp. I sandblasted it and cerakoted with the same finish as engine.

K1100RS triple tree clamp by wooboodoo, on Flickr

K1100RS triple tree clamp by wooboodoo, on Flickr

K1100RS triple tree clamp by wooboodoo, on Flickr


As about controls I decided to go with quick throttle from ACCOSSATO, I'm pretty happy with these silicone grips and quality. Got them from OmniaRacing Italy.

Accossato quick throttle by wooboodoo, on Flickr

Accossato quick throttle by wooboodoo, on Flickr

Next step was to install Motogadget m-Blaze Disc Bar End LED Turn Signal into the ABM strap-ons handebar.
As you can see on the pic the hole in the ABM strap-ons handlebar is too small for installation so I had to re-drill the holes. It was a two steps drilling process, first bit I used was 1/2” (12,7mm) then second one 15mm.
At the same time I installed the motogadget m.button on the throttle side, I drilled the hole about 3” deep so I could fit m.button device and easily pass the turn signal wires on the side of it. The clutch side handlebar hole is about 1,5” deep.

Untitled by wooboodoo, on Flickr

m.blaze by wooboodoo, on Flickr

m.blaze by wooboodoo, on Flickr

m.blaze by wooboodoo, on Flickr

m.blaze by wooboodoo, on Flickr

m.blaze by wooboodoo, on Flickr

m.blaze by wooboodoo, on Flickr

The space left between the grip and turn signal is for motogadget Motogadget m.View Flight Bar End Metalmirrors

m.view by wooboodoo, on Flickr


Ok, next step was to create some seat


Seat by wooboodoo, on Flickr

Seat by wooboodoo, on Flickr

Seat by wooboodoo, on Flickr

For the first 3 fiberglass layers i used liquid epoxy then for additional layers I got pro grade very durable thick epoxy to make the base about 3/8" thick and very strong. On the top I installed aluminum plates to make holes later and thread them for seat support.

Seat by wooboodoo, on Flickr

Seat by wooboodoo, on Flickr

Seat by wooboodoo, on Flickr

Seat by wooboodoo, on Flickr

To design stitches took me a few days and finally got something like this...

Seat by wooboodoo, on Flickr

Then ride to the McCoys upholstery in Woodside NY to get it done the right way !

Seat by wooboodoo, on Flickr

Seat by wooboodoo, on Flickr

Seat by wooboodoo, on Flickr

Since my bike is a Roach it will have a few Witcher accents here and there. I'm from Poland and love this books since I was kid so why not 

[talvare]

Thanks for the progress update. That triple tree clamp is a thing of beauty.

Ted