BMW R80 restoration

[Nicko]

Haven't begun the engine OH yet, wondering how far to go with it.

Unless it's done huge mileage or has obvious signs of abuse, I'd probably be inclined to split the engine/gearbox and eyeball the clutch parts with a view to any replacement parts needed and to check for any oil contamination thanks to a leaky crank seal. And pull off the front cover and replace the timing chain.

These would be awkward jobs once it's all back together....

Looking forward to some more pictures.

Nick.

[Ancientmariner]

Unless it's done huge mileage or has obvious signs of abuse, I'd probably be inclined to split the engine/gearbox and eyeball the clutch parts with a view to any replacement parts needed and to check for any oil contamination thanks to a leaky crank seal. And pull off the front cover and replace the timing chain.

These would be awkward jobs once it's all back together....

Looking forward to some more pictures.

Nick.

So I've already split gearbox/clutch and no signs of leaks though clutch will be replaced as it doesn't look great.
Front cover etc is all off as needed to do this to remove engine so will replace timing chain. Plan to take off heads so I can see inside as well and check for scoring/damaged rings.
Will also pop off sump cover and have a look inside.

It's done fairly high milage but was always serviced annually so hope it's all ok internally. If it needs fully stripping and rebuilding it's not the end of the word.

Photos of frame as is and will post engine photos tomorrow.if I get over to where it is.

[Ancientmariner]

Looking at what came out of the engine today I'm leaning towards fully strip and rebuild.
Not such clean oil and I think for the extra work a strip and rebuild is the way to go.

[Ancientmariner]

Though as it's cleaned up quite well I have high hopes for how it will look post parts washer and blasted.

[Tim Marlow]

Coming along handsomely James. Rather a mucky beastie though….

[Nicko]

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 M8.
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.

[Nicko]

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

Nick

[Ancientmariner]

So washed and started blasting......