28/09/17
-       Brought in a Brake Bleeder Kit, a Fluid Pump and an Engine Oil Drainage Pan
-       Took more pictures of the original bike.
-       Began stripping, was able to strip all the fairings off along with a few other parts.






5/10/17
-     Today I was wanted to remove the airbox so that I could fit new air pods. However to remove the air box I had to first remove the tank which I found to still have fuel left in it which luckily I was able to not cause any spills. After the tank was removed I was able to remove half of the airbox as can be seen in the photos. This space I think I am going to use to store other parts to reduce overall look of clutter.   














 10/10/17
-     I was able to remove the large portion of the exhaust. I also began designing a seat by first establishing a riding position by moving the readers back and lowering the handlebars.







Update:
It is now 21/11/17
 - I was able to install one side of the grips and handlebar indicators and temporarily have it wired up. However I forgot a rubber grommet for the inside of the grip so will need to install that next time and neaten all wires.





 

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DBRMN

That poor K looks very lonely there, all on its own......

Even better is that it looks a really good place......

K pox is likely to break out there, perfect conditions for it. Wonder how long that will take.

Kpox: the unquenched desire of a K to have a stable mate.....

you probably cant add pods to the standard k 8 valve (unless they are just cosmetic )

all the air it breaths has to go through that weird thing in the airbox ...called an afm ...it measures the airflow and feeds the under seat computer the information as for how much fuel to inject ( lots of other things come into the equation as well )

but  the later 16 valve models and k1100 do it differently

good luck

+1. As Charlie says, the AFM (the gadget in the top half of the airbox) is an integral part of the fueling system.

Somewhere there is a line on someone who put carburettors on a K100.....not sure about the wisdom of some of these changes but some do things simply because they can.

I have a feeling someone has put 16v Motronic etc without the airbox on an 8 valve too.........

That guy used Suzuki GS1000 carbs. I remember that because I had a set in the garage and was tempted for about 0.0001s.

   lol

I mean who would convert a K100 into a bicycle.....

92KK 84WW Olaf wrote:That poor K looks very lonely there, all on its own......

Even better is that it looks a really good place......

K pox is likely to break out there, perfect conditions for it. Wonder how long that will take.

Kpox: the unquenched desire of a K to have a stable mate.....

It is a brilliant facility at my school it is perfect for K pox. Funnily it did attract another K bike but sadly only to charge the battery not for a long stay lol.

charlie99 wrote:you probably cant add pods to the standard k 8 valve (unless they are just cosmetic )

all the air it breaths has to go through that weird thing in the airbox ...called an afm ...it measures the airflow and feeds the under seat computer the information as for how much fuel to inject ( lots of other things come into the equation as well )

but  the later 16 valve models and k1100 do it differently

good luck

Ye thats what I thought I've decided to refit it which I'm annoyed about but its definitely the right choice because it would run without it lol

DBRMN wrote:

92KK 84WW Olaf wrote:That poor K looks very lonely there, all on its own......

Even better is that it looks a really good place......

K pox is likely to break out there, perfect conditions for it. Wonder how long that will take.

Kpox: the unquenched desire of a K to have a stable mate.....

It is a brilliant facility at my school it is perfect for K pox. Funnily it did attract another K bike but sadly only to charge the battery not for a long stay lol.

I think my K might be coming down with something as well...Only 3 months in on my project and I'm already thinking about another...

So since the last update my little K bike has come a long way!




After this I decided I needed to start getting stuff painted. So over the Christmas break I decided to take my wheels and tank home (However I wouldn't be able to get the tank painted as I forgot I needed to remove the unnecessary tabs). After taking the front wheel of it seemed an obvious step to take the forks off and after the forks came the triple tree as I wanted both items repainted and cleaned as well. I also gave the whole bike a general clean with my friend which made it look noticeably nicer. Also having taken both wheels off I had to find a way of propping the bike up so I used a scrap bit of wood which seems to be doing the job and is relatively stable. 





At the moment however I am looking into a GSXR fork conversion and extending the rear shock to give a more racer stance however this is only in the imagination stages yet. Also for anyone who's curious the most parts including the wheels are going to be painted Satin Black and the tank is going to be painted a Ferrari colour called Grigio Medio, here's it on a BMW:

Like this?

Chocolate wrote:Like this?

Yeah similar except more glossy and more black on the rest of the bike.

Hey guys so I've been documenting my entire Cafe Racer project for my Extended Project Qualification (EPQ) but I thought I'd treat you all so I will be posting my EPQ on this forum after it has been marked and fully completed. This means that I won't be updating this thread until then. The EPQ should be finished by the end of this school year so summer time. It contains everything from a full diary to why I picked certain parts and their alternatives.

Exams and such have been getting in the way but I thought I'd just update you all because I am very proud of the progress. The indicators and speedometer are now fully functioning and the seat is made and upholstered. I have also began prep for the rear cowl that I'll be making out of sheet aluminium. Any questions please do ask but I will be posting a comprehensive document once I have finished. Thanks DBRMN.

I'd have killed to be allowed to build my first bike on school premises!!! Especially with that set of tools to play with. The most I was allowed was to turn up replacement parts for a 5cc aero-engine.

Well done you!

Dai wrote:I'd have killed to be allowed to build my first bike on school premises!!! Especially with that set of tools to play with. The most I was allowed was to turn up replacement parts for a 5cc aero-engine.

Well done you!

I know I'm so lucky its going to be an experience I remember for the rest of my life!! Took years of saving up and years of begging my parents lol. I'm in that room practically free moment I get its amazing.

I like that little LED speedo.

Is that a brick on your brick?

Mate this looks awesome can't wait to see the final product! 

duck wrote:I like that little LED speedo.

Is that a brick on your brick?

Ye I love motogadget products the handlebar indicators are them as well!

lol yeah my lovely sanding block!!

tborosak wrote:Mate this looks awesome can't wait to see the final product! 

Thank you so much! I love your profile picture your Brick is beautiful!!!!

Just a few extra pictures to reveal the colour I went with (Grigio Medio). Enjoy!!!



[url=https://servimg.com/view/19788995/62][/url]

[url=https://servimg.com/view/19788995/60][/url]

[url=https://servimg.com/view/19788995/67][/url]

[url=https://servimg.com/view/19788995/68][url=https://servimg.com/view/19788995/70][/url][/url]

Nice color !

Cheers

Chocolate wrote:
Nice color !

Cheers

Thank you, can never go wrong with a Ferrari colour!!

New fuel cap from Flatracer

I've been playing around with the idea of this color or Space Grey, like my last e92.  This color looks great!  Nice job on the build so far!

fox1486 wrote:I've been playing around with the idea of this color or Space Grey, like my last e92.  This color looks great!  Nice job on the build so far!

It's honestly beautiful in person it's subtle and sophisticated   . Nardo Grey is also beautiful. If your on the fence I would definitely recommend Grigio Medio. Thanks btw its almost finish I have my presentation evening tomorrow evening.

As promised, all the information on my project:

http://dbrmn.kforum-tech.com

New update, Was away over summer so didn't get to see my K but back to working on it. I've started aiming for aesthetics and neating it up now because I want it to have that professional look. I've started with polishing and cleaning by hand each visible nut and bolt which I'm actually enjoying so much as they already make the bike look so much better, I'll be posting pictures soon.

I've also got the rocka covers off and I'm planning on painting them myself so currently at the prepping stage which is taking a lot of time as they were quite beat up. Pictures coming soon.

Below I few pictures of the engine which you've all probably seen before but made me and my friends very excited. lol

DBRMN wrote:I've also got the rocka covers off and I'm planning on painting them myself so currently at the prepping stage which is taking a lot of time as they were quite beat up.

The project is looking good. Do you still have the contact spring kicking around somewhere? It's easy to lose.

Laitch wrote:

DBRMN wrote:I've also got the rocka covers off and I'm planning on painting them myself so currently at the prepping stage which is taking a lot of time as they were quite beat up.

The project is looking good. Do you still have the contact spring kicking around somewhere? It's easy to lose.

Oh my god no I don't think so, does it pop out when you take the cover off?? Or is there a chance its still in it's spot in the engine block?

It could still be sitting on the no.3 cam cap. It's about 30mm long and 20mm diameter. The cam cover is isolated from the rest of the engine by rubber gaskets, both on the cover itself and on all the mounting bolts. This gives the potential to build up a really nasty static charge which, according to BMW, possesses the ability to zap the ICU and FICU when it goes off and sets up a huge back-EMF in the coils.

Yes, I left the bloody thing out last time I had the cover off . No, I didn't want to take the cam cover off again - because reasons. I ended up running a short length of wire from the HT lead cover (the plate that says 'BMW') to the fuel rail.

Here's how it is fitted, from the Haynes manual.

Dai wrote:It could still be sitting on the no.3 cam cap. It's about 30mm long and 20mm diameter. The cam cover is isolated from the rest of the engine by rubber gaskets, both on the cover itself and on all the mounting bolts. This gives the potential to build up a really nasty static charge which, according to BMW, possesses the ability to zap the ICU and FICU when it goes off and sets up a huge back-EMF in the coils.

Yes, I left the bloody thing out last time I had the cover off . No, I didn't want to take the cam cover off again - because reasons. I ended up running a short length of wire from the HT lead cover (the plate that says 'BMW') to the fuel rail.

Okay I'm gonna have a check on Monday. What is the function of it? I don't really understand. Also whats the part number incase I have lost it.

Laitch wrote:Here's how it is fitted, from the Haynes manual.

Ye I don't see it in any of my pictures I'll have a look round for it something tells me I've lost it.

DBRMN wrote: What is the function of it? I don't really understand. Also whats the part number incase I have lost it.

Dai explained part of its function in post #36. Getting shocked by touching the camshaft cover while the engine is running also has been presented as a possibility if that spring is missing. I haven't been interested in testing the outcome without one so I've always been certain to install it.

The part number is available in any parts fiche. Try looking it up in this one under the category Engine.

Whaddyaknow!!! I just found my missing contact spring in a box of Moto Guzzi parts!

Dai wrote:Whaddyaknow!!! I just found my missing contact spring in a box of Moto Guzzi parts!

I really think I would have noticed if it fell out. What if someone left it out before I got my bike, would it be that noticeable? I'm gonna have a look later. Thats honestly so funny.

Found it it's all good lol it was sitting right where it should be.

DBRMN wrote:Found it it's all good lol it was sitting right where it should be.

It looks like the current photo software here can't enlarge enough for my eyesight.
I see it now as what I mistook previously for grease or shadow.
 

Laitch wrote:

DBRMN wrote:Found it it's all good lol it was sitting right where it should be.

It looks like the current photo software here can't enlarge enough for my eyesight.
I see it now as what I mistook previously for grease or shadow.
 

Yeah from that angle it's incredibly hard to see lol I still find it hard to see it on the picture. Thank god its there.

Freshly Painted engine covers look fantastic! I have also taken apart the throttle bodies and given them a good clean and polish.

[url=https://servimg.com/view/19788995/89][/url]

Got the throttle bodies fitted along with the airbox. I decided to wrap the Airbox in a carbon fibre style vinyl just to make it a bit more interesting. 

I also rerouted the fuel injector wires through the back rather than the front for a less cluttered look. Hopefully try starting her up next week after my preflight checks. 

I also got a new LED H4 light bulb that i'll be testing tomorrow hopefully. 

Enjoy the pictures, next mini project is rear sets.

Currently working on the airbox modification, which means I'm going to need to change the angle that the air sensor comes out of the second airbox, if that makes sense. You can see it in the pictures, hopefully going to mount it with this bracket and relocate some bits and bobs there, like the coolant overflow tank and maybe the alarm. 

So another update:

Been working on a coolant overflow tank which I am going to relocate to the front left of the bike, just like the BMW K101 Gatermann, that we all know and love. Next step welded it all together and make it water tight. I've also bought a barbed hose joint that i'll tap in to my box. I Also might knick the sight glass from the original tank. Here are a few pictures:



I am also working on the airbox modification, so in order to attach the air sensor to the plenum chamber, I've 3D printed a part for this job, I've got one end to fit perfectly, the other end however is going to need a bit of editing:


Next step is coat of paint for the airflow sensor housing, and an adapter so I can put a nice big Air Pod on the end K&N style.

Had to redesign the box as it was impossible to weld, the result has a lip which looks ugly but i'm going to fill the welds to make them smooth then paint the box so I think it's going to look beautiful. I'm yet to tap the hole for the fill cap, and the inlet/outlet pipe. I also need to explore if I want a level sight glass, was thinking of recycling the one off the original box. Here are some pictures,


[url=https://servimg.com/view/19788995/124]
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There Air intake system is really coming together, I made an o-ring for the Airbox-to-air sensor side which makes it a snug fit. I've also made a another adapter for the other side which gives me a rectangle to circle conversion so I can pop an Pod filter on (Picture below, I'll be test fitting it Friday). I've painted the Air sensor and will post pictures soon. But for now heres my new filter: (RC-8300)