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Author Topic: Up and Riding! Building a new rig for my BMW 1200 GS Adventure  (Read 13625 times)

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Offline 2bfree

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Re: Building a new rig for my BMW 1200 GS Adventure
« Reply #60 on: October 19, 2015, 03:28:22 pm »
Gel coat on!  :thumleft:
 

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Re: Building a new rig for my BMW 1200 GS Adventure
« Reply #61 on: October 19, 2015, 07:12:37 pm »
Might be a stupid question, but how do you get the plug out.  ???  I know nothing about fibreglass, though practical, I don't get this out. Do you use the plug only once.

I tried the rest and still stick with the best.  -   ROOIVLEIS
2006 Hp2 - 2006 Hp2 - 2008 R1200 GSA -  2009 R1200 S - 1998 R1200 C       

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Offline frans1

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Re: Building a new rig for my BMW 1200 GS Adventure
« Reply #62 on: October 19, 2015, 08:47:05 pm »
Shoe. 
You are brilliant!!

Like to watch your building of your rig to the end.

Thank you for sharing it with us.

I was thinking the other day, that this will be the only option for me to go for a ride on dirt if the legs are to old to keep the heavy bike upright.
BMW 1200GSA (What a Machine!!!)
BMW R100RS (Busy with the repairs)
BMW 1200GS (Love the bike)
WR 450 Yamaha (Sold)
Yamaha 500 XT (Sold) Yamaha 175 DT (Sold) Honda 90 cc (Gave it away)
 

Offline stevo

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Re: Building a new rig for my BMW 1200 GS Adventure
« Reply #63 on: October 19, 2015, 11:45:12 pm »
 :thumleft: looking good
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Offline Laban

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Re: Building a new rig for my BMW 1200 GS Adventure
« Reply #64 on: October 20, 2015, 03:07:49 am »



....man oh man...this is nice... :thumleft:
..."sometimes the people around you won't understand your journey, they don't need to, it's not for them"...Joubert Botha

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Offline TeeJay

Re: Building a new rig for my BMW 1200 GS Adventure
« Reply #65 on: October 20, 2015, 06:53:35 am »
Is the body just made of fibreglass or do you use some carbon fibre and/or Kevlar as well? - or does that make it too expensive (and difficult to work with)?
Eat life!
 

Offline 2bfree

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Re: Building a new rig for my BMW 1200 GS Adventure
« Reply #66 on: October 20, 2015, 11:44:59 am »
Might be a stupid question, but how do you get the plug out.  ???  I know nothing about fibreglass, though practical, I don't get this out. Do you use the plug only once.
I've split it bottom and top you'll see the white gelcoat on the top and the black on the bottom, once the top is done, flip it over and do the bottom, the spit is a piece of plastic I used, you lay up onto thisthen when you flip it over you take away the plastic and put a release agent on the lip and lay up on to this, when all done crack it open and there's your top and bottom molds, bolt them together again to lay up a new sidecar body.  :thumleft:

Its an absolutely ridiculous amount of work I've discovered... but I guess somebody has to do it.  :imaposer:
 

Offline 2bfree

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Re: Building a new rig for my BMW 1200 GS Adventure
« Reply #67 on: October 20, 2015, 11:49:22 am »
Shoe. 
You are brilliant!!

Like to watch your building of your rig to the end.

Thank you for sharing it with us.

I was thinking the other day, that this will be the only option for me to go for a ride on dirt if the legs are to old to keep the heavy bike upright.
Cheers!  :thumleft: By fitting one of these you can ride forever... and they're so much fun to share your passion with others... dogs, kids, girlfriends, wives... :ricky:
 

Offline 2bfree

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Re: Building a new rig for my BMW 1200 GS Adventure
« Reply #68 on: October 20, 2015, 11:50:38 am »
Is the body just made of fibreglass or do you use some carbon fibre and/or Kevlar as well? - or does that make it too expensive (and difficult to work with)?
No, just fibreglass at this stage reinforced in the right places.
 

Offline TeeJay

Re: Building a new rig for my BMW 1200 GS Adventure
« Reply #69 on: October 20, 2015, 12:29:41 pm »
Is the body just made of fibreglass or do you use some carbon fibre and/or Kevlar as well? - or does that make it too expensive (and difficult to work with)?
No, just fibreglass at this stage reinforced in the right places.

 :thumleft:
Eat life!
 

Offline 2bfree

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Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
« Reply #70 on: November 04, 2015, 07:11:43 am »
Well... Six weeks of hard labour and finally my new body is ready!  :thumleft:

My initial attempt at building a mold onto the foam 'plug' I shaped and designed failed miserably so I started all over again and laid up my fibreglass over the thing and then broke out the foam after. I am truly amazed at the strength and weight of the final product, I reinforced the base with 5 layers of cloth and the upper half has 3 layers, breaking the foam and body filler out after setting was a real job and I had to go at chipping, grinding and hammering it out using a hammer and screwdriver smacking directly on the fibreglass... didn't even make a dent!!

Found some nice LED indicators and the marine hatch boot fits beautifully with lots of room to get in there, along with a new seat I am having made up I will be putting a fold down 3 mm aluminium backrest in that will also allow one to put larger things in and out of the boot if desired. The photos here are before I've done my final water papering on the flowcoat I put on to smooth it all out... from this I now have a professional boat builder who is going to build me a quality mold so I can make more of these bodies.
 

Online VaalBaas

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Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
« Reply #71 on: November 04, 2015, 07:35:06 am »
It is really looking good. :thumleft: Nice job

I tried the rest and still stick with the best.  -   ROOIVLEIS
2006 Hp2 - 2006 Hp2 - 2008 R1200 GSA -  2009 R1200 S - 1998 R1200 C       

2003 Yamaha 350 Banshee SE   2006 Yamaha 200 Blaster SE   TW200 Project Bike
 

Offline NeilV

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Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
« Reply #72 on: November 04, 2015, 08:34:01 am »
Really looks great, excellent job!  :thumleft:  :drif:
Love is the feeling you get when you like something as much as your motorcycle.
 

Offline stevo

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Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
« Reply #73 on: November 04, 2015, 08:34:58 am »
Looking really good..
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Offline T Rex

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Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
« Reply #74 on: November 04, 2015, 08:42:20 am »
This looks very nice  :thumleft:
 

Offline chopperpilot

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Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
« Reply #75 on: November 04, 2015, 08:46:15 am »
Light and strong! Well done!


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Offline Gérrard

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Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
« Reply #76 on: November 04, 2015, 08:56:10 am »
Its really nice and I know its hard work, but preferred the shape and ergonomics of your previous one.

Why did you change to Glass fibre ? Ease of construction, cost, weight, weight to strength, aesthetics ?
A F'ugly is a different sort of bike, the 1150 is boring and the 1100s makes me smile.

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Offline Vis Arend

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Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
« Reply #77 on: November 04, 2015, 09:02:09 am »
Its really nice and I know its hard work, but preferred the shape and ergonomics of your previous one.

Why did you change to Glass fibre ? Ease of construction, cost, weight, weight to strength, aesthetics ?

+1 
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Offline 2bfree

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Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
« Reply #78 on: November 04, 2015, 09:21:36 am »
Its really nice and I know its hard work, but preferred the shape and ergonomics of your previous one.

Why did you change to Glass fibre ? Ease of construction, cost, weight, weight to strength, aesthetics ?
Yep... for all of the above reasons.  :thumleft:
 

Offline Gérrard

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Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
« Reply #79 on: November 04, 2015, 09:28:36 am »
OK Oom Chris, kry een van die, ek wil joune hê  :lol8:
A F'ugly is a different sort of bike, the 1150 is boring and the 1100s makes me smile.

...dis nooit te laat om n happy childhood te he nie !