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Author Topic: Up and Riding! Building a new rig for my BMW 1200 GS Adventure  (Read 17332 times)

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Offline Lew

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Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
« Reply #120 on: December 08, 2015, 07:08:09 am »
Whats happening Keith?
 

Offline 2bfree

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Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
« Reply #121 on: December 08, 2015, 07:39:32 am »
Almost there Lew, almost there... ran out of funds so have had to sell a few things to get my new design chassis out from the engineers, a new swingarm system and an additional 100mm clearance cost more than I thought to develop and build as I had to scrap what I'd done and paid for previously and start all over again.

Anyways, tomorrow morning I'll be picking it up and I'll be fitting the new body and test riding it here on the dirt roads for the first time over the coming week. I'll post pics as soon as I get the chance... I can't wait, it's all looking amazing!  :thumleft:
« Last Edit: December 09, 2015, 01:58:54 am by 2bfree »
 

Online woody1

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Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
« Reply #122 on: December 09, 2015, 11:28:30 am »
What size and wall thickness square tubing are you using ?

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Offline 2bfree

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #123 on: December 10, 2015, 07:05:29 am »
Well, at long last I fitted my new chassis yesterday, bolted the body on and took her for a 50km spin on the dirt on the 7 Passes... all I can say is WOW! The additional 100 mm ground clearance makes this into a completely different machine to my previous rigs, she stands taller, (same height as a Toyota Fortuner I noticed)  feels a lot more 'nimble' and just all around it gives you the feeling of a true off road adventure vehicle... no more worries about 'middle mannetjies', large rocks and I can't wait for some heavy rains for river crossings!  :ricky:

Every 'weakness' I saw in my previous rigs I've rectified, the ground clearance, a MUCH stronger swingarm attachment with brass bushings and a grease nipple to keep it all well lubricated, a longer swingarm in the rear with a pivot point near the shock to stop the wheel leaning like a beach buggy under load, a larger gap between the tyre and the shock to stop rocks getting wedged between, a much stronger wheel hub and bearing setup, a better engineered and more easily accessible telelever rod and lean in / lean out connector set up for easier removal of the rig for solo riding... etc etc

All in all, so far I'm extremely happy with the result... the body I am still working on, now that I can actually see it fitted on the rig I can now finalise the design idea I envisaged from the beginning. I really want to move away from the Ural look, I envisage a custom built body made for serious expedition riding combined with the ability to comfortably carry a passenger... and / or doggy.  :thumleft:
« Last Edit: December 11, 2015, 07:20:56 am by 2bfree »
 

Offline ClimbingTurtle

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #124 on: December 10, 2015, 07:13:44 am »
Damn, but that is fine!!

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Offline Vis Arend

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #125 on: December 10, 2015, 07:27:44 am »
Dig your new chassis and swingarm.   :thumleft: :thumleft:

Is there a brake system for the rig in your future plans?
No matter how slow you go, you're still lapping everybody on the the couch
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Offline 2bfree

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #126 on: December 10, 2015, 07:31:41 am »
Dig your new chassis and swingarm.   :thumleft: :thumleft:

Is there a brake system for the rig in your future plans?
Absolutely Louis... it's all about time and money though right now... I have time but I've run out of money.  :imaposer:

Its just sooooooooo good to be riding a rig again!  :ricky:
« Last Edit: December 10, 2015, 07:38:00 am by 2bfree »
 

Offline Vis Arend

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #127 on: December 10, 2015, 07:42:27 am »
Dig your new chassis and swingarm.   :thumleft: :thumleft:

Is there a brake system for the rig in your future plans?
Absolutely Louis... it's all about time and money though right now though... I have time but I've run out of money.  :imaposer:

Its just sooooooooo good to be riding a rig again:ricky:

 :thumleft: :thumleft:

Know the feeling.  So glad for your sake that everything is slowly but surely getting there.  Stay positive and stick it out.   :thumleft:
No matter how slow you go, you're still lapping everybody on the the couch
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Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
« Reply #128 on: December 10, 2015, 07:45:49 am »
What size and wall thickness square tubing are you using ?

Just curious to know.

I WOULD RATHER BE AN HONEST ASSHOLE .... THAN A FLIPPEN LIAR !   


Ducati 100cc Mountaineer, Honda 550 K3, Suzuki Gs1000E, Suzuki Gs1000G, Suzuki 1100 Katana, BMW R1100RT, BMW R1150RT,,,,,All gone. Only 2014 ST in the garage at the moment... And Honda XL 600
 

Offline 2bfree

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Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
« Reply #129 on: December 10, 2015, 07:57:27 am »
What size and wall thickness square tubing are you using ?

Just curious to know.
38 mm x 3 mm
 

Online woody1

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #130 on: December 10, 2015, 08:00:44 am »
Thanks.  I thought 50 x 50 x 3 would be used for such a big rig.
Surprised it is only 38mm


I like the 3mm then you can WELD and TAP into it without problem.  :thumleft:

I WOULD RATHER BE AN HONEST ASSHOLE .... THAN A FLIPPEN LIAR !   


Ducati 100cc Mountaineer, Honda 550 K3, Suzuki Gs1000E, Suzuki Gs1000G, Suzuki 1100 Katana, BMW R1100RT, BMW R1150RT,,,,,All gone. Only 2014 ST in the garage at the moment... And Honda XL 600
 

Offline 2bfree

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #131 on: December 10, 2015, 08:09:08 am »
Thanks.  I thought 50 x 50 x 3 would be used for such a big rig.
Surprised it is only 38mm


I like the 3mm then you can WELD and TAP into it without problem.  :thumleft:
The wheel and the strong subframe takes most of the weight, the 'S' bend you see coming out from under the bike in the front to create the extra ground clearance is made from solid high tensile steel, a real piece of engineering to cut, shape, weld and 'sleeve' it into the tube.
 

Online woody1

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #132 on: December 10, 2015, 08:13:15 am »
Thanks.  As I am no engineer and does not know how strong steel construction is.
 I thought that you should put some gussets between the UPRIGHT pieces for support.
Currently it is only the weld that keep it there.  Under stress will it not break easily there.

Tried to illustrate it with this picture where I think I would like to see extra support.


I WOULD RATHER BE AN HONEST ASSHOLE .... THAN A FLIPPEN LIAR !   


Ducati 100cc Mountaineer, Honda 550 K3, Suzuki Gs1000E, Suzuki Gs1000G, Suzuki 1100 Katana, BMW R1100RT, BMW R1150RT,,,,,All gone. Only 2014 ST in the garage at the moment... And Honda XL 600
 

Offline 2bfree

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #133 on: December 10, 2015, 08:23:26 am »
Thanks.  As I am no engineer and does not know how strong steel construction is.
 I thought that you should put some gussets between the UPRIGHT pieces for support.
Currently it is only the weld that keep it there.  Under stress will it not break easily there.

Tried to illustrate it with this picture where I think I would like to see extra support.


Well spotted, The shock absorber post is certainly going to get one but I wanted to fit the body first so I know how much space I have and where to position it. The 'A' frame is not really necessary but it wouldn't hurt to brace it.
 

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #134 on: December 10, 2015, 08:34:34 am »
Thanks, Now I am happy.... happier.  :imaposer:
Where does the A- Frame top bolt onto the bike?
Does it also go through the bike or is there a mounting point on the GS frame strong enough to handle the stress ?

Sorry for all the questions.  Where did you buy those turnbuckles ? What are they called ?  Are they S/ Steel ?

Thank's

I WOULD RATHER BE AN HONEST ASSHOLE .... THAN A FLIPPEN LIAR !   


Ducati 100cc Mountaineer, Honda 550 K3, Suzuki Gs1000E, Suzuki Gs1000G, Suzuki 1100 Katana, BMW R1100RT, BMW R1150RT,,,,,All gone. Only 2014 ST in the garage at the moment... And Honda XL 600
 

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #135 on: December 10, 2015, 08:36:27 am »
Sorry man... one more.  Why did you opt for an adjustable bar on the back ?

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #136 on: December 10, 2015, 08:43:29 am »
Wait,  I think I know... Because the frame is pretty much fixed on the bike, you use this to adjust toe- in on the sidecar wheel.

Please tell me I am correct.  :imaposer:

I WOULD RATHER BE AN HONEST ASSHOLE .... THAN A FLIPPEN LIAR !   


Ducati 100cc Mountaineer, Honda 550 K3, Suzuki Gs1000E, Suzuki Gs1000G, Suzuki 1100 Katana, BMW R1100RT, BMW R1150RT,,,,,All gone. Only 2014 ST in the garage at the moment... And Honda XL 600
 

Offline 2bfree

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #137 on: December 10, 2015, 08:53:36 am »
Thanks, Now I am happy.... happier.  :imaposer:
Where does the A- Frame top bolt onto the bike?
Does it also go through the bike or is there a mounting point on the GS frame strong enough to handle the stress ?

Sorry for all the questions.  Where did you buy those turnbuckles ? What are they called ?  Are they S/ Steel ?

Thank's
In all honesty these are R 200 000 questions Woody... R 80 000 (so far) is what it just cost me to design, test and manufacture these components for this particular rig... add another R 120 000 'down the tube' for R&D and a year of testing for the previous rigs I made for guys like Louis.

The BMW telelever 'axle' I remove and replace with my own, the turnbuckles you can get from any decent bearing shop.
 

Offline stevo

Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #138 on: December 10, 2015, 09:01:33 am »
Hi Keith

I think it looks stunning. I agree with Woody on the gussets, especially the upright post for the shock, you will need to transfer some of that movement back to the frame and support the weld. Simple explanation, but you will understand the meaning.

I do have a question though, your adjustable bar on the back, this pivots in an arc as the swingarm moves... is there enough movement in the rose joints used to compensate for this? A torsion bar will do the same, but allows for movement. Otherwise the bushing in the front of the swing arm will wear quickly...

Have you used a solid insert for the wheel axle where it joins and is welded to the swingarm end?

Otherwise, I like, simple straightforward and robust.  
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Offline Mev Vis Arend

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Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
« Reply #139 on: December 10, 2015, 10:03:21 am »
Thanks, Now I am happy.... happier.  :imaposer:
Where does the A- Frame top bolt onto the bike?
Does it also go through the bike or is there a mounting point on the GS frame strong enough to handle the stress ?

Sorry for all the questions.  Where did you buy those turnbuckles ? What are they called ?  Are they S/ Steel ?

Thank's
In all honesty these are R 200 000 questions Woody... R 80 000 (so far) is what it just cost me to design, test and manufacture these components for this particular rig... add another R 120 000 'down the tube' for R&D and a year of testing for the previous rigs I made for guys like Louis.

The BMW telelever 'axle' I remove and replace with my own, the turnbuckles you can get from any decent bearing shop.

Haaibo, that Karretjie was not made for Louis.   :o I merely allow him to ride it.  :pot:   
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