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Author Topic: Ever dreamed about building an HPN?- Year 1 roundup  (Read 25855 times)

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Offline airHEAD

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Ever dreamed about building an HPN?- Year 1 roundup
« on: November 21, 2009, 08:52:23 am »
Well Iíve more than dreamt about it, Iíve obsessed about it for way too long and now its actually happening! The frame has finally arrived, been powder coated and work has started on the assembly. I am really focused on getting the bike built but I am going to try and tell the story as I go along.
The frame finally arrived from HPN in Germany. This is what the customs inspector was faced with when he opened the box ???



You have to look really carefully to see the HPN modifications but for my money you donít want to be doing R&D on something like this. They have decades of experience and understand how to reinforce these frame to handle the extra stresses of running the long travel suspension.



I couldnít wait to get started but first the frame had to get prepared. I went with the power coating option rather than painting which will hopefully have better durability. This is after all a bike that once it is done I will have to ride forever  ;)

Main frame


Modified swing arm (100mm section added), main stand pannier frames and half seat rack. Identify the items and win a prize :D


Rear sub frame, rear rack and seriously lengthened side stand

« Last Edit: April 29, 2011, 07:33:33 pm by airHEAD »
 

Offline edgy

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Re: Ever dreamed about building an HPN?
« Reply #1 on: November 21, 2009, 08:54:12 am »
Awesome project.....subscibed!
www.astonesthrow.co.za

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`11 CRF 230F `12 KTM 200  BEER..."I drink it when I`m happy or when I`m sad. I drink it when I`m alone. When I have company I consider it obligatory. Trifle with it if I`m not hungry and drink it when I am. Otherwise, I never touch it - unless I`m thirsty"
 

Offline michnus

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Re: Ever dreamed about building an HPN?
« Reply #2 on: November 21, 2009, 08:59:24 am »
 :drif:  hel  ye!!

please make sure you follow this report through to the end.........or else!

 :biggrin:

Offline Brink

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Re: Ever dreamed about building an HPN?
« Reply #3 on: November 21, 2009, 09:04:21 am »
 :drif: :drif: :drif:
I know nothing but I can not prove it,,,,,
 

Offline gummikuh

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Re: Ever dreamed about building an HPN?
« Reply #4 on: November 21, 2009, 09:12:07 am »
Hi!


Yeah! Been there, tried a bike for a test ride.....ended up with a empty bankaccount and never regreted the choice  :ricky:

Don't forget to show the progress !

Werner
2 Valves are enough!
 

Offline fat b

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Re: Ever dreamed about building an HPN?
« Reply #5 on: November 21, 2009, 09:12:57 am »
SUBSCRIBED !!!! I dream of a HPN every day !!! I recently bought a old r100rs with a kickstart , that I am busy rebuilding , that motor will eventually be in my airhead gs . I am going to however make a naked bike out of the rs in the meantime and use it as a daily rider. Altus's HPN gives me wet dreams LOL !! :drif:

 THE CHALLENGE MAY NOT BE EASY , BUT IT'S NOT IMPOSSIBLE.
SO MANY PLACES, SO LITTLE TIME !

MOSSEL BAY
 

Offline BMWPE

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Re: Ever dreamed about building an HPN?
« Reply #6 on: November 21, 2009, 09:13:56 am »
Rallye
 

Offline fat b

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Re: Ever dreamed about building an HPN?
« Reply #7 on: November 21, 2009, 09:17:26 am »
Have you done any engine and gearbox mods ?? ???

 THE CHALLENGE MAY NOT BE EASY , BUT IT'S NOT IMPOSSIBLE.
SO MANY PLACES, SO LITTLE TIME !

MOSSEL BAY
 

Offline Rickus

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Re: Ever dreamed about building an HPN?
« Reply #8 on: November 21, 2009, 10:34:52 am »
awesome project......I've just watched a few youtube vid's of the HPN and now I'm jealous  :drif: good luck and keep us posted


OMVAL EN OPTEL.....
 

Offline billy-joe

Re: Ever dreamed about building an HPN?
« Reply #9 on: November 21, 2009, 11:45:53 am »
keep it coming, seems to be a dream for a lot of us on here... :thumleft:
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Offline fixit

Re: Ever dreamed about building an HPN?
« Reply #10 on: November 21, 2009, 11:53:13 am »
Woooohoooo! Subscribed :thumleft:

Question: What diff is in that bike in the background?
 

Offline zetman

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Re: Ever dreamed about building an HPN?
« Reply #11 on: November 21, 2009, 11:58:40 am »
.
Hou die Tyres op die Grondpad...
 

Offline fat b

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Re: Ever dreamed about building an HPN?
« Reply #12 on: November 21, 2009, 11:59:53 am »
Woooohoooo! Subscribed :thumleft:

Question: What diff is in that bike in the background?
Well spotted !! I'm feeling slightly sick now ... looks like the lucky bugger has two airhead g/s's ! :drif:

 THE CHALLENGE MAY NOT BE EASY , BUT IT'S NOT IMPOSSIBLE.
SO MANY PLACES, SO LITTLE TIME !

MOSSEL BAY
 

Offline Aquatic

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Re: Ever dreamed about building an HPN?
« Reply #13 on: November 21, 2009, 01:20:42 pm »
.
The conundrum that is life...
You have to be absolutely smashed to have the guts to attempt it,
But perfectly sober to achieve any success!
 

Offline Dustdevil

Re: Ever dreamed about building an HPN?
« Reply #14 on: November 21, 2009, 02:29:52 pm »
.

Aquatic you must look out for this in your neck of the woods. It recently emigrated to Brisbane and although it is not an HPN it is the most expensive restoration I have ever done on a standard G/S.



Sorry for the highjack Mike :biggrin:
« Last Edit: November 21, 2009, 02:31:39 pm by Dustdevil »
 

Offline SlŠinte Mhaith

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Offline madmike999

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Re: Ever dreamed about building an HPN?
« Reply #16 on: November 21, 2009, 02:55:43 pm »
 :happy1:
'82 R100 RS,  '98 Africa Twin,  Vespa 180 Rally
 

Offline Dustdevil

Re: Ever dreamed about building an HPN?
« Reply #17 on: November 21, 2009, 04:15:37 pm »
Woooohoooo! Subscribed :thumleft:

Question: What diff is in that bike in the background?
Well spotted !! I'm feeling slightly sick now ... looks like the lucky bugger has two airhead g/s's ! :drif:

Yes he has but that is not it. Once the HPN is done Airhead might sell the other one. Airhead is doing the work in my workshop with help from me here and there, so there will always be some other bikes hanging around in the background.
The drive you see is from an R100RS fitted to a G/S. Not an HPN but by someone who have dreamed about the rally bikes for a long time and decided to make his own. I will post some pics here but although it looks good to the eye it is an good example of how not to do it.

Airhead's G/S is the one on the left

 

Offline airHEAD

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Re: Ever dreamed about building an HPN?
« Reply #18 on: November 21, 2009, 07:50:39 pm »
Have you done any engine and gearbox mods ?? ???

I am planning a full engine rebuild, replacing the R80 barrels with the 1000cc Siebenrock upgrade kit.



This is a bit of a compromise. I would have loved to go all the way and build a 1043cc Mahle rally motor but my pockets are not that deep :( The Siebenrock conversion, if it lives up to the hype, should provide a boost in low down torque without a major increase in fuel consumption. I decided to throw in the HPN high torque cam and oil cooler with thermostat just so the bottom end is ready for the Mahle if I ever decide to go that way one day  ;)

There is lots of work still to do on the motor though. The casings have been sand blasted and then glass bead blasted, a technique Altus has developed to give  a better than new look.




The gearbox was complete this week. I am using a box that had the full G/S Workshop restoration treatment about 14000KM back. All seals and  bearings were replaced so there was no point in redoing that. What we did do is open it up to fit the longer 5th gear. I am keeping the standard GS diff which has a shorter ratio than the R100. This should give great performance in the lower gears but I wanted to drop the revs when in top gear. The one tooth difference gives about a 5% reduction in the 5th gear ratio, so 5% less revs for the same speed

Standard on the left HPN on the right


The gearbox is one of those "dont try this at home" jobs. If you want to do it properly there are a number of special tools that you need to get it all apart and  back together properly. Fortunately there isn't a special tool made by BMW that the G/S Workshop doesn't have  8)

220Nm for that nut on the output shaft  :P




 

 





Offline buzzlightyear

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Re: Ever dreamed about building an HPN?
« Reply #19 on: November 21, 2009, 08:36:36 pm »
.

Aquatic you must look out for this in your neck of the woods. It recently emigrated to Brisbane and although it is not an HPN it is the most expensive restoration I have ever done on a standard G/S.



Sorry for the highjack Mike :biggrin:

I think I've seen this bike. Did the owner work at PetroSA?
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