1977 BMW R100RS Project: Remove & Repair Bodywork

I wrote up how I removed all the body work on this bike. I discovered a broken upper fairing bracket that was held on with only a hose clamp. There was a broken plastic boss with a threaded insert and numerous cracks and other damage to the fairing panels and side covers. I repaired all of them except for the top center panel that goes around the headlight. The damage was significant with a multitude of hairline cracks and I opted to buy a used panel rather than risk cracks showing up in the paint work after I tried to repair it.

Here are links to the write-ups.

I’m ready to start removing the forks and working my way towards the rear as I strip it down to the frame. Then I can see what other surprises are in store 🙂

Here are a couple pictures from the write-ups.

Screen Damage So I Will Replace It

Windscreen Damage

Drill Bit and Hammer Removing Center Pin of Windscreen Rivet

Tapping Drill Bit with Plastic Hammer to Drive Center Pin Out of Windscreen Rivet

Windscreen Removed

Windscreen Removed

Carefully Drilling Inside of Dash Rivet

Carefully Drilling Inside of Dash Rivet

Dash Removed From Fairing Panels

Dash Removed From Fairing Panels

Broken Upper Fairing Bracket Steering Stem Mount

Broken Upper Fairing Bracket Steering Stem Mount

Fairing Panels Removed

Fairing Panels Removed

Headlight Panel Badly Broken

Headlight Panel Badly Broken

Headlight Panel Lower Right Corner Badly Damaged

Headlight Panel Lower Right Corner Badly Damaged

Upper Side Panel with Large Crack

Top Left Side Panel with Large Crack

Top Side Panel Cracks Routed Out with Dremel Tool

Top Left Side Panel Cracks Routed Out with Dremel Tool

Top Side Panel Plast-aid Repair

Top Left Side Panel After Plast-aid Repair and Sanding

Bottom Side Panel Repair to Brass Insert Boss

Bottom Right Side Panel Repair to Brass Insert Boss

Bottom Side Panel Brass Insert Final Hole Size

Brass Insert Final Hole Size-5/16″

Bottom Side Panel Brass Insert Test

Testing Integrity of Boss & Brass Insert Repair

5 thoughts on “1977 BMW R100RS Project: Remove & Repair Bodywork

  1. Very Timely, Brook. The RT I’m working on has similar windscreen issues and you are showing me the way. I much appreciate your devotion to the Airhead Sect.

  2. Great series. Thank you very much.
    With respect to Plastic-aid Repair of the fairing I wonder as to its long term strength. Perhaps the cracks should have had heat ‘welding’ with strengthening metal clips or the application of Acetone to the inside of the of of the affected areas prior to the plastic-aid?
    Pls keep up the excellent work

    • Hi Ralph,

      Thanks for stopping by. What I learned from the inventor who I’ve talked to a number of times is it creates chemical bonds into the existing plastic as it hardens. Hence the seam is not a structural weak point as is the case with adhesives which are weak in shear. He recommends using the liquid component applied to the original plastic to promote this bonding. So I followed his advice.

      I can bend the plastic at the repair and nothing cracks. I’d say the repair is as strong as the original plastic. Here is a YouTube video made by who I believe is his UK distributor showing how strong the repair is when used on a plastic motorcycle part.

      https://www.youtube.com/watch?v=uPKtyTNydis

      Again, I have no business or financial interest in the product or company. I just use it when I need to.

      Best.
      Brook Reams.

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