Maryland Airheads SuperTech 2.2

Out of the blue last November, I received an email from Maryland Air Marshal, Will Andalora, asking if I would be willing to be their special guest at the 2017 SuperTech 22.  To say the request was unexpected is an understatement. I called Will and after he assured me there was no mistake, it was me they wished to invite, he talked about his expectations and I accepted the invitation.

Will encouraged me to come out early so I could see some airhead sites before SuperTech started on Friday night. So, on Wednesday morning, I flew from my home in Colorado to Baltimore where Mark Lipschitz picked me up and took me to his home. I met the merry band of Maryland airheads who put this extravaganza of Air Head goodness together; Will Andalora, Mark Lipschitz, Bill Lambert, Jim McKinna. Also joining us was Chris Kennedy who puts on the “Techno Barn” Tech Day. They came over to Mark’s house where we enjoyed home cooked specialties of the house. By the end of the evening, I felt like family.z

Thursday was set aside to visit two museums catering to BMW motorcycles, ephemera, lore and to experience the passion of those who love collecting all things BMW Motorad and hearing the stories of how they came by the many items they had collected. The first stop was Jim Hopkin’s home. Jim has pursued photographs, clothing, pins, badges, trophies, bikes, toys, sculpture, and paintings all accompanied by fascinating accounts of his hunts around the world for this cornucopia of BMW motorcycle objects. Jim has one of the original M2B15 flat twin BMW engines supplied to the Victoria motorcycle company for use in their KR 1 motorcycle in the early 1920’s, letters, awards and trophies from racing legends, women riders and racers, and those who guided the destiny of BMW’s motorcycles.

BMW First Flat Twin Engine-M2B15 Used by Victoria in Their KR 1 Motorcycle

1920’s Race Leathers

airheaeds pre super tech
Motley Airhead Gang Poses at Jim Hopkins’ Museum for A Group Mug Shot

Here is a slide show of the pictures I took at Jim’s place.

And a short video of a neat toy BMW that reminded me of toys I played with in the 1950’s.

And a video of a distinctive sculpture Jim commissioned. The artist uses junk from automobile junk yards.

We then met Bob Henig, owner of Bob’s BMW, for lunch followed by a tour of his museum. Bob’s collection of BMW motorcycles is on two floors. I’m working on rebuilding a 1977 R100RS and he has one in his collection so I took some photos of the details I wasn’t sure about.

Bob Henig Leading the Way into His Vintage BMW Museum

Bob has an R32, several famous race bikes, iconic models and even a single wheel MV Agusta.

First BMW Bike, Model R32
1925 R32 in Front of the Iconic K1

1984 Krauser MKM 1000/4
1984 Krayser MKM 1000/4

1970 R75/5 Land Speed Record Bike
1970 BMW R75/5 Land Speed Record Bike

1950’s MV Agusta 60 cc Monomoto Superleggera
1950’s MV Agusta 60 cc Monomoto Superleggera

Here is a slide show of the pictures I took at Bob’s museum.

Friday afternoon was spent setting up for SuperTech at the Tuckahoe Steam and Gas museum including unloading all the cut-away models Bob Sipp brought and getting a guided tour of the machine tools museum. This collection goes back to the beginning of the 20th century. The tools work and many are powered by overhead shafts with belts and pulleys.

Site of SuperTech 2.2 Meeting
Tuckahoe Steam and Gas Association Facility in Maryland-Home for SuperTech 2.2

Just a Few of the Many Machine Tools in the Working Museum

Here are two short videos of the inside of the machine shop. The second shows the overhead shaft and pulley system operating.The overhead shaft and pulley system used to distribute power to the old machine tools that did not have separate electric motors. This was a common method of distributing power in factories at the end of the 19th and early 20th century.

SuperTech has a fantastic collection of cut-away models. This is just one them, a beautifully done cutaway of a Bing carburetor.

One of Three Bing Carburetor Cut-away Models Bob Sipp Brought

Friday evening starts the festivities for the 65 attendees who came from as far away as California with pizza, BYOB, lots of introductions, conversations and a short presentation about how my motorcycling life led me to start rebuilding airhead bikes in earnest in 2009 and documenting the work on my web site, “Motorcycles and Other Musings”.

Some of the Airhead State Flags From Those in Attendance
State ABC Flag Display

Friday Night Pizza & BYOB
Friday Night at the Hotel for Pizza, Beer and Comradery

The format for Saturday included technical, product and riding adventure presentations. The new Kat Dash instrument flex-boards (Kat and Paul Connell), how ethanol affects our bikes (Bill Lambert), the mental preparation for a good ride (Mike Friedle), understanding electricity and wiring systems (Bill Dudley), high mileage riding (Ed Fule), stump the expert (Tom Cutter), a seminar on the on-board toolkit, bike parts and roadside flat tire repair.(Will Andalora), bringing an R75/5 back to life (Dave Fish), details about new replacement wiring harness (Todd Millican) and the story behind the “Motorcycles and Other Musing” web site (Brook Reams). Dinner was served, BYOB was consumed and conversations broke out like daffodils after the spring thaw.

Me and Ed Fule with Our Presenter Aprons
The Author and Ed Fule Wearing Presenter Aprons and Enjoying the Spring Day

Paul and Kat Connell Making Their Presentation in Stereo
Paul and Kat Connell’s Presentation Was in “Stereo”

Dave Fish Rode This Bike To SuperTech
Dave Fish Rode his Presentation Bike to SuperTech

Sunday morning started off with a presentation by Jim Hopkins of the story behind his museum. He captured the imagination and commanded the complete attention of everyone in the room with his slides and storytelling.

Jim Hopkins Presentation on His Museum and His Passion
Jim Hopkins’ Stories Command the Rapt Attention of the SuperTech Audience

At the wrap up, the coveted Dung Beetle award was presented to our Airstore manager Dave Cushing.

Coveted Dung Beetle Award
The Coveted Dung Beetle Award

This is a slide show of pictures I took during SuperTech 2.2

1983 R100RS Repair Instrument Circuit Board Foil

One indicator bulb in the instrument housing was not lighting. I pulled the instrument cluster out and tested the bulb which was good. However the foil trace that goes on the tab inside the hole in the circuit board the bulb holder plugs into had broken.

Tab Bulb Connector Lead Touches-Copper Foil Missing

The Tab The Bulb Holder Lead Touches-Copper Foil Is Missing

I used some copper foil to make a repair and I documented how I did it here.

The same technique can be used to repair any of these boards when a cracked or broken foil trace causes intermittent or complete bulb failure bulb. But sometimes the circuit board is broken, badly corroded and it isn’t salvageable.

BMW no longer sells the circuit board but you can find used ones for sale on eBay and some are in good condition. However someone took the time and effort to design a replacement light housing and circuit board that uses LED lights instead of the original incandescent bulbs. For a badly damaged circuit board where the simple fix I made is insufficient, these replacement boards will likely do the trick. I’ve not had occasion to install one of these, but you will find information about them here:

1977 BMW R100RS Bing Type 94/40 Carburetor Rebuild-Refinish

This is the fourth set of Bing CV carburetors I’ve completely rebuilt. This is the link to the current work on the 1977 R100RS that uses the Bing 94/40 model of carburetors and specifically the 103-104 series used on the 1977 “CFO” engine version of the R100RS.

The previous rebuilds include the smaller 64/32 series used on the R75 series /5, /6 and /7, and the R90/6 bikes and the larger 94/40 series used on the later R100 model bikes. I documented the procedures of the earlier work in the following write-ups.

As is often the case, I found the o-rings were hard and brittle and in one instance I found two o-rings on the idle fuel jet! The internals were pretty clean so I someone cleaned the carburetors and for some reason added an o-ring instead of replacing it on the idle fuel jet.

I decided to shoot some short videos to demonstrate how I understand the way the Bing CV carburetors work. Each video covers one of the four major functions, or circuits, used in these carburetors. The operation of the model 64 and 94 CV carburetors is the same.

Constant Velocity Circuit Operation

Here is a short video showing how the constant velocity circuit works.

Main + Needle Jet Circuit Operation

Here is a short video showing how these components work in the main+needle jet circuit.

Enriching Circuit Operation

Here is a short video showing how the enriching circuit works.

Idle Circuit Operation

Here is a short video showing how the idle circuit works.

Here are some pictures of the completed carburetors.

Refinished Outside

Refinished Outside

Refinished Inside

Refinished Inside

Refinished Back

Refinished Back

Refinished Front

Refinished Front

Refinished Top with Added Rondel

Refinished Top with Added Rondel

1977 BMW R100RS Replace Rocker Arm Needle Bearings, Remove & Inspect Valves

When I pulled the valve covers off, I found loose needle bearings in the left valve cover when I was tearing down the top end. This is not uncommon as the bearing cage lip wasn’t wide enough on the earlier needle bearing cages and can fracture. So I replaced all the needle bearings in the heads. Each rocker has a pair of needle bearing cages so there are eight total.

I removed the valves and cleaned the heads to see what I could see. Some of the valve faces are worn down and the valve springs are sacked past the minimum. I suspect the exhaust valve seats are original so I’m planning on having new exhaust seats installed. I’ll also replace all the valve guides, springs and the valves so these heads, which are dual-plugged, should last for a long time.

Here is the link to the write-up on how I did this work.

Here are a couple of pictures from the write-up.

Left Exhaust Rocket-Bottom Rocker Needle Bearing Cage Damaged

Left Exhaust Rocket-Bottom Rocker Needle Bearing Cage Damaged

Left Exhaust Lower Rocker-Recovered Needle Bearings and Cage Pieces

Left Exhaust Lower Rocker-Recovered Needle Bearings, Some Broken, and Pieces of The Cage Lip (Tooth Pick For Scale)

Rocker Arm Bearings in Bottom of Oil Pan

Rocker Arm Bearings in Bottom of Oil Pan

Left Exhaust Top Rocker Needle Bearings-Note Gap Between Needles at Bottom Which is Normal

Left Exhaust Top Rocker Needle Bearings-Note Gap Between Needles at Bottom Which is Normal

Ready to Drive Bearing Cages Out of Rocker Arm

Ready to Drive Bearing Cages Out of Rocker Arm

Valve Spring Compressor

Valve Spring Compressor

Valve Spring Compressor Ready To Remove Valve

Valve Spring Compressor Ready To Remove Valve

Portion of Valve Face is 1 mm Thick

Portion of Valve Face is 1 mm Thick

Portion of Valve Face at 0.5 mm

Portion of Valve Face is 0.5 mm

1977 BMW R100RS Remove Pistons and Connecting Rods

I pulled the pistons and connecting rods for inspection. This write-up shows my procedure.

I found a score in one of the rod bearings and I’m going to replace the bearings. The pistons are in good condition, but this bike had the original top end replaced at some point with the later Nikasil cylinders, pistons, rings and gudgeon pin (wrist pin). Unfortunately this reduce the compression from 9.5:1 to about 8.2:1 producing less horsepower and torque. There are European versions of the pistons and rings that provide the original 9.5:1 compression. Hmmm …

Here are a few pictures & a short video or two from the write-up.

"Al-Fin" Cylinder with Steel Liner

“Al-Fin” Cylinder with Steel Liner

Nikasil Cylinder is Aluminum And Does Not Have A Steel Liner

Nikasil Cylinder is Aluminum And Does Not Have A Steel Liner

Napa 12 Point "Serrated Wrench" for Rod Bolts (part# 2305)

Napa 12 Point “Serrated Wrench” for Rod Bolts (part# 2305)

Piston Rings, Left to Right, Top, 2nd and Two Part Oil Control

Piston Rings, Left to Right, Top, 2nd and Two Part Oil Control

Score in Right Cap Bearing Shell

Score in Right Cap Bearing Shell