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.
- 46 BMW 1977 R100RS Remove, Disassemble Bodywork
- 46 BMW 1977 R100RS Repair Fairing Panels & Side Covers
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.
Windscreen Damage
Tapping Drill Bit with Plastic Hammer to Drive Center Pin Out of Windscreen Rivet
Windscreen Removed
Carefully Drilling Inside of Dash Rivet
Dash Removed From Fairing Panels
Broken Upper Fairing Bracket Steering Stem Mount
Fairing Panels Removed
Headlight Panel Badly Broken
Headlight Panel Lower Right Corner Badly Damaged
Top Left Side Panel with Large Crack
Top Left Side Panel Cracks Routed Out with Dremel Tool
Top Left Side Panel After Plast-aid Repair and Sanding
Bottom Right Side Panel Repair to Brass Insert Boss
Brass Insert Final Hole Size-5/16″
Testing Integrity of Boss & Brass Insert Repair
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.
Hi Michael,
Thank you for the kind words. I saw your bike yesterday at Don’s. Progress is being made.
Best.
Brook.
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.
Thanks for your kind reply.
I guess there’re many ways to skin a cat
The you tube clip was very Interesting
Cheers
R