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

1977 BMW R100RS Project: Getting Started

I picked this bike up in April 2016. Finally, on September 1, I got started on it. I had to finish up work on the 1975 R75/6 “S” update and completed that in July. I’ve put about 600 miles on that bike and its running well. You can see all the work I’ve done on the R75/6 here:

I wrote up a project page and added my build plan. You can find these here:

My goal is to complete the build by September 1, 2017 so I can ride the bike to the 40th anniversary get together in Pennsylvania later in September.

I will be posting a write-up on how I repaired the numerous cracks and broken parts on the fairing panels soon.

Here’s what I brought home, and what it looks like in the shop now.  Progress is being made.

"10 Foot" View

“10 Foot” View

"10 Foot" View

“10 Foot” View

"10 Foot" View

“10 Foot” View

10 Foot View

10 Foot View

Body Work & Wheels Removed

Body Work & Wheels Removed

1977 BMW R100RS Project

Okay, I’ve yet to achieve the first of the 12 steps for recovery: Admitting You Are Powerless Over Your Addiction. I see no problem in adding one more bike to “Brook’s Garage” inventory of BMW Airhead projects. So, I’ve acquired a 1977 BMW R100RS with about 37,300 miles. Yes, I already have the 1983 R100RS bike project, but 1977 is the first year for this innovative machine from BMW.  So, getting one has been on my “Lust List” for awhile.  Now, it’s in the last remaining storage space next to my car in our garage.

[Hey, maybe if I just sell the car I get 1/2 a garage for more bikes!!! But, I think that way lies divorce, so an even half dozen Beemer Bikes is the limit for “Brook’s Garage”.]

My intent is to complete a frame-up restoration of the bike, but when I start that, I haven’t decided yet. Right now I just began assembling the 1975 R75/6 “S” project bike and the 1983 R100RS was next in line; but that was before the 1977 came home.  I’ll see what grabs me when I get the R75/6 “S” out of the shop.

The bike is a “10 foot bike”: It looks nice from 10 feet away :-):

"10 Foot" View

“10 Foot” View

"10 Foot" View

“10 Foot” View

"10 Foot" View

“10 Foot” View

10 Foot View

10 Foot View

I’ve ridden it about 75 miles and it certainly shows the value of the 40 mm Bing carburetors and lack of EPA mandated emissions modifications compared to the 1983 R100RS.  It has dual plug heads, oil pressure and oil temperature senders and VDO gauges (not installed at present, so I’m not sure the gauges or senders still work), heated grips and is claimed to have the reinforced snowflake wheel installed.

The cosmetics need attention, and we shall see what surprises are inside in due course. Someone did invest in it at one time as evidenced by the modifications, but there are also signs of being parked and ignored as well.

Here is a slide show of some close-up photos: