Building a café racer called „Uschi“

[LastMohawk]

Hello,
many years ago, I fall in love with these old Goldwings, but I never thought, that I will have my own Wing  Last year we bought the wing in the Netherlands, we call it Uschi. It was a really good feeling, driving the first 300km home.
My other favorites are the café racers from the British Ton-up Boys in the 60th. So we built our Beemer few years ago as a café racer.
And this picture was taken from the tour home.

the first ride

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The painting is from the late 70th and we want to keep this cool looking. We like the seat ist an old Giuliari seat an the best, no crack or hole in the covering.
First we changed the handlebars. The new one is an Italian Tomaselli Condor M-Style.

the new handlebars

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Hey it looks like a real café racer  The clutch lever and the brake lever are from Magura.

clutch lever

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I have to remake the clutch cabel, because the old will not fit in.

brake lever

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Look, a new brake lever without the front master cylinder. I’m no friend of the front master cylinder in front of me. From my old BMW I still have the front master cylinder witch is mounted under the tank. I will mount this one. And then stainless steel braided brake hoses to the front brake caliper.
He the renewed brake caliper of the front wheel

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Greeting
Harald

[LastMohawk]

......
And the Disc too

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An awesome work was to sand the rusty spokes… but it saved much money… I think this money is better for buying gasoline for driving 
Here the rebuild front wheel. It’s a colored one

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Next we will sand the rear fender and renewed the rear light.

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The rear brake calipers looks not funny, so we have to disassemble it and clean it, and thanks for having a rebuild kit

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The rear master cylinder still have to wait for money to buy a repair kit.

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....

[LastMohawk]

.....
Next station, the cardan shaft and the rear drive (hope this ist the name)

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This week we started do strip down the frame and took off the engine

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Much work to do till the engine looks fine….

[LastMohawk]

…. And then the water pump is defect. I can move the wheel of the pump nearly 5mm from left to right and up and down… I think the bearings are damaged and I have to buy a new one

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Yes it will be a long way for the next ride….. but hey I like this job and at the end I can say: yes it’s my bike.
I’m sure, I will continue this thread till Uschi will raise again.

Greetings
Harald

[josh.wingo]

looking good! did you dissassemble the spokes on the wheel to paint them?

[wingrider]

Looks like a great project! I rebuilt my water pump...actually got it on Ebay, seem to recall that it actually came from Germany. Might save you a little money for other things.

[Roady]

Piece by piece she's coming along nicely.

[past in time tony]

Great work! Love the paint.

[sunnbobb]

Nice project.

[LastMohawk]

Thanks for answer...

@josh.wingo : no i sanded the spokes and paint them without dissassemble - because I'm not able to mount the spokes correctly

@ wingrider: thanks for the idea. I found the reseller on ebay and I hope to save a lot of money. But i could cry, this afternoon i drove throu Munic (the Town of this reseller) - not having read your answer. So i will order by post.

Next i will change the belt tensioners by using the Hyundai rollers - I've read several threads in here... The rolers are orderd, hope they will arrive this week.

Greetings
Harald

[LastMohawk]

Hello,

last saturday i spend my time in the garage . First i had to dismount the waterpump just looking if the pump is able to be rebuild - good news: yes . So i ordered the rebuild kit that wingrider told me.

Next to do was rebuilding the timing belt tensioner pulleys. The ordered Hyundai rollers arrived

Hyundai Coupe belt tensioner pulley

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first take a look that the new part will be fit - looks good
these parts are much cheaper than the Honda parts:
Honda parts for both: 195 Euros
Hyundai parts for both: 35 Euros and 5 Euros for the nuts, bolts and washers

looking for fit

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The left tensioner was cut with a small metalsaw and the right tensioner i tried to dismount by using a hammer - that was much easier.

destroyed Honda tensioners

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The headshields had do be modified 'cause the head of the stainless steel bolt is looking out the metal plate.

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Mounted with a M10 stainless steel Allen bolt and Nylon self-locking nut.

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The blue Paint ist just for fun and keeps the rust away.

Next, i hope the repairkit for the waterpump will arrive... meanwhile, my wife is cleaning the frame

greetuings
Harald

[sunnbobb]

Nice idea for the tensioners.

[Neil]

Coming along nicely .... fun to watch.

[LastMohawk]

Hello again,

i will show you the next steps i did in my garage. But "Uschi" had to wait, my wife and i were on a short Trip in Germany to a bike-meeting for the old BMW airheads.... most of them are also UnderGround and CustomiZing

Here my wife and our beemer:

my wife Sabine and our airhead BMW

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and some of the about 200 beemers at an old calste in Mid-Germany

beemers at the boxerkunst meeting

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i like this one - brown colcor for a caferacer - why not?

a cool cafe BMW

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but now back to work on the GL1000

[LastMohawk]

.... back to work

first i finished with the frame. There was a lot of rust, so i had really to sand this piece of Uschi. Than i thought, it would be nice to take a color other than the black one. So i had chosen a hammered finish dark blue. No spry, i take a paintbrush to colour it.

Look heres the result:

hammered finish blue

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and then the carbs will be renewed. They looked awful

carbs before cleaning

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With steelwool, polish an many elbow grease i think the result looks very pretty?
I replaced the bolts with some of brass and polished them, with the head of the carbs, i did the same.
Of course the interior of the carbs is more importand, and you can believe me, i took care of it.

heres is the right side of the 4th cyl carb:

carb right side

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on the head of the carbs are white plastic caps.... they look not very nice, so i mounted a crown cap of a special german beer from Cologne... looks funny now

carb left side

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hope you enjoy the building of my caferacer....

greetings
the Mohawk