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Project Cafe Racer

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Adam Arcane
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Project Cafe Racer

OTL is beginning the task of building a svelte, powerful, compelling cafe bike from an unloved, beat up and unwanted
donor R100RT. Go ahead, state your ire at people who'd ruin a great machine. Truth is, there are a plethora of these bikes out there. This one was purchased for $3K. The R100 platform will be the palette from which a custom designed and built authentic airhead cafe racer is crafted. Your input is welcome, pro and con. OTL can take any jabs, and redress them within the context at hand.
We have input from Master BMW Builder Chris Hodgson, German tech/artist/OTL correspondent Harald Sauer, and many others. We'll keep it in your face in OTL magazine until it's completed.

The donor bike graces the May OTL cover, and the mastermind and wallet behind this project is OTL Art Director, Bill Costello, famous within BMW circles world wide for his touching video on the restoration of his Dad Richard's R50.

Edited by: Adam Arcane on 2013-01-25 11:52
George Nyktas
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Will - We're looking forward to this project.

Will - Do you have a timeline?

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bill42
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Thanks Will, OTL Editor, for painting me in such an illustrious light. Let me stress as I will in the upcoming article that I am very much a novice at bike building. However I hope to make up for that fact by relying on my enthusiasm, severe optimism, and most of all, the master BMW Craftsmen I have surrounded myself with thanks to being part of the OTL staff. Since the magazine issue has not shipped yet, I don't want to divulge too much. I look forward to hearing from people, and I am expecting some controversy which I will debate with pleasure. I am passionate about motorcycles and I love to hear from others who are as well.
/bill

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BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

bill42
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Allow me to answer that, George.
The original goal was to complete this project in just a few months, but very recently I have gotten word that there is an interest in this cafe project among many of our high level BMW friends and even bike builders. If we can gather more resources and outside help as far as advice or donated parts, then maybe we will take more time than originally expected and build ourselves a much higher level machine than originally anticipated. This project could take off in directions I can't yet imagine, in just a month's time. That is what makes this such an exciting project. After the first introductory article reaches our readers, who knows who will contact me here to offer assistance or suggest a great idea or more likely, tell me what an idiot I am!

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

George Nyktas
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Bill,

This sounds like a fascinating project. A few years ago I took the front end off a perfectly good R90/6 and replaced it with an Earles Leading Link Fork since the R90 was the mule for a sidecar rig. There were all sorts of details to consider - such as finding a bearing that fit the R90 and the Earles at the same time. I was able to find help from folks a lot more knowledgeable than me that allowed me to make that conversion work. With the resources you have at hand I think you will end up with an outstanding result. Caution: Don't put a ceiling on the budget yet as you may not be able to finish without some flexibility on the upper limit. http://www.bmwra.org/forum/images/icons/icon7.png

BoxerCafe.com
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Hello Bill,
My name is Craig Schmidt, I own BoxerCafe.com . I saw your article in OTL about the cafe project and that you are looking for resources. I think I can help. You can see the parts we offer at boxercafe.com (I ran 1/2 page ads in OTL all last year). If you want to visit, my number is 479-359-2429 or you can email me at info@boxercafe.com . I have a few ideas about this subject.
Thank you,
Craig

Radar41
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Looking forward to see how and what you do with this project.

Please take lots of photo's, notes, etc., and tell us of the problems you have to overcome AND how you solve them. It would be interesting to know the REAL cost of the project.

New life for an old machine??

GO FOR IT!! Smile

Don (Radar) Wreyford

RA # 27032, ABC #7915, MOA #91738

00 K1200LTi, 98 GS, 84 R100RS, 76 R75/6

bill42
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Thanks Craig. I have checked out your parts on your site numerous times, and I certainly will email you tomorrow to hear your ideas and opinions!

/bill

BoxerCafe.com » wrote:
Hello Bill,
My name is Craig Schmidt, I own BoxerCafe.com . I saw your article in OTL about the cafe project and that you are looking for resources. I think I can help. You can see the parts we offer at boxercafe.com (I ran 1/2 page ads in OTL all last year). If you want to visit, my number is 479-359-2429 or you can email me at info@boxercafe.com . I have a few ideas about this subject.
Thank you,
Craig

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

bill42
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Thanks Don! I am making a few changes to the project based on the fact that 5000 people are now watching it being built. For instance I have pretty much decided to switch to spoke wheels instead of my original plan to powder coat the alloy wheels. So my cost is going to be higher than the bargain basement cost I had originally planned. Good idea though- I will tally up the parts and give a total at the end for the readers.Thanks!
/bill

Radar41 » wrote:
Looking forward to see how and what you do with this project.

Please take lots of photo's, notes, etc., and tell us of the problems you have to overcome AND how you solve them. It would be interesting to know the REAL cost of the project.

New life for an old machine??

GO FOR IT!! Smile

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

1bmwmc
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Having only owned 1 airhead (1981 R100S clone from a crashed RT) over many 2 wheeled years I also will be watching the progression and transformation of this BMW.

My personal preference would be to keep project on the simple/bargain basement side - I find a functional practial bike always more interesting than a collection one off exotic pieces. After all the end result

should be something to ride and not worry about getting a piece of art dirty.

By all means however good luck on your project and enjoy the process as well as the end result.

bill42
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1bmwmc » wrote:
Having only owned 1 airhead (1981 R100S clone from a crashed RT) over many 2 wheeled years I also will be watching the progression and transformation of this BMW.

My personal preference would be to keep project on the simple/bargain basement side - I find a functional practial bike always more interesting than a collection one off exotic pieces. After all the end result

should be something to ride and not worry about getting a piece of art dirty.

By all means however good luck on your project and enjoy the process as well as the end result.

I have now met quite a few people who have converted RT bikes into naked or S bikini faired airheads. That is basically what I am doing, except I am going just a bit more custom. By definition, a cafe racer was never a clean polished show bike with exotic parts. While I am seeking out parts to use that in many cases are made by small machinist companies, my first priority is that none of the parts take away from the practicality ok the motorcycle. Within the confines of the way I will ride it of course. For instance, I never have more time than a few hours to ride, so I don't require bags or racks. A backpack will suffice. The hand position will be maybe one inch lower than euro bars. I want to lean forward and low but not too much like a real racing style cafe racer. The seat that is being built is designed for airheads. Yes it will have less padding than stock but I also want to sit lower. It will have front and rear fenders for the occasional puddle. And as for worrying about getting it dirty, I am going for the urban look with a matte black paint job. The more dirt and patina, the better it will look! I already have a 1958 R50 that is restored with a new paint job. That one I worry about scratching and getting dirty. This project bike is my idea of the ultimate riding machine- it will be the way an airhead would have been sold by BMW if I was the lead designer.
Thanks for writing!

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

tlcoulter
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Attached are a couple photos of my '78 R80. It has been converted to an R100, and it has dual plugs, electronic ignition, Epco exhausts, Emgo fairing, stainless fenders from flatracer.com, modified Corbin seat, etc. It is a work in progress!

bill42
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Thanks for posting pics of your ride Tom. Bike looks sweet! We are putting the same Epco Exhaust on the OTL bike. How does it sound? I requested our exhaust to be scotch-brited or sanded by Epco and they actually charged a bit less than polished stainless for that finish. It looks like you have the Monza gas cap from Flatracer as well? ANother piece we are adding to the OTL bike. How lucky you are to already have spoke rims. We are learning that is costs a fortune to build a pair. Your bike really is beautiful. It is basically a slightly modified version of BMW's S-bike with little bits like the corbin seat and stainless fenders to make it more personalized.
Nice job and keep us posted if you make changes.

/bill

tlcoulter » wrote:
Attached are a couple photos of my '78 R80. It has been converted to an R100, and it has dual plugs, electronic ignition, Epco exhausts, Emgo fairing, stainless fenders from flatracer.com, modified Corbin seat, etc. It is a work in progress!

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

tlcoulter
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bill42 » wrote:
Thanks for posting pics of your ride Tom. Bike looks sweet! We are putting the same Epco Exhaust on the OTL bike. How does it sound? I requested our exhaust to be scotch-brited or sanded by Epco and they actually charged a bit less than polished stainless for that finish. It looks like you have the Monza gas cap from Flatracer as well? ANother piece we are adding to the OTL bike. How lucky you are to already have spoke rims. We are learning that is costs a fortune to build a pair. Your bike really is beautiful. It is basically a slightly modified version of BMW's S-bike with little bits like the corbin seat and stainless fenders to make it more personalized.
Nice job and keep us posted if you make changes.

/bill

Thanks for the compliments! The Epco exhaust is loud, but not obnoxiously loud. They pop and crack a lot, but I'm learning to like it (I'm 65, so it doesn't take much to excite me!). The bike had MAC exhausts when I got it, and they are quiet in comparison. Yes, the monza cap is from flatracer. The fenders and gas cap are both from flatracer, and they are superbly made. The fit is just spectacular.

bill42
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Ah, I had the Mac 2 into 1 exhaust too at first. It was so loud it sounded like open pipes! It is going out on ebay. Sounds like I will love the sport mufflers on the Epco exhausts. A little crackle and pop for breakfast is just what I need as I already have a gentleman's R50 that is super quiet. Can't wait to hear it but it will be a while before we fire the OTL bike up.

tlcoulter » wrote:
Thanks for the compliments! The Epco exhaust is loud, but not obnoxiously loud. They pop and crack a lot, but I'm learning to like it (I'm 65, so it doesn't take much to excite me!). The bike had MAC exhausts when I got it, and they are quiet in comparison. Yes, the monza cap is from flatracer. The fenders and gas cap are both from flatracer, and they are superbly made. The fit is just spectacular.

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

tlcoulter
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bill42 » wrote:
Ah, I had the Mac 2 into 1 exhaust too at first. It was so loud it sounded like open pipes! It is going out on ebay. Sounds like I will love the sport mufflers on the Epco exhausts. A little crackle and pop for breakfast is just what I need as I already have a gentleman's R50 that is super quiet. Can't wait to hear it but it will be a while before we fire the OTL bike up.

The MAC exhaust I had was the dual, stock-looking system. It was barely louder than stock. I have looked at their 2 into 1 systems. How much do you want for yours?

I also am interested in rear sets and lower handlebars (not necessarily clip-ons). I have heard that flatracer was developing their own rear sets, but I don't yet see them on their website. My only concern with lower handlebars is hitting the gas tank.

bill42
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My 2-into 1 MAC exhaust is in excellent shape. I repacked it myself with new fiberglass which cut out the high chatter. It was just a bit loud for the sound I am going for. One thing I liked is how light the system was.
I will sell it for the exact price I paid for it- $150 plus shipping.
I used it for 5 minutes.
The 2 best options for rear sets in my humble opinion at Boxer Metal rear sets and the ones that Flatracer are about to release which are Tarozzis with Flatracer designed linkages. The difference between the two is that the Boxer metal ones mount only a little further back than stock and the Flatracer ones will go where the rear pillion pegs are. I am not sure which are better yet as I haven't tried both, but the Boxer Metal ones are ready now and are likely cheaper. The Tarozzi Flatracer ones will look less conspicuous as they are cast and not billet machined.
I have clip-ons and they do not hit the tank. The stops set by BMW for the R100RT don't let the bars hit the tank.

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

tlcoulter
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Let me think about that. It's tempting, but I really like the look and sound of the Epco Sport exhausts. I wish you hadn't told me about Boxer Metal; I found lots of stuff I might need to purchase!!!

bill42
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tlcoulter » wrote:
Let me think about that. It's tempting, but I really like the look and sound of the Epco Sport exhausts. I wish you hadn't told me about Boxer Metal; I found lots of stuff I might need to purchase!!![/

Boxer Metal makes awesome stuff the rear set quality is unmatched. He makes a cool BMW logo cap for the triple clamp too that I have.

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

tlcoulter
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bill42 » wrote:
tlcoulter » wrote:
Let me think about that. It's tempting, but I really like the look and sound of the Epco Sport exhausts. I wish you hadn't told me about Boxer Metal; I found lots of stuff I might need to purchase!!![/

Boxer Metal makes awesome stuff the rear set quality is unmatched. He makes a cool BMW logo cap for the triple clamp too that I have.

I ordered his Air Box Eliminator Kit last night. Have you had any experience using individual air pods, rather than the air box?

bill42
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I know that it requires you to rejet your carbs so I put that off for another time.
I suggest you contact Chris from Boxer Metal on his site and ask him questions. He is extremely knowledgable with modifying airheads. Tell him Bill from OTL magazine sent you!

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

tlcoulter
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Have you decided on clip-ons. I like the look of them, but I don't want to risk banging the fuel tank. My steering stop is drilled through, so I will be able to reduce the steering movement somewhat. I also looked at Boxer Metal's flat bars. I would like to be able to use my present cables, and have new, lower bars installed easily!

bill42
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tlcoulter » wrote:
Have you decided on clip-ons. I like the look of them, but I don't want to risk banging the fuel tank. My steering stop is drilled through, so I will be able to reduce the steering movement somewhat. I also looked at Boxer Metal's flat bars. I would like to be able to use my present cables, and have new, lower bars installed easily!

Yes, I have the Tarozzi clip-ons installed. While they don't come close to banging the tank when mounted below the top tree as they are supposed to be, I am mounting mine on top of the triple tree which doesn't look as nice but it raises them up to a level that doesn't make my arms and neck hurt after 30 seconds!

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

tlcoulter
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bill42 » wrote:
Yes, I have the Tarozzi clip-ons installed. While they don't come close to banging the tank when mounted below the top tree as they are supposed to be, I am mounting mine on top of the triple tree which doesn't look as nice but it raises them up to a level that doesn't make my arms and neck hurt after 30 seconds!

Do you have any photos of them installed? Is your steering stop OEM, or does it have a bolt and nut through it to reduce the steering limits?

bill42
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tlcoulter » wrote:
Do you have any photos of them installed? Is your steering stop OEM, or does it have a bolt and nut through it to reduce the steering limits?

I have the factory R100RT stops, yes, to protect the large RT fairing.
Here is a pic of the position of the clip-ons on top of the triple tree:

Attachments: 

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

tlcoulter
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bill42 » wrote:
I have the factory R100RT stops, yes, to protect the large RT fairing.
Here is a pic of the position of the clip-ons on top of the triple tree:

That does look good, and comfortable! Thanks. Did you raise the forks through the triple tree? Did you have to adjust the cables?

tlcoulter
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What is going on now with your Cafe Racer? I put RS (flat bars) and an air box eliminator kit on mine, and I just got Flatracer.com's new rear sets to install. The tank and side panels are being painted and pin-striped, and I put yellow vinyl over my headlight. Now if only spring would hurry and get here.....

bill42
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Sorry for not posting right away. You know how life gets in the way... Well, it is safe to say you are far ahead of me. The OTL project has not been worked on much for the last few months, but now that the Holidays will be over soon, the pace will pick up once again. Our custom made seat ran into some problems when it did not sit flat on the shortened seat frame I cut down. Have you ever noticed that the seat frames bend downhill right past the shock mounts? I had not, and either had the guy who built our custom seat. The subframe and seat were shipped back to him and he was able to modify the seat so it sits flush. When the seat comes back I will finally mount the new seat and then move onto the next area. If you saw the most recent OTL issue, I ended with a teaser photo of the mounted Acewell gauge. Well that has 14 hundred wires to hood up, which I will have to figure out next. Then finally I will switch the final drive to rear drum brakes and mount the new spoked wheels. After that will be the Boxer Metal rearsets, and then we will have the finished riding position dialed in, which I am sure will be an exciting moment.

Did you rejet your carbs when you eliminated the air box? What did you do with the crankcase vent? Did you run a hose down low to eliminate blow-by? I will probably keep the airbox on while finishing the rest of the bike and then only at the end decide if it should be removed. Also, how do you like the rearsets you got from Flatracer? Are they the Tarozzi rearsets with the custom linkage that Edgar had custom manufactured?
/bill

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

tlcoulter
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I too apologize for not posting sooner! I have not rejetted the carbs, but the bike has not been started since the air box eliminator was installed. I took my gas tank and side panels in October to be painted and pinstriped, and I still have not got them back. I hope to get them before spring!

I ran the crankcase vent up through the vent slot at the top of the engine, along the upper frame, to a cannister I got on ebay. I had a heck of a time getting the hose bent enough to fit through the slot, but I was able to do it. I got a fitting to reduce the hose size to 3/8", and the cannister has a fitting that size.

I got the rear sets installed, and they look great! My feet will be back and up further than the Boxer Metal kit, so I'm anxious to see if I can get comfortable. My 65-year old body won't withstand many contortions, you know! The brake on the rear set seems to function correctly, but I am not yet sure about the shifter. With the bike stationary, on my lift, I tried shifting, and it does not seem to want to get out of neutral. However, I have a '95 K75 project bike, and when I tried shifting it, while sitting stationary, it did the same thing. I will have to get it rolling before I know for sure how it works. Yes, the rear sets are Tarozzis with Edgar's fittings. They look, and fit, superb, like all of his other stuff!

I really like the Acewell guage, and I am anxious to hear how it works out.

bill42
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I think now that I will probably eliminate the airbox as well. It is not believed to really add much power if any, but I happen to think the engine looks more raw without the plastic airbox of my R100. I will probably run a vent line to the ground rather than use a collector canister. First I have to ask around to confirm that there is no danger of oiling up my rear tire. I would love to see a photo of your rearsets installed.

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

tlcoulter
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bill42 » wrote:
I think now that I will probably eliminate the airbox as well. It is not believed to really add much power if any, but I happen to think the engine looks more raw without the plastic airbox of my R100. I will probably run a vent line to the ground rather than use a collector canister. First I have to ask around to confirm that there is no danger of oiling up my rear tire. I would love to see a photo of your rearsets installed.

I'll post some photos before the end of the week.

tlcoulter
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Here are photos of each side.

t.wesley
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Re: Project Cafe Racer

It was nice to see the culmination of the cafe racer project in the Jan/Feb '14 OTL - especially the before & after photos!  Amazing transformation.

You're bringing it to the Rally in Birmingham, right?? Smile

<p>--<br />
'05 R12GS / '98 K12RS w/Hannigan sidecar</p>

Gr8Dane
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Re: Project Cafe Racer

Awesome job. What could I possibly come up with to top this ? Nothing .... and I've built a few caf- racers myself. Back in the 70's . I'm jealous!

bill42
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Re: Project Cafe Racer

t.wesley wrote:
It was nice to see the culmination of the cafe racer project in the Jan/Feb '14 OTL - especially the before & after photos!  Amazing transformation. You're bringing it to the Rally in Birmingham, right?? Smile

 

 

 

 

Thanks and I am glad so many have enjoyed the build articles.

Unfortunately this year the Rally is just a bit too far for me to ride the bike to, I think. Last year I showed it in the Vintage Tent at the Rally so that was its debut. This year it would just be old news anyway!

 

/bill

 

 

BMWbill Costello

–1958 R50

–1981 R100RT project bike

BMW RA#39671

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