Project 88- 1988 BMW R100
Project 88 begins its journey here!
Project 88 started as a sound riding platform for a proper Café Racer conversion.
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The wiring on this project was a mess to begin with. The Subframe had been chopped to accommodate a homemade seat.
Project 88 began RT model. All the wiring was in extra length for an RT Fairing and patched, spliced, taped, and tucked to accommodate new turn signals.
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All leftover emission control components were removed and a standard starter cover was used.
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The seat cowl is being measured for fit and alteration on the newly fabricated de-tabbed and reinforced subframe by TCB fabricators in Chico CA.
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It was at this point that it was decided that if we are going to do a proper conversion, that we should start from scratch by completely disassembling the bike.
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Some of the powder coated parts back from All Star Powder Coating In Rocklin, CA.
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New Bearings installed here and throughout.
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New Race installed, top and bottom.
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Greased and packed bearings installed.
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Assembly of Project 88 begins!
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Wiring loom was removed, inspected, and tested.
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Wiring harness fitted on frame for fit with all the powder coating that was done to the frame we wanted to make certain that everything fit as expected.
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Preparation for wiring the Acewell Digital/Analog Speedo and other electrical components.
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Wiring loom was then re-wrapped with Tessa Tape per factory standards.
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Confirming the wiring schematics against the BMW wiring diagram for this particular bike.
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All wires for the electrical system prepped and labeled.
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Stripping the ends of the wires.
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Properly wrapping the joined wires for a proper solder joint.
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Soldering each wire into position. No wire ties, crimped fittings were used here.
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Shrink tubing used to prevent contact of soldered joints with other wires.
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Soldered wires were cut at different points on the same harness so when the harness is wrapped no one area would bulge out of the loom.
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Temporary mock up of the rear turn signals, brake and running light before sending off bracket for powder coating.
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Permanent connections fitted to all wiring with option to remove for service. Custom length battery wires were used. Battery mounted on Boxer Metal fender eliminator kit.
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Confirming wiring control key.
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Acewell Gauge fitted to anodized Toaster Tan upper clamp by way of Boxer metal mount.
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Newly painted rear drive attached to swing arm and preload set.
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It was decided to remove the perch controls and have them powder coated too.
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Painted body parts and upholstered seat fitted to frame. Paint by www.ryansworkshop.com. Seat upholstered by Don Vigarino of Wrocket Products in Foresthill Ca.
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Artie Cathcart of TCB Fabricators in Chico, CA mocking up the new stainless mounts for the reverse megaphone mufflers. www.artiecathcart.com
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Welding the newly fabricated brackets in place.
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Mufflers and brackets complete.
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Mufflers installed as is the new header wrap and new Brown side side stand.
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Header wrap and muffler complete on both sides. At this point the bike is now complete.
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Click the picture above to read about "Dan's Story- Mango Tango"