the Generals latest visit 2017

[SCARFEY]

All good getting bits from pommy land

[Christian Raith]

FROM PETER BUTLER AT BUTLER ENGINEERING
George,
Thanks for your enquiry.
It may be possible, but there are a few risks involved.
?         I would assume that the gears are hardened. They would have to be annealed (softened) before repair. Sometimes you can get away with a hardened repair, but it usually forms cracking in the heat affected zone around the weld and fails leaving shrapnel throughout your gearbox.
?         We don?t really know what the material is which makes choosing the correct  welding consumables risky. A material analysis could be done but it is destructive and will ruin the part you are testing.
?         If we could weld it successfully, machine it back to original, and heat treat to the original hardness, it is likely the parts will distort during heat treatment. So the gearbox will not run smoothly unless the gear faces were reground. This in turn means that there will be more clearance between the gears and you will find more of a knock between acceleration and deceleration. Also finding someone in Australia to grind custom gears is hard work.
Although I understand that you may be emotionally attached to the bike, it may well be cheaper and more reliable to go and buy a new one.
Sorry I couldn?t be more help.
 
Thanks,
 
Pete Butler

What about Munich in WA, a bloke I knew a while ago got some bits from them??

[Jonesy :-)]

At least he was honest and up front with the risks, rather than doing it and taking your money....I'll give you $50 for the BM

Back to steptoe. hijack complete with no one injured

[SCARFEY]

FROM PETER BUTLER AT BUTLER ENGINEERING
George,
Thanks for your enquiry.
It may be possible, but there are a few risks involved.
?         I would assume that the gears are hardened. They would have to be annealed (softened) before repair. Sometimes you can get away with a hardened repair, but it usually forms cracking in the heat affected zone around the weld and fails leaving shrapnel throughout your gearbox.
?         We don?t really know what the material is which makes choosing the correct  welding consumables risky. A material analysis could be done but it is destructive and will ruin the part you are testing.
?         If we could weld it successfully, machine it back to original, and heat treat to the original hardness, it is likely the parts will distort during heat treatment. So the gearbox will not run smoothly unless the gear faces were reground. This in turn means that there will be more clearance between the gears and you will find more of a knock between acceleration and deceleration. Also finding someone in Australia to grind custom gears is hard work.
Although I understand that you may be emotionally attached to the bike, it may well be cheaper and more reliable to go and buy a new one.
Sorry I couldn?t be more help.
 
Thanks,
 
Pete Butler

[SCARFEY]

Thanks Jonesy.  If I come it'll be for Saturday night and I'll camp. Fair chance I'll be there. I'm collecting BMW's these days. I have two 1150 GS (one is for sale) A 1976 R100S, and a R1100RS with a busted gearbox.

[Jonesy :-)]

Ay Scarfey, how goes it? Are you coming to Wellington next year?
Any reputable engineering workshops near you?
or give Butler Engineering a call in Bathurst, they did some work on my spoke wheel hub that my little lathe couldnt handle
http://www.butlereng.com.au/

[SCARFEY]

Gentlemens I have a gearbox with worn shift dogs. Any recommendations on where I can have them built up and re-machined.  Sorry it's out of a 1995 R100RS BMW (I could use a spare box for parts if you know anyone with one)

[Jonesy :-)]

Where'd ya get ya bearings?

[excess.11]

moving along steady steady,
bearings both main and big end have been sourced and purchased from the states, {should be here d'rectly as nan used to say}
Ev came over and we re-assembled the head, turned it upside down and filled the chamber with fuel to check, and within 15 minutes we had wet ports. I said they were leaking when we pulled it apart, still leaks with a lapping session so it's at the engineering shop have seats and faces re-cut

Any chance the valves didn t end up where they came from ?

[steptoe]

Bearings are here now, I have 2 correct boxes now instead of 1 wrong one,, work will recommence on my next days off

[steptoe]

moving along steady steady,
bearings both main and big end have been sourced and purchased from the states, {should be here d'rectly as nan used to say}
Ev came over and we re-assembled the head, turned it upside down and filled the chamber with fuel to check, and within 15 minutes we had wet ports. I said they were leaking when we pulled it apart, still leaks with a lapping session so it's at the engineering shop have seats and faces re-cut

[steptoe]

that was a long time ago Makzy,  , and it's the blue ones,, still is

things have moved along quiet considerably since then,  we need to keep em going, so we gotta do it right

[makzy]

Steptoe, you and I had a very similar conversation to this years ago when I donated my old bottom end to you, I told you how difficult it was to obtain all the correct shells to get back to within tolerances. But you said nah just chuck brown ones in that’s what I did, but I wasn’t havin that because I know better, that’s why I gave it to you, no sour grapes Geoff but it’s good to see that you have been enlightened.

[steptoe]

what's been happening I hear you ask,
             I've been a little sponge soaking up all the info that has come my way via phone calls and talking to people in the know.
I call his majesty the other night to sponge more info,,

--1, yes our bikes are over engineered, that does not mean the cranks have metal to spare,
--- do not polish or linish our cranks "just because they are out", if they don't have "furry bits" leave well alone, polishing for the sake of it takes away metal for  clearances you need when replacing bearings,
--2, the colour and number codes on the crank end are for brand new fitment, 40 yrs on clearances are a little larger, so to get technical you need more replacement bearings than ordering what is in motor now, and with larger clearances a lot thicker oil should be run to compensate, {warming up the motor before launching onto the highway is a good step also} that being said OEM replacement will be fine, but if being pedantic like I am with this motor it,s not .
           I'm going to have to bite the bullet $$ wise and buy a full kit of bearings to have in shed, that way when measuring , different colours in journals I should be able to get back inside tolerances, it'll take some time and some effort but it'll be worth it at end game
 

[steptoe]

that's right Paul,  be the main reason one could assume