got the bike
Picked up a used 1989 BMW K100. I’ve been wanting to learn how to do vacuum forming of carbon fiber by resin-infusion for some time, and thought this would be a fun project
First things first, stripping it down
Found some carbon fiber tubing on Amazon. Not strong enough to be a handlebar, but sleeved over an aluminum bar it works.
3d printed new instrument cluster. Relocated guages, and picked up a GPS speedo.
Much needed new headlight
First carbon part, starting small. I modeled and 3d printed a mold for the clutch cover and went for it.
Pulling vacuum, pretty easy on this small of a part
a little sanding and finishing, and it turned out alright
mocking up where I wanted the seat and cowl to be with cardboard before cutting the frame
bye bye frame
3d printed rear cowl which is also where I’ll hide the battery
for the seat panel, decided to just drape and cut to size. no vacuum needed here
picked up a lightweight Ballistic battery to fit under the new cowl
side cover. A bit larger, but not too bad holding a vacuum. Ended up using the original cover, and left it in there, so essentially this is just wrapped.
Now for the gas tank…
had to chase leaks around the gum tape forever. Very hard to keep vacuum on. Also the cap I used to seal off the tank volume didn’t work well. Ended up with some ripples.
cleaned up decently, but a bit rougher than I was going for. Rear cowl wrapped as well
picked up some carbon fiber looking BMW logos that matched well
Ended up going bigger on the seat than I originally planned out of comfort necessity. The smaller options I tried were unbearable for any significant distance
got the instrument cluster panel laser cut from aluminum. Also picked up a hydro-dip kit from Amazon and dipped the triple tree and gas cap
more hydro dip fun on the clutch cover. custom welded short exhaust
ended up opening the insides a bit more to clean it up. Relocated the water reservoir using a smaller bottle, and changed the air filter to come directly off of the flow meter. 3d printed adapter to relocate AFM.