Frame modifications - R100 GS (paralever)

**Fuzzy Duck** · #1 27 Jan 2005

Hello

I've stripped the bike down to get the frame powder coated and have been removing some of the welded brackets as I've modified the electrics to accomodate extras for alarm, horn, twin plugs, etc so they were just in the way and I've welded on new ones where I need them.

There WAS a small plate (just below the front of the seat) that was welded between the central column (where the pump can be stored) to a side beam which the top end of the shock fits to. I had to cut into this plate, in order to fit a bracket for the HPN tank, and it was in the way - so I've removed it.

Now I'm thinking it might have been there for a structural purpose (apart from holding some electrical device like a relay) - as the forces from the shock will be pushing up against the side beam and perhaps this small plate was there to take some of the load or prevent the frame bending or twisting.

Any thoughts?

Have I been over enthusiastic with my angle grinder?

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Fuzzy Duck
(I'm quackers about bikes)

**Grant Johnson** · #2 28 Jan 2005

yep, way overzealous - I ADDED to that bracket to make it stronger. The entire thrust of the shock is on that...

Have a look at it from the shocks point of view...

and then you'll want to beef it up - lots.

**Grant Johnson** · #3 28 Jan 2005

and of course don't forget the entire rear subframe needs beefing up badly, and the front of the frame at the steering head should be gusseted... search, there's a link to pics and more here somewhere.

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Grant Johnson

Seek, and ye shall find.
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One world, Two wheels.
www.HorizonsUnlimited.com

**Mr. Ron** · #4 28 Jan 2005

Hello Fuzzy. I'm with Grant on this one, definitelt re-enforce the shock tower. I used a piece or 1" square tubing cut into somewhat of a pie shape and welded to the frame and tower creating a gusset. This will transfer energy over a larger mass. I'll e-mail you a photo or two of what i've done.
Grant, i haven't forgotten yet, my photo's of the frame and panniers are still on my to-do list

**Fuzzy Duck** · #5 28 Jan 2005

I thought so...

Thanks for the feedback, I think I'll pack it off to Ernie at Overland Solutions for a bit of strengthening.

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Fuzzy Duck
(I'm quackers about bikes)

**mavis cruet** · #6 6 Feb 2005

if youre having some welding done id double up the bits on the main frame where the subframe joins it, ie have the subframe sandwitched between two brackets on the main frame with a bolt going through all three pieces. stops the bolts being pulled at an angle. also thicken the metal round the bolt holes for the rear shock to stop them going oval.

**Fuzzy Duck** · #7 22 Feb 2005

Hi guys

In case anyone's interested here are some pics of the strengthening don to a R80G/S - but it's applicable to other airheads I suppose.

www.berettaconsulting.com/nohorizons/Powder%20coating%20&%20modifications.htm

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Fuzzy Duck
(I'm quackers about bikes)