Workshop Rebuild

As most of you know, BMW Airhead footpegs are typically offset to accommodate the engine layout. While it’s entirely possible to mount an adapter to the original mounting points and create a custom offset for parallel foot positioning, I decided to take a different approach.
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The newly custom CNC-machined adapters provide a parallel setup, with reasonable amount of offset while allowing the footpeg position to be rotated and adjusted across 30 different positions.
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To be fully transparent, this flat-bar adapter plate is only V1. I’ll continue developing the design to make it more visually appealing while also improving its functionality and compatibility with footpegs currently available on the market.
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There is still a fair amount of redesign and testing ahead, so the final version is still some time away.
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I’ll be going into more detail in an upcoming short video, where we can discuss design ideas, share experiences, and hopefully gather some useful feedback to make this potential product even better.
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Looking forward to sharing more of the development process with you.

Would you like to see this BMW R100GS revived in a short video series?
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This GS has been all over the world, and after countless years off the road, it might finally be time to get it running again.
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This should be a fun one! 😁🔨

Over the next few days I‘ll be CNC-machining a few custom parts for the BMW R100 motorcycle project with the Makera Z1 Pro, desktop mill.
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I’ve already started designing the first parts that will be machined into aluminum prototypes for a universal footrest adapter designed to fit BMW Airhead frames from 1969 onward.

It’ll be interesting to see how well the first prototypes fit and where the design can be further optimized for appearance, weight reduction, and overall functionality.

More to come very soon in some upcoming videos!

Note: This is not a sponsored post.

With such a clean engine layout on BMW’s air-cooled engines, there’s always been one thing that I thought looked out of place… the dangling spark plug lead! 🥲
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To maintain a minimalistic appearance of a custom BMW R100 and give the engine an even cleaner look, I’m rerouting the spark plug lead through the aluminum cooling fins of the top end.
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The simple part is drilling a hole through the cylinder, but to make the process accurate and repeatable, I designed and 3D-printed a jig based on the position I established in CAD.
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The base was printed along with two locating keys, allowing the cylinder and jig to be accurately positioned on my drilling/milling machine.
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After picking up a few reference points, the hole was drilled and the spark plug lead can now be neatly hidden within the cooling fins.
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That dangling cable is finally out of the way! Next, I’ll be modifying the cylinder head and producing a custom spark plug cap to suit the new routing.

Over the past few weeks, I’ve been working on creating a dedicated space that offers a proper office / 3D printing environment.

This controlled space will allow me to keep a closer eye on the printers while also giving me room to grow and expand the design and production side of things in the future.

I’ve been sending out a lot of parts lately, which has been keeping me busy in a good way, but it has also meant that the content creation side of things has slowed down…

Building this space from the bare bones has also been very time consuming. I wanted to make sure everything was properly planned and accounted for to create an environment that works well for both designing and manufacturing.

Even though it’s not completely finished yet, I wanted to share this step of the journey with you before more new products make their way onto the website.

The latest custom spacers I produced were shipped off to the UK, where a client is using the rear passenger footpeg mounting locations to install a set of custom rearsets. It was another cool project and a product I really enjoyed bringing to life on the desktop CNC mill.

Hopefully, there will be more to share on that soon too!

I’ve been chipping away at the BMW R100 final drive modifications, and to my surprise, I found a green PLA spool dated back to 2019 that came with the very first 3D printer I ever purchased…
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I’ve never printed anything in green before, but for some quick-and-dirty testing, it has done a surprisingly good job😄
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The output shaft still needs some refinement, and I’ll be mounting everything onto the bike for test-fit purposes, but I believe this setup is going to work.
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More details will follow as I print a custom rear wheel hub to complement the modified final drive assembly.😎🤙🏼

When relocating rearsets to your preferred position, you may choose to use existing holes or mounting points on the frame…
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The rear frame mounts, which are designed to support the silencers and subframe, also feature an additional mounting hole.
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If you mount a flat bracket or spacer directly against this surface, you may notice that the footrests shift forward as the hardware is tightened.
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The primary reason for this is the lack of support at the front and lower portion of the spacer.
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The mounting holes in the frame are stamped very close to a raised feature, which means you must either weld on a dedicated boss to support a flat spacer or design a custom-shaped spacer to suit the contour.
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The best solution depends on whether you are comfortable modifying the frame or would rather create a custom component.
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I wanted to share this as an example of how an unconventional shape can require a unique solution. I’m sure there are other approaches and modifications that could achieve the same result, and I’d be interested to see how others have solved this challenge.
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These custom spacers are now on their way to , and I hope they’ll help get his beautiful BMW R100 SP back on the road very soon!