DIY: BMW 650 Sertao engine crash guard

Introvert

Elder Lister
Dropping your bike is very painful.
Few things are as unsettling as a dent in a tank.
Standard solution, import OEM guards from eBay or wherever.
Kenyan solution, build own.
😁

Step 1
Get good gauge steel plate and pipe, make wire template in exact shape and take to Gikomba for bending.
WP_20150808_005.jpg


Step 2
Carefully identify mounting points, shape your flat plates and mount on frame.
WP_20150808_001.jpg


WP_20150808_018.jpg


Step 3
Do a test fit.
Use spot welds to correctly place the bars.
Check for symmetry at each stage.
Be sure to leave clear access to bits that need frequent replacement so that future maintenance can be done without having to remove the crash bars.
Also, sit on the bike to see how your knees relate to the position of the bars.
Spot welds allow you to break, reposition and align and reset.
WP_20150808_027.jpg


Once sure of the positions, unbolt entire assembly and seal all spot welds thoroughly.
WP_20150808_029.jpg


Step 4
Use a grinder to even out the weld joints, corners and edges, filler to smoothen, then prime the bars and paint.
Powdercoating is a better option for a finer and more durable finish.
Mount bars.
WP_20150809_007.jpg

WP_20150809_008.jpg

WP_20150809_012.jpg

WP_20150809_013.jpg


Step 5
Two glasses WD40, neat...and a ham and cheese.

Step 6
Abuse @Mongrel in English.
 
Very impressive @Introvert ; this is like a local version of those car overhaul shows.

On another note; a cousin had one of these monster BMW bikes and once gave me a ride down Thika Rd hadi Kahawa Sukari and back to Utalii area. The acceleration of that machine is just unbelievable; lakini I don't trust myself to ever handle such power.
 
Dropping your bike is very painful.
Few things are as unsettling as a dent in a tank.
Standard solution, import OEM guards from eBay or wherever.
Kenyan solution, build own.
😁

Step 1
Get good gauge steel plate and pipe, make wire template in exact shape and take to Gikomba for bending.
View attachment 33732

Step 2
Carefully identify mounting points, shape your flat plates and mount on frame.
View attachment 33733

View attachment 33734

Step 3
Do a test fit.
Use spot welds to correctly place the bars.
Check for symmetry at each stage.
Be sure to leave clear access to bits that need frequent replacement so that future maintenance can be done without having to remove the crash bars.
Also, sit on the bike to see how your knees relate to the position of the bars.
Spot welds allow you to break, reposition and align and reset.
View attachment 33735

Once sure of the positions, unbolt entire assembly and seal all spot welds thoroughly.
View attachment 33736

Step 4
Use a grinder to even out the weld joints, corners and edges, filler to smoothen, then prime the bars and paint.
Powdercoating is a better option for a finer and more durable finish.
Mount bars.
View attachment 33737
View attachment 33738
View attachment 33739
View attachment 33740

Step 5
Two glasses WD40, neat...and a ham and cheese.

Step 6
Abuse @Mongrel in English.
Do you powder coat mwenyewe ama una outsource the services ?
 
Dropping your bike is very painful.
Few things are as unsettling as a dent in a tank.
Standard solution, import OEM guards from eBay or wherever.
Kenyan solution, build own.
😁

Step 1
Get good gauge steel plate and pipe, make wire template in exact shape and take to Gikomba for bending.
View attachment 33732

Step 2
Carefully identify mounting points, shape your flat plates and mount on frame.
View attachment 33733

View attachment 33734

Step 3
Do a test fit.
Use spot welds to correctly place the bars.
Check for symmetry at each stage.
Be sure to leave clear access to bits that need frequent replacement so that future maintenance can be done without having to remove the crash bars.
Also, sit on the bike to see how your knees relate to the position of the bars.
Spot welds allow you to break, reposition and align and reset.
View attachment 33735

Once sure of the positions, unbolt entire assembly and seal all spot welds thoroughly.
View attachment 33736

Step 4
Use a grinder to even out the weld joints, corners and edges, filler to smoothen, then prime the bars and paint.
Powdercoating is a better option for a finer and more durable finish.
Mount bars.
View attachment 33737
View attachment 33738
View attachment 33739
View attachment 33740

Step 5
Two glasses WD40, neat...and a ham and cheese.

Step 6
Abuse @Mongrel in English.
Hii mataa inakaa funny
 
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