Westwerk - CS - BMW R80 & BMW R100 - chcete legálně upravenou přestavbu?

Westwerk (Plzeň) — BMW R80 & R100 rebuilds (summary)

This summary covers a video visit to Westwerk in Plzeň (Pilsen), showing two BMW boxer rebuilds (an R80 scrambler and a larger R100/1‑liter scrambler) and other shop projects. The focus is on building attractive, functional, legally road‑worthy customs rather than static showpieces.

Build concept and style

• Owner-driven design: the customer chose a BMW boxer and wanted a scrambler / flat‑track look. Westwerk kept the bikes usable for countryside rides and everyday use.
• Hybrid of classic styling and modern components: retro appearance (retro wheels, minimal fenders, gold accessories) combined with modern brakes, electronics and quality parts.
• Distinctive, practical features:
  • Welded lattice under‑seat subframe housing lights and electrics.
  • Detachable connector for lights/license plate for showroom display or easy removal.
  • Stainless‑steel “lids” repurposed from professional kitchen cookware used as covers.
  • CNC‑milled owner logo and many custom milled parts.

Mechanical and electrical details

• Modern controls and tidy displays: Motogadget control unit and custom microswitches.
• Brake upgrades: larger modern 4‑piston calipers; wheels look retro but are new.
• Carburetor and fuel issues discovered during test rides:
  • Fuel feed problems traced to float material change (original → plastic).
  • Non‑vented tank cap caused additional fueling problems.
• Exhausts: aftermarket systems shaped like originals; at least one muffler type (referred to as ISSO?) has homologation papers.
• Many custom fasteners and small parts are made from anodized duralumin and black‑zinc for a finished look.

Build and test workflow (practical steps and advice)

1. Early consultation with the customer about style versus usability; agree on constraints (example: owner insisted on a “shovel” seat).
2. Build a functional prototype / rough assembly first.
3. Road‑test the bike unpainted to find and fix mechanical and electrical issues (carburetion, tank ventilation, wiring).
4. After testing and fixes, disassemble and perform final painting / finishing.
5. Design electricals to be removable where possible for easier servicing and inspection.
6. Use quality, homologated components where possible (turn signals, lights, mufflers). Cheaper parts (AliExpress) often fail, give poor visibility, or complicate homologation.
7. Involve the technical inspection / homologation authority early in the build to avoid rework and to secure any necessary exceptions (for example, nonstandard license plate placement).

Regulation and homologation

• Westwerk aims for each custom to be road‑legal: bikes keep license plates and undergo final testing.
• They obtain paperwork and certificates where needed. For nonstandard placements (license plate mounted on the right side), they secure exceptions through the test lab.
• Practical tip: discuss requirements with the inspector during production to avoid late changes and costly rework.

Other shop projects and culture

• Ongoing projects include:
  • A one‑liter scrambler (R100).
  • A Rickman‑framed Kawasaki racer.
  • Possible Triumph and other exotic jobs.
• Collaboration with local specialists: upholsterer, CNC shop (sekela.cz), metalworkers.
• Creative reuse of materials (example: gastro lids used as stainless covers).
• The team prefers to keep projects moving—testing and riding—instead of leaving finished bikes idle in storage.

Practical takeaways

• Prioritize functionality and homologation from the start to save time and money.
• Test bikes in rough form, identify real‑world problems, then finalize cosmetics.
• Pay for quality, homologated components for safety and to ease approval.
• Keep wiring and electrics serviceable/removable to simplify troubleshooting and inspection.

Notable locations, products, and people

• Location: Westwerk workshop, Plzeň (Pilsen), Czech Republic
• Products / suppliers mentioned:
  • Motogadget control units
  • Profi Gastro stainless lids (repurposed)
  • sekela.cz (CNC milling)
  • Aftermarket exhausts (ISSO? — discussed)
  • AliExpress parts (criticized for quality/homologation issues)
• Speakers / people:
  • Westwerk team (including Lukáš and Pepa)
  • Interviewer / host
  • Project owner “Kapi”
  • Friend / rider Michal

Key point: Build for real‑world use and legal compliance first — make it rideable, test it unpainted, fix functional issues, then finish the cosmetics.