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Title: Ducati 996 engine custom build Post by: buzzer on March 03, 2019, 06:29:24 AM I know it’s not a Monster... but you guys seemed to be interested in my multi special build, so I thought I would start a new post on my next custom build, which is going to be based an ST4s http://www.ducatimonsterforum.org/index.php?topic=76771.0 So here it is as it arrived. It’s a running bike with 22k on the clock. it’s not as tidy as it looks in the pictures, the paintwork in particular lets it down. It’s a runner, but it had some electrical issues, which were easy to trace, the loom was a mess! I have now stripped off all the parts that I definitely know I won’t use, and these are being sold to fund some of the build. First little job has been to machine the top yoke and rough some clamps out so I can fit conventional handlebars, to make it easier for me to move it around, and so I can sell the originals. I am not sure yet on the style this will end up, but it needs to be reasonably easy to ride, no clip ons! I am also going to make a tank in alloy this time, and work is already underway designing and making an English wheel which I am quite excited about. I took the Multi out yesterday for its first short ride and was REALLY pleased with the way it run on the new ignition and carbs... and that got me thinking... I don't think anyone has done a 996 engine on carbs...(most will say why the hell would you!!) I like the idea! So I have sourced a pair of nice flat slide 48 mm carburettors! Watch this space! (https://jtccc.files.wordpress.com/2019/02/aadsc01491.jpg) (https://jtccc.files.wordpress.com/2019/03/46436827504_581bf7370a_o.jpg) (https://jtccc.files.wordpress.com/2019/03/46436827574_3f6e0d5fdd_o.jpg) (https://jtccc.files.wordpress.com/2019/03/33391376238_fe6f919109_o.jpg) Title: Re: Ducati 996 engine custom build Post by: Speeddog on March 03, 2019, 07:31:22 AM I used a set of HSR's on a race bike in the 90's, is that what you've got?
Title: Re: Ducati 996 engine custom build Post by: buzzer on March 03, 2019, 07:49:38 AM I used a set of HSR's on a race bike in the 90's, is that what you've got? They are off a Honda Firestorm, similar sort of power output I think Title: Re: Ducati 996 engine custom build Post by: koko64 on March 03, 2019, 12:01:23 PM So HSR48's as used on big inch HD drag racers?
Title: Re: Ducati 996 engine custom build Post by: buzzer on March 06, 2019, 01:08:53 PM I have decided to give the keihin 48mm CV flatslides a go... these are off a Honda VTR, and apparently they are some of the biggest carbs fitted to a bike... unless you know different of course! they have come up really well...
(https://jtccc.files.wordpress.com/2019/03/32360640327_5f95b7162a_o.jpg) (https://jtccc.files.wordpress.com/2019/03/47302528711_26c5d29d3d_o.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on March 06, 2019, 04:13:47 PM Yep gotcha, oem VTR1000 CV carbs, I envisaged Mikuni flatslide HSR48's. Biggest CV carbs I've heard of. Maybe S&S have a bigger drag racing carb in imperial size, but they're a straight butterfly carb.
Title: Re: Ducati 996 engine custom build Post by: buzzer on April 06, 2019, 10:59:37 AM a little bit of progress, I have made the first manifold out of plate and tube, its come out quite well... I have managed to mount the carb at the same angle it was on the Honda VFR it came off.
(https://jtccc.files.wordpress.com/2019/04/32608189397_da56a4c963_o.jpg) (https://jtccc.files.wordpress.com/2019/04/32608189377_3d1433b1ce_o.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on April 06, 2019, 11:25:31 AM It's great that you can just whip up a manifold like that. [thumbsup]
I think they're the biggest CV type carbs used on a bike iirc. You going with the VTR jetting as a baseline since it's a 1000cc, twin OHC, 4 valve V-twin, or have another setting? Title: Re: Ducati 996 engine custom build Post by: Howie on April 06, 2019, 10:11:46 PM [popcorn]
Title: Re: Ducati 996 engine custom build Post by: buzzer on April 07, 2019, 02:27:08 AM It's great that you can just whip up a manifold like that. [thumbsup] I think they're the biggest CV type carbs used on a bike iirc. You going with the VTR jetting as a baseline since it's a 1000cc, twin OHC, 4 valve V-twin, or have another setting? at first yes, I think the configuration and power output of both bikes is similar enough. we will see... Title: Re: Ducati 996 engine custom build Post by: buzzer on April 07, 2019, 11:56:34 AM I have mounted to other carb, it sits high so I had to cut a panel in the tank to clear it. I may end up making a tank for this build, but for now I will use the original to get it all running
(https://jtccc.files.wordpress.com/2019/04/manifold-1.jpg) (https://jtccc.files.wordpress.com/2019/04/tank-12.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on April 07, 2019, 03:10:02 PM [thumbsup] ;D
Title: Re: Ducati 996 engine custom build Post by: buzzer on April 11, 2019, 12:46:18 AM [thumbsup] ;D thanks, there wont be any updates to this thread until late September... I have put the bike to the back of the garage and covered it up. it was meant to be my next winter project, and I said I would not start it... but its a good time to sell off all the parts I dont need, hence the strip down. I couldn't resist a little play! so its days out, riding, and some big holidays until September! Title: Re: Ducati 996 engine custom build Post by: buzzer on August 21, 2019, 07:44:04 AM Late August and the weather is terrible… so I have made a start… for a few weeks before we go on holiday anyway no going back now as I have had the angle grinder out on the rear of the frame. I really don't want to use the ST4 tank though so I have managed to find a badly dented Ducati alternative in a breakers, which seems to fit after a bit of under tank surgery!
(https://jtccc.files.wordpress.com/2019/08/48566249052_3980bcdbfe_o.jpg) (https://jtccc.files.wordpress.com/2019/08/first-chop.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on August 21, 2019, 08:12:41 AM The way the tank exposes the rear head looks good.
Title: Re: Ducati 996 engine custom build Post by: buzzer on August 28, 2019, 12:02:26 PM I was going to try to make a tank, but I really like the 996 one i have picked up cheap... but its taking quite a bit of work to modify to fit over the carbs. I have had to cut the bottom out and fabricate a new base. some of the welding is done, and I thought it best to dye pen the joints as its easier to correct leak on the outside of a joint, rather than inside when its all welded up... good job i did as there were two leaks. Dye penetration works amazingly well as you can see.
(https://jtccc.files.wordpress.com/2019/08/48638038211_769c6fca9f_o.jpg) (https://jtccc.files.wordpress.com/2019/08/48637569442_16266b36d2_o.jpg) (https://jtccc.files.wordpress.com/2019/08/leak-detection.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on August 30, 2019, 09:05:37 AM Finished the fabrication on the bottom of the tank, all pressure tested and no leaks! I have had problems finding a fuel tap big enough... most are 8 mm but the Honda carbs require 10mm pipe, they were a thirsty beast! found one in the end... but I wont be running a reserve. Also made a couple of short bellmouths to fit under the pod filters. they were made out of tube, and spun in the lathe to bell the ends out. to do this you need to soften the alloy first by annealing it. I have struggled with this in the past as you need to get the temperature right, but if you go too far, it suddenly melts into s a blob! the answer is simple, a trick picked up from a mate... scribble on the alloy with a sharpie pen... heat until the pen marks disappear, and stop heating! then let it cool. it works a treat!
(https://jtccc.files.wordpress.com/2019/08/tank-fab.jpg) (https://jtccc.files.wordpress.com/2019/08/bell-mouths.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on September 05, 2019, 09:39:37 AM sometimes you make stuff but are not sure… this is an example. I wanted the front of the bike to be clean looking… so I made this speedometer using a cheap GPS module that will come on automatically when the ignition is on. the holes are for some warning LED’s… not sure if I will use it yet. I am aware that technically its no legal to have a GPS speedo… but…!! Whats peoples opinions on the look?
Also been practising my alloy welding with my new TIG welder to make a battery box for under the tank. (https://jtccc.files.wordpress.com/2019/09/speedo-4.jpg) (https://jtccc.files.wordpress.com/2019/09/speedo-3.jpg) (https://jtccc.files.wordpress.com/2019/09/speedo-1.jpg) (https://jtccc.files.wordpress.com/2019/09/speedo-5.jpg) (https://jtccc.files.wordpress.com/2019/09/batery-box.jpg) Title: Re: Ducati 996 engine custom build Post by: stopintime on September 05, 2019, 10:14:55 AM ... oval instead of rectangular? 8)
Title: Re: Ducati 996 engine custom build Post by: koko64 on September 05, 2019, 02:34:42 PM More tidy work.
Nice velocity stacks too. Title: Re: Ducati 996 engine custom build Post by: buzzer on September 17, 2019, 02:53:31 AM The exhausts are now fabricated, as is the seat, but I may shorten that a bit.. and I am undecided on the moto GP or the mega style of silencer, I guess I have plenty of time to decide.
The seat was made out of insulation foam, and cut and sanded to shape, which is VERY easy to do. its then covered with a few layers of glass mat and resin. I also had the headlight brackets water jet cut, they came out really well! No updates for a while as we are off on holiday for a few weeks! (https://jtccc.files.wordpress.com/2019/09/exhaust-1.jpg) (https://jtccc.files.wordpress.com/2019/09/48748027508_41b0ba50b6_k.jpg) (https://jtccc.files.wordpress.com/2019/09/48745457461_c2c5259613_k.jpg) (https://jtccc.files.wordpress.com/2019/09/48745121388_f863ed85a9_k.jpg) (https://jtccc.files.wordpress.com/2019/09/48736122872_1408608266_k.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on September 19, 2019, 07:57:18 AM I pondered how to make a coolant header tank… ended up making one from scratch! I love the TIG welder!
(https://jtccc.files.wordpress.com/2019/09/48760045167_2ee95f4f65_k.jpg) (https://jtccc.files.wordpress.com/2019/09/48760045162_bf664eac68_k.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on September 19, 2019, 09:53:56 AM Nice work on the header tank [thumbsup]
I think the mega pipe is better, cleaner style. Title: Re: Ducati 996 engine custom build Post by: buzzer on September 20, 2019, 12:49:52 AM Nice work on the header tank [thumbsup] I think the mega pipe is better, cleaner style. Thanks! yes, I am leaning towards the Mega... Sometimes it the little details that give the greatest pleasure… I needed some headlight brackets but they look terrible when you just crush the end in the vice… so I made this little tool to shape the ends. (https://jtccc.files.wordpress.com/2019/09/brracket-die.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on September 20, 2019, 02:33:30 AM Another tidy touch. [thumbsup]
Title: Re: Ducati 996 engine custom build Post by: buzzer on October 11, 2019, 10:13:38 AM I have been on holiday for a few weeks, hence no updates... Now as winter approaches I will be spending a bit more time in the garage!
For now, I have finished the GPS speedo, and think I will use it. It worked well on test in the car, and the warning LEDs are very bright. (https://jtccc.files.wordpress.com/2019/10/speedo-4.jpg) (https://jtccc.files.wordpress.com/2019/10/speedo-6.jpg) (https://jtccc.files.wordpress.com/2019/10/speedo-7.jpg) (https://jtccc.files.wordpress.com/2019/10/speedo-8.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on October 11, 2019, 03:20:01 PM Damn easier to read at speed than the stock gauge . [thumbsup]
Title: Re: Ducati 996 engine custom build Post by: buzzer on October 20, 2019, 04:22:42 AM I sat for a long time in the garage, imagining how I could make the footrests. I knew exactly where they should be as I want the riding position to be “just Right” like my other bike. one important factor was some sort of rubber mounting. the design proved to be difficult, and after mocking some up in plywood, I came to the conclusion it would actually be quite difficult. In the end I have used the footrest assemblies off a Multistarada, which combine all the attributes I wanted, with the bonus they were an easy fit! I have also braced the frame. A considered decision… so many of these bikes break their crankcases. hopefully this will prevent that.
The throttle linkage is also now done… The right throttle action can make the world of difference to how a bike rides. I bought a cheap twist grip and played around with different diameters until it felt right. I will make a replacement now to the correct dimensions. Sign the weather is getting cooler... I have moved to the other side of the garage, near the radiators! (https://jtccc.files.wordpress.com/2019/10/rh-footrest.jpg) (https://jtccc.files.wordpress.com/2019/10/lh-footrest.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on October 31, 2019, 12:55:06 PM Made a couple of items in the last few days... first I have mounted the front mudguard, made some stays out of alloy tube, complete with formed ends to make them look better, and also less prone to cracking.
Also finished off the tank plate and mounted the ignition switch. this took a while as I panel beat it out of some alloy plate into a compound curve. I made a tool to press the raised portion to add a little strength, and make it look a little better. I have mounted it with some 5mm anti vibration rubbers. Of course all will need a polish, but that all comes after the mock up stage! (https://jtccc.files.wordpress.com/2019/10/press-and-ends.jpg) (https://jtccc.files.wordpress.com/2019/10/mudgaurd-1.jpg) (https://jtccc.files.wordpress.com/2019/10/key-suround.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on November 05, 2019, 08:40:29 AM Took the frame in to my mates factory today to fully weld it… its easier on the big bench, and his gas is a 10th of the cost of my small bottle at home! I noticed the cracks on the underside of the cross over frame tubes, both sides! really glad that I braced it now. I don’t feel its the best designed frame…
(https://jtccc.files.wordpress.com/2019/11/crack-2.jpg) (https://jtccc.files.wordpress.com/2019/11/crack-4.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on November 06, 2019, 01:38:12 PM well I dye pen tested all the welds on the frame today, all OK apart from the obvious ones...
been stripping the wheels tonight, first I had problems getting the front bearings out as the inner spacer tube is a tight fit and I could not get on edge of the bearing to knock it out, ended up grinding a piece of flat with a tang on... this soon had it our. MUCH harder were the cush rubbers... I simply could not get to the back of them to get them out. I made a split collet in the end and pulled them out with a big socket! (https://jtccc.files.wordpress.com/2019/11/wheel-bearing-1.jpg) (https://jtccc.files.wordpress.com/2019/11/wheel-bearing-4.jpg) (https://jtccc.files.wordpress.com/2019/11/wheel-bearing-3.jpg) (https://jtccc.files.wordpress.com/2019/11/wheel-bearing-5.jpg) Title: Re: Ducati 996 engine custom build Post by: greenmonster on November 07, 2019, 10:25:32 AM Yep, those cush rubbers are always a PITA....
Title: Re: Ducati 996 engine custom build Post by: buzzer on November 09, 2019, 05:02:14 AM Bit of a departure from bike building just for a change... thought I would share a couple of other projects I have done recently... One bike related... a table lamp for my study made from a scrap 1000DS piston and barrel. Not bike related, a fire pit come BBQ that I made Stainless Steel. I had the dish spun out of a 750mm diameter blank of 6mm stainless 316. its an interesting process! Initially it was going to be just one grill, but my wife said she wanted a separate veggie grill... hence the two! Bonus brownie points! its been used a lot over the summer, when the BBQ is done, the grills come off, and we throw a few logs on and it becomes a fire pit!
(https://jtccc.files.wordpress.com/2019/11/lamp-1.jpg) (https://jtccc.files.wordpress.com/2019/11/lamp-3.jpg) (https://jtccc.files.wordpress.com/2019/11/lamp-4.jpg) (https://jtccc.files.wordpress.com/2019/08/123.jpg) (https://jtccc.files.wordpress.com/2019/08/123456.jpg) (https://jtccc.files.wordpress.com/2019/08/48530618101_c5ca2706fd_z.jpg) (https://jtccc.files.wordpress.com/2019/08/48530618751_f0066071ea_z.jpg) (https://jtccc.files.wordpress.com/2019/08/48544806187_5da04539e5_o.jpg) (https://jtccc.files.wordpress.com/2019/08/48544806152_1b6212c152_o.jpg) (https://jtccc.files.wordpress.com/2019/08/48552014932_e382eb6c82_o.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on November 13, 2019, 12:31:05 PM I did the tappets… pleased to say they were all in tolerance! I also took the cams out to check the rockers, they were pretty near perfect, which was a relief! Took the frame to the powder coaters… but he called me today to say there were marks on one of the frame and he was not happy to coat over them… they must have been under the original paint with filler in them! I took it back home and just touched them with a sharp drill and TIG welded them up and sanded them down. I have also Etch primed the engine ready for a coat of 2K silver tomorrow. It took a lot of hours to remove the paint. I was lucky to find 5 LTR of old stock paint stripper which should keep me going a long time. the modern stuff is next to useless. I masked the engine off, a tip i picked up when I was an apprentice in a Bentley dealership for making gaskets was to tap around the gasket material with a plastic hammer... I do the same masking off.. put the tape on and go around the edge with a small plastic hammer. you get a perfect edge! (https://jtccc.files.wordpress.com/2019/11/d10.jpg) (https://jtccc.files.wordpress.com/2019/11/d9.jpg) (https://jtccc.files.wordpress.com/2019/11/d5.jpg) (https://jtccc.files.wordpress.com/2019/11/d7.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on November 14, 2019, 07:17:01 AM the painting came out rather well! just got to put it back together now!
(https://jtccc.files.wordpress.com/2019/11/ducati-996-engine-paint-1.jpg) (https://jtccc.files.wordpress.com/2019/11/ducati-996-engine-paint-2-1.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on November 15, 2019, 11:25:31 AM I see a lot of builds spoilt by detail, and have been guilty of it myself in the past, in particular withe old plated parts... One thing I gave been meaning to do for a long time is have a go at DIY plating. Well I did some today and I have to say I am quite pleased with the results! I have used the blue passivate but there is a yellow gold one in the kit.
(https://jtccc.files.wordpress.com/2019/11/diy-plating-3.jpg) (https://jtccc.files.wordpress.com/2019/11/finished-zinc-plating.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on November 20, 2019, 01:08:02 AM Start of putting the engine back together! I know its a risk but I have decided to go open belts, I just love the look... If anyone notices the weld on the engine stand, well I am truly ashamed... I have no excuse other than i was really down on gas, and had the wrong tip in the MIG welder. A poor workman always blames his tools so they say!
(https://jtccc.files.wordpress.com/2019/11/engine-part-built-1.jpg) (https://jtccc.files.wordpress.com/2019/11/engine-part-built-2.jpg) Title: Re: Ducati 996 engine custom build Post by: Mhanis on November 21, 2019, 03:21:59 AM Shiny!
I like it!! Mark Title: Re: Ducati 996 engine custom build Post by: Duck-Stew on November 21, 2019, 06:05:01 AM Looking good!
I’m surprised that Ducati left the two bosses under the alternator cover for the carbureted ignition pickups on even the 996 engine... Title: Re: Ducati 996 engine custom build Post by: stopintime on November 21, 2019, 11:43:21 AM Looking good! I’m surprised that Ducati left the two bosses under the alternator cover for the carbureted ignition pickups on even the 996 engine... "They" didn't tell the engineers to delete them? Title: Re: Ducati 996 engine custom build Post by: Duck-Stew on November 21, 2019, 04:34:06 PM I know later engines don’t have them. Just was a bit surprised that a 996 still had the bosses cast, machined down and even drilled/tapped for the M6 studs...
Title: Re: Ducati 996 engine custom build Post by: Speeddog on November 21, 2019, 07:53:00 PM That is odd, '996 block' motors never had carbs.
Title: Re: Ducati 996 engine custom build Post by: buzzer on November 23, 2019, 06:34:15 AM the frame and wheels are back from the shot blasters... another superb job by Redditch Shotblasters! he really is a meticulous guy! he does a nice Ducati Red, and a matt gold very close to the original!
(https://jtccc.files.wordpress.com/2019/11/frame.jpg) Title: Re: Ducati 996 engine custom build Post by: stopintime on November 23, 2019, 08:49:09 AM I hate to be the one to tell you, but that's neither red or gold...
[drink] Title: Re: Ducati 996 engine custom build Post by: buzzer on November 23, 2019, 08:53:32 AM I hate to be the one to tell you, but that's neither red or gold... [drink] it was almost gold... changed my mind at the last minute [laugh] [laugh] Title: Re: Ducati 996 engine custom build Post by: koko64 on November 23, 2019, 11:09:10 AM ;D
Title: Re: Ducati 996 engine custom build Post by: buzzer on November 25, 2019, 11:22:42 AM well the engine is all back together… there wont be any updates for a while as I have to divert my attention to making a jewellery box for my wife for Christmas!
(https://jtccc.files.wordpress.com/2019/11/engine-111.jpg) (https://jtccc.files.wordpress.com/2019/11/engine-222.jpg) Title: Re: Ducati 996 engine custom build Post by: Blackout on November 25, 2019, 11:41:57 AM I wanna see that jewelry box. ;D
Title: Re: Ducati 996 engine custom build Post by: buzzer on November 29, 2019, 05:19:38 AM I wanna see that jewelry box. ;D I will post some pictures soon, its gone to be flocked at the moment [laugh] Finished off the clamps and top yoke... and gave everything a polish... Polishing is a long, dirty, and quite dangerous job! I try to do everything at once as it makes a mess in the workshop! (https://jtccc.files.wordpress.com/2019/03/33391376238_fe6f919109_o.jpg) (https://jtccc.files.wordpress.com/2019/11/top-yoke.jpg) (https://jtccc.files.wordpress.com/2019/11/polishing-finished.jpg) (https://jtccc.files.wordpress.com/2019/11/dirty-polishing.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on November 29, 2019, 09:54:11 AM ;D [thumbsup]
It's been great watching this progress. Cheers. Title: Re: Ducati 996 engine custom build Post by: buzzer on November 30, 2019, 06:34:49 AM ;D [thumbsup] It's been great watching this progress. Cheers. Thanks! its getting to the interesting bit now, putting it all together and of course the wiring... I will be making a loom from scratch, I love doing that and cant understand why people hate it so much! Engine installed in the frame! I cant think of any bike that is so simple to get the engine in the frame… I remember three of us struggling to get a Laverda 1000 lump in a freshly painted frame years ago, trying desperately not to mark the paint! (https://jtccc.files.wordpress.com/2019/11/frame-on-engine.jpg) Title: Re: Ducati 996 engine custom build Post by: Duck-Stew on November 30, 2019, 10:40:48 AM Now that I’m seeing the engine AND frame together, I really like where this is headed. Just was having a hard time seeing it before. Congrats!!
Title: Re: Ducati 996 engine custom build Post by: buzzer on December 03, 2019, 01:18:41 PM Now that I’m seeing the engine AND frame together, I really like where this is headed. Just was having a hard time seeing it before. Congrats!! Thanks! I wanted to change the colour of the rear spring from yellow to red, and tidy up the shocker… which meant getting the spring off! its no easy task as its VERY strong. I drew up a couple of plates on CAD and sent the drawing to the laser cutter… few days later these came. made it an easy and safe job! (https://jtccc.files.wordpress.com/2019/12/frame-on-engine-3-small.jpg) (https://jtccc.files.wordpress.com/2019/12/spring-2-small.jpg) (https://jtccc.files.wordpress.com/2019/12/spring-1-small.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on December 05, 2019, 05:51:19 AM well its back on its wheels... I am pleased at how the Multistrada footrest conversion has worked out, it brings the foot pegs forward quite a bit and should achieve the riding position I was looking for.
Just about to rebuild the brakes... the fronts are fine and the pistons came out easily, but the rear caliper is seized absolutely solid! I have left it connected to the air line overnight, but the pistons have not moved yet! [bang] Not sure about the gold discs on the front... they may have to be changed... we will see... (https://jtccc.files.wordpress.com/2019/12/engine-5-small.jpg) Title: Re: Ducati 996 engine custom build Post by: DarkMonster620 on December 05, 2019, 07:54:05 AM Been following here and on the book of faces . . . Sick
Title: Re: Ducati 996 engine custom build Post by: buzzer on December 07, 2019, 03:10:47 AM Been following here and on the book of faces . . . Sick yea, I cant hide now [laugh] Yesterday I rebuilt all the hydraulics. I replaced the seals on the rear caliper as this was seized solid and I had to use some penetrating oil to free the pistons. The calipers came out nice... My bead blaster now gives a really nice finish, that with a coat of ACF-50 keeps its shine. I was never happy with the finish until I picked up a tip from the guy who blasts my big bits... he said my problem was I was working at too high a pressure, and that was shattering the tiny glass beads! sure enough, I turned the pressure right down and the difference is clear! I may try an anodising kit in the future after the success of the zinc plating! Also made a wheel spacer to replace the speedo drive which I am not going to use. (https://jtccc.files.wordpress.com/2017/12/bead-blast-comparrison.jpg) (https://jtccc.files.wordpress.com/2019/12/img_0894-copy.jpg) (https://jtccc.files.wordpress.com/2019/12/img_0898-copy.jpg) (https://jtccc.files.wordpress.com/2019/12/img_0901-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: Duck-Stew on December 07, 2019, 06:36:02 AM Nice spacer. As a low-buck option, you can shatter the OE plastic with a hammer and retrieve the OE steel spacer for free. (Posted for those who may not know.)
Title: Re: Ducati 996 engine custom build Post by: buzzer on December 08, 2019, 08:56:19 AM Nice spacer. As a low-buck option, you can shatter the OE plastic with a hammer and retrieve the OE steel spacer for free. (Posted for those who may not know.) good tip... I am not that keen on alloy spacers as they tend to crush, but this was beefy enough not to worry I know its a bit old school… just like me 😁 but I love the look of a mega on a bike… plan was to make a pair but I had trouble finding anyone here who could roll a cone, so I ended up modifying a couple of cheap stainless silencers I bought off Ebay. the removable baffles will satisfy the MOT man 😂and they are now re-packable (https://jtccc.files.wordpress.com/2019/12/49187760423_b63409eb06_o-copy.jpg) (https://jtccc.files.wordpress.com/2019/12/49188453772_8005f85d5c_o-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: l88m22vette on December 08, 2019, 09:58:27 AM I just got an old but mint set of Staintune reverse cones, I really like your homemade ones, very nice! It seems like this muffler style has like 5 different names.
(https://i162.photobucket.com/albums/t279/l88m22vette/Ducati%20Monster%20750/IMG_20191027_173633_3_zpsp4lrrb89.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on December 08, 2019, 10:49:59 AM good tip... I am not that keen on alloy spacers as they tend to crush, but this was beefy enough not to worry I know its a bit old school… just like me 😁 but I love the look of a mega on a bike… plan was to make a pair but I had trouble finding anyone here who could roll a cone, so I ended up modifying a couple of cheap stainless silencers I bought off Ebay. the removable baffles will satisfy the MOT man 😂and they are now re-packable (https://jtccc.files.wordpress.com/2019/12/49187760423_b63409eb06_o-copy.jpg) (https://jtccc.files.wordpress.com/2019/12/49188453772_8005f85d5c_o-copy.jpg) Very tidy. Title: Re: Ducati 996 engine custom build Post by: koko64 on December 08, 2019, 10:50:49 AM I just got an old but mint set of Staintune reverse cones, I really like your homemade ones, very nice! It seems like this muffler style has like 5 different names. (https://i162.photobucket.com/albums/t279/l88m22vette/Ducati%20Monster%20750/IMG_20191027_173633_3_zpsp4lrrb89.jpg) Good score [thumbsup] Title: Re: Ducati 996 engine custom build Post by: buzzer on December 12, 2019, 09:15:27 AM the weather has been crap for a few days, so some garage time :D made some ends for the swinging arm as I didn't like the originals and they were marked... also made some new stainless bolts. may wheel it out the garage tomorrow
(https://jtccc.files.wordpress.com/2019/12/49209249626_f881773458_o-copy.jpg) (https://jtccc.files.wordpress.com/2019/12/49208764273_bf5f13aaf0_o-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on December 13, 2019, 06:37:04 AM Got the bike out today into the daylight for the first time in months... Have to say my Iphone takes great pictures! Next job is to start the wiring... its a job I actually love doing, making a loom from scratch. here is my collection of wire from meany years! there is some new stuff in there as well that I got from some newish cars in the vehicle dismantlers last year. Its just too expensive to buy all the colours you need new, its a great source of wire!
(https://jtccc.files.wordpress.com/2019/12/side-1-copy.jpg) (https://jtccc.files.wordpress.com/2019/12/side-2-copy.jpg) (https://jtccc.files.wordpress.com/2019/12/49212813162_a2e25d9224_o-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: stopintime on December 13, 2019, 06:58:22 AM [laugh] [laugh] [cheeky] [thumbsup]
You're different. Title: Re: Ducati 996 engine custom build Post by: buzzer on December 13, 2019, 07:06:16 AM [laugh] [laugh] [cheeky] [thumbsup] You're different. [laugh] [laugh] [laugh] [laugh] [thumbsup] Title: Re: Ducati 996 engine custom build Post by: koko64 on December 13, 2019, 12:05:21 PM Got the bike out today into the daylight for the first time in months... Have to say my Iphone takes great pictures! Next job is to start the wiring... its a job I actually love doing, making a loom from scratch. here is my collection . (https://jtccc.files.wordpress.com/2019/12/49212813162_a2e25d9224_o-copy.jpg) Whoa! :o Serlina from MIB II was banished to a shed somewhere in Britain ;D Title: Re: Ducati 996 engine custom build Post by: buzzer on December 18, 2019, 09:45:54 AM I wanna see that jewelry box. ;D Well here you go... Its finished! It started life as a writing box, my wife saw it when we were helping clear a friends mothers house, and it was going to be thrown out as it was badly damaged... But my wife liked the box so we took it... been in the loft for a couple of years, I saw it a few months ago, around the time she mentioned she would like a jewellery box... I hope she likes it! The way its been flocked makes it look and feel nice inside, and I am pleased the way the wood has come up with a few coats of 2K lacquer (https://jtccc.files.wordpress.com/2019/12/box-3.jpg) (https://jtccc.files.wordpress.com/2019/12/box-1.jpg) (https://jtccc.files.wordpress.com/2019/12/box-4.jpg) (https://jtccc.files.wordpress.com/2019/12/box-6.jpg) (https://jtccc.files.wordpress.com/2019/12/box-7.jpg) (https://jtccc.files.wordpress.com/2019/12/box-8.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on December 18, 2019, 11:09:17 AM Handy [thumbsup]
Title: Re: Ducati 996 engine custom build Post by: buzzer on December 21, 2019, 06:20:45 AM I have been pondering how to switch the radiator fan on and off as I am no longer running with an ECU... I popped around to my mate yesterday and he suggested using one of these units which is adjustable for temperature. he uses them on factory machinery. I have put the thermocouple in the original sensor (snug fit, but used some heat sink Grease used on computer CPU's) and some Araldite to hold it in place. Its 12V, you can adjust the temperature and it has a 20 amp relay on the board which is more than enough for the fan... tested it today in some boiling water and it works well! The unit is very cheap at around £5!
Also made a good start on the wiring.. I know a lot of people struggle with this but I find it easy, enjoyable and quite therapeutic! Sad I know! I start by making a drawing of each circuit on a page, and wire that circuit on the bike. As I go along I write the wire colours on the diagram for future reference. Use pipe cleaners to hold the wire bundles together till all the circuits are in place. then run them through sheathing , and then crimp/solder the ends on! (https://jtccc.files.wordpress.com/2019/12/sence-2.jpg) (https://jtccc.files.wordpress.com/2019/12/sense-1.jpg) (https://jtccc.files.wordpress.com/2019/12/fan-wire.jpg) (https://jtccc.files.wordpress.com/2019/12/wire-3.jpg) Title: Re: Ducati 996 engine custom build Post by: Speeddog on December 21, 2019, 07:28:40 AM Who makes that fan control widget?
Title: Re: Ducati 996 engine custom build Post by: buzzer on December 21, 2019, 10:26:31 AM Who makes that fan control widget? here it is... my mate uses a lot of these and says they are quite reliable... https://www.ebay.co.uk/itm/Temperature-Control-Digital-LED-Thermostat-Relay-Switch-12V-DC-With-Sensor/232987888186 Title: Re: Ducati 996 engine custom build Post by: Speeddog on December 21, 2019, 10:56:37 AM here it is... my mate uses a lot of these and says they are quite reliable... https://www.ebay.co.uk/itm/Temperature-Control-Digital-LED-Thermostat-Relay-Switch-12V-DC-With-Sensor/232987888186 Thanks! [beer] Title: Re: Ducati 996 engine custom build Post by: buzzer on December 31, 2019, 02:38:33 AM The wiring is coming on well, just a couple of minor circuits to do. I like this fuse box. one lead in, and all the fuses come off that, and it has a single earth point as well. All the ends are crimped and soldered… and covered with the glue lined heat shrink. When its finally done I can tidy it up and tape the joints with self amalgamating tape. As I had changed the location of the coils I needed custom leads, cheap and easy job. That crimp tool has not seen much use since the 70’s though, when it was used all the time! I had better get some resistor plugs as there is not much in the leads!
Also finished the throttle cable. I wanted to make the bracket slightly adjustable, so I made the mounting eccentric. couldn’t be bothered to change the chuck! (https://jtccc.files.wordpress.com/2019/12/leads.jpg) (https://jtccc.files.wordpress.com/2019/12/wiring-1.jpg) (https://jtccc.files.wordpress.com/2019/12/throttle-1.jpg) (https://jtccc.files.wordpress.com/2019/12/ofset.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on December 31, 2019, 02:50:02 AM [thumbsup]
Happy NY Title: Re: Ducati 996 engine custom build Post by: buzzer on January 14, 2020, 11:42:33 AM [thumbsup] Happy NY and the same to you! Not much progress of late... I came down with the flu, and its knocked me sideways... getting there now though.... here is a 15 second clip of the throttle linkage https://youtu.be/GdabgnFPGMs Title: Re: Ducati 996 engine custom build Post by: Duck-Stew on January 14, 2020, 11:48:17 AM Smooth!
Title: Re: Ducati 996 engine custom build Post by: dbran1949 on January 16, 2020, 04:31:01 PM The wiring is coming on well, just a couple of minor circuits to do. I like this fuse box. one lead in, and all the fuses come off that, and it has a single earth point as well. All the ends are crimped and soldered… and covered with the glue lined heat shrink. When its finally done I can tidy it up and tape the joints with self amalgamating tape. As I had changed the location of the coils I needed custom leads, cheap and easy job. That crimp tool has not seen much use since the 70’s though, when it was used all the time! I had better get some resistor plugs as there is not much in the leads! Where did you get the fuse blockAlso finished the throttle cable. I wanted to make the bracket slightly adjustable, so I made the mounting eccentric. couldn’t be bothered to change the chuck! Title: Re: Ducati 996 engine custom build Post by: buzzer on January 17, 2020, 06:33:19 AM Where did you get the fuse block Off Ebay, quite cheap and good quality! https://www.ebay.co.uk/itm/6-Way-Blade-Fuse-Box-Bus-Boat-Car-With-Cover-Marine-Fuse-Box-Holder-12V-32V-New/153570881372?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908131621%26meid%3D933ad579e4a6429eb699bc7347374dba%26pid%3D100678%26rk%3D1%26rkt%3D5%26mehot%3Dpp%26sd%3D153570881372%26itm%3D153570881372%26pmt%3D1%26noa%3D1%26pg%3D2380057&_trksid=p2380057.c100678.m3607&_trkparms=pageci%3A2ece4af5-3936-11ea-b813-74dbd180990e%7Cparentrq%3Ab3eb661a16f0a4d2523f4189ff7d2130%7Ciid%3A1 Title: Re: Ducati 996 engine custom build Post by: buzzer on January 22, 2020, 01:17:12 PM spent a couple of yours in the garage today... still getting over the flu, so I have not been in there long... but long enough to get it started! It actually fired up almost straight away, which I was pleased about. at first I didn't have a spark though.... Seems the kill switch now works backwards. it will be a good anti theft! here its is running for just a few seconds, as there is no water in it yet...
https://www.youtube.com/watch?v=HU0TSbZg13g Title: Re: Ducati 996 engine custom build Post by: buzzer on January 26, 2020, 06:02:22 AM another short video! there is water in it now so I got it warm...
https://www.youtube.com/watch?v=t_zGWiIyVQs Title: Re: Ducati 996 engine custom build Post by: Duck-Stew on January 26, 2020, 06:13:15 AM Looks great. Sounds even better! You’ve got to be excited...
Title: Re: Ducati 996 engine custom build Post by: Speeddog on January 26, 2020, 08:47:57 AM Excellent progress!
I'm likin that castered rearstand. Title: Re: Ducati 996 engine custom build Post by: buzzer on January 27, 2020, 06:28:12 AM Excellent progress! I'm likin that castered rearstand. yes, its really useful to be able to move the bike around the garage... just dont look at the welding! For Christmas this year my best mate bought me a new MIG welder as he was so disgusted at the standard of my MIG welding wih the old welder I had [laugh] [laugh] Looks great. Sounds even better! You’ve got to be excited... yes, its always exciting when they start up... not been doing much lately though, still recovering from the flu, and with that and a big holiday coming up I am behind plan somewhat... still achievable though I think for the of 1st April Title: Re: Ducati 996 engine custom build Post by: koko64 on January 27, 2020, 07:19:55 AM Great work and here's to a full recovery.
Title: Re: Ducati 996 engine custom build Post by: Speeddog on January 27, 2020, 08:01:21 AM Tell him a real friend would have bought you a TIG. ;D
Title: Re: Ducati 996 engine custom build Post by: greenmonster on January 28, 2020, 11:25:53 AM It started with original Honda jetting and the 1000DS ignition map?
Title: Re: Ducati 996 engine custom build Post by: buzzer on January 29, 2020, 04:14:40 AM It started with original Honda jetting and the 1000DS ignition map? well Its the standard honda jets, enough to get it running... the ignitech software is different for this unit, so I just created a new map, with a bit less full advance for now. what I really need is a map from a standard ECU... if you know anyone? Title: Re: Ducati 996 engine custom build Post by: Speeddog on January 29, 2020, 08:29:13 AM ~~~SNIP~~~ what I really need is a map from a standard ECU... if you know anyone? An ignition map for an St4s? Title: Re: Ducati 996 engine custom build Post by: buzzer on January 29, 2020, 11:13:16 AM An ignition map for an St4s? yes, just a standard map, would love to take a look. I thought I had one, but I cant find it! Title: Re: Ducati 996 engine custom build Post by: Speeddog on January 29, 2020, 01:08:30 PM This is for an ST4, I've got no ST4s files.
I've no idea why it has a fully functional map all the way up to 14k rpm. Honestly, I think it's not a good idea to go that far, if you botch the rev limiter setting It'll willingly free rev up til it breaks. There's some oddness in the low rpm low throttle range, not sure what's going on there. (https://live.staticflickr.com/65535/49460684818_4f4e3f7a64_c.jpg) (https://flic.kr/p/2imEWpU) (https://live.staticflickr.com/65535/49461164256_888212ba1d_c.jpg) (https://flic.kr/p/2imHoW5) (https://live.staticflickr.com/65535/49461199836_cf36c1ba5f_c.jpg) (https://flic.kr/p/2imHzvw) Title: Re: Ducati 996 engine custom build Post by: buzzer on January 30, 2020, 03:32:38 AM thanks! brilliant, its not far off the multistrada map I have... I may ask on the other forums if anyone has a specific 996 map
Title: Re: Ducati 996 engine custom build Post by: buzzer on January 30, 2020, 12:03:21 PM Spent a couple of hours making a chain guard today… should keep the MOT man happy. He follows my builds, and sometimes messages me to say he will fail it!
(https://jtccc.files.wordpress.com/2020/01/chain-small.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on January 30, 2020, 03:04:10 PM [laugh] How's that for MOT feedback.
That motor looks beautiful. Title: Re: Ducati 996 engine custom build Post by: buzzer on February 01, 2020, 11:22:10 AM well thanks to a member on the Ducati Custom manufactures group mentioning a case saver, I have now made one out of stainless steel and put it under the chain guard I have made. a bit of googling suggests that chain breakages, and subsequent case damage is all too common on some Ducati bikes! Plenty of case savers on the market and quite cheap, and a dam site cheaper than new cases!
Also made a start on the tank and seat... my wife is moaning about filler dust on her plants!! A trick I learned many years ago is that when you want to get filler to shape, make sharp edges so you can see the lines, then when you are satisfied they are right, sand them off! its much easier that way. its the best way to get something like a car wheel arch spot on… I know the seat will divide opinion… I could have made it any shape, and played around with quite a few shapes at the foam stage… but in the end I decided on this on, as I like it, and that’s all that matters at the end of the day, I build bikes for me! (https://jtccc.files.wordpress.com/2020/02/chain-3-copy.jpg) (https://jtccc.files.wordpress.com/2020/02/seat-1-copy.jpg) (https://jtccc.files.wordpress.com/2020/02/seat-3-copy.jpg) (https://jtccc.files.wordpress.com/2020/02/tank-2-copy.jpg) (https://jtccc.files.wordpress.com/2020/02/tank-1-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on February 01, 2020, 11:31:00 AM As the song says," can't please everyone, gotta please yourself" [thumbsup]
Title: Re: Ducati 996 engine custom build Post by: Duck-Stew on February 02, 2020, 06:52:40 AM I’m joining the “I like it” camp. [thumbsup]
Title: Re: Ducati 996 engine custom build Post by: buzzer on February 06, 2020, 01:52:57 AM Well here it is in primer... just got to decide on colour now... I have plenty of time to think about it, this will be the last update for a while... I am being kidnapped and sent to a tiny (and I mean tiny!) island where there are no cars, bikes, transport, just beaches... and sun... and no internet. Quite frankly, I don't know how I am going to cope [roll]
(https://jtccc.files.wordpress.com/2020/02/primer-small.jpg) Title: Re: Ducati 996 engine custom build Post by: Duck-Stew on February 06, 2020, 02:51:03 AM [drool]
[popcorn] Enjoy the R&R!!! Title: Re: Ducati 996 engine custom build Post by: koko64 on February 06, 2020, 03:06:57 AM Yes the incarcera.. I mean R & R. ;D
How about a hi gloss black? Title: Re: Ducati 996 engine custom build Post by: buzzer on February 09, 2020, 03:55:23 AM squeezed a bit of time in the garage before we go!
Here is the seat being made… I have used closed cell EFP30 foam, which is firm, but has the advantage that it can be sanded to shape. it will be covered with some 6mm foam and trimmed. Trimming is one of the jobs I cant do at home! (https://jtccc.files.wordpress.com/2020/02/seat-small.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on February 26, 2020, 01:33:38 AM Back from Holiday... to cold, wet and rain...
well its that time of indecision.... i have Photoshoped on other colours, but its either red or orange... I have to decide by tomorrow as I want to get the paint... (https://jtccc.files.wordpress.com/2020/02/49585003472_90971d2f36_o-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on February 26, 2020, 02:13:21 AM Red. Still think gloss black would look sharp. Actually, yellow would look wild. If you go orange, go real deep Charger orange and paint the shock spring jet black.
Title: Re: Ducati 996 engine custom build Post by: Orange16 on February 26, 2020, 02:14:35 AM I'd always say orange. Front disc centres, pressure plate and rear spring in black?
Add black or silver into the orange somehow as highlights? Title: Re: Ducati 996 engine custom build Post by: stopintime on February 26, 2020, 03:34:00 AM Orange.
I'll tell you why I think so ;) The tank + seat section looks quite long and the headlight + handle bar section is quite forward and high. Both features are less obvious and blend better with orange. Title: Re: Ducati 996 engine custom build Post by: buzzer on February 27, 2020, 04:13:21 AM Well sorry to disappoint you guys that said Red... its going to be orange!
The seat is back from the trimmer, and as usual its a perfect job, Karen at Aldridge trimming is simply fantastic! (https://jtccc.files.wordpress.com/2020/02/49591426411_609a22d2e1_o-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on February 27, 2020, 04:40:29 AM Karen's good.
With orange fit a black clutch cover and also paint the shock spring black IMO . Consider the outlawish Charger orange colour. ;D Title: Re: Ducati 996 engine custom build Post by: buzzer on February 27, 2020, 08:13:50 AM here is the first coat of lacquer… For 40 years I used my trusty Binks Bullows 230 but it was starting to give problems… I tried several guns off Ebay, but despite the Binks problems always went back to it… then a few years ago I bought a cheap (£20) gun off amazon… it had great reviews, and sure enough its brilliant! this is the gloss straight from the gun!
(https://jtccc.files.wordpress.com/2020/02/49592196951_1c7daf403b_o-copy.jpg) (https://jtccc.files.wordpress.com/2020/02/49592196966_96970e6781_o-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on February 27, 2020, 08:58:25 AM The glossy depth gives it the look of a modern art installation. [thumbsup]. A mate has 900 Supersport fairings hanging in his lounge room.
Title: Re: Ducati 996 engine custom build Post by: buzzer on February 28, 2020, 10:41:21 AM And the final coat.... my heart is always in my mouth when painting over decals... I have found by experience you MUST wipe them over with panel wipe, and make sure the first coat of lacquer is a mist coat which then has to tack off... then a couple of coats on top. if you go with a full coat first you always get runs off the lip on each letter! I will let them dry fully in the drying oven... OK, the small bathroom as that is the hottest room in the house!
(https://jtccc.files.wordpress.com/2020/02/49596514347_40c3b75bfa_o-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on February 28, 2020, 12:11:47 PM Excellent model designation [clap]
Title: Re: Ducati 996 engine custom build Post by: buzzer on March 06, 2020, 09:33:11 AM out in the sunshine... people are saying I have an obsession with Orange!
Clutch cover is now on... tank plate now finished.... lost an entire day as I could not get the TPS voltage to register on the ignition... turns out that I had the TPS load in pin 9 and it should have been pin 6.... wrong way up! its registering voltage readings now so next few days I will post a video (https://jtccc.files.wordpress.com/2020/03/49626771776_8f599fafd9_o-copy.jpg) (https://jtccc.files.wordpress.com/2020/03/49626761278_44f1ec797f_o-copy.jpg) (https://jtccc.files.wordpress.com/2020/03/49627550962_eedd186c4d_o-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on March 06, 2020, 09:51:46 AM Very nice. Congratulations.
Title: Re: Ducati 996 engine custom build Post by: Pinion on March 06, 2020, 10:38:25 AM Very cool
Title: Re: Ducati 996 engine custom build Post by: Howie on March 06, 2020, 10:41:39 AM Great work!
Title: Re: Ducati 996 engine custom build Post by: Duck-Stew on March 06, 2020, 03:55:55 PM I like the plate in front of the tank. Very nice
Title: Re: Ducati 996 engine custom build Post by: buzzer on March 07, 2020, 12:00:59 AM I like the plate in front of the tank. Very nice Thanks! It took a while to make... i used a sand bag to planish it into shape, and a press tool to make the raise for the ignition switch... working with alloy makes me want to make a tank! Title: Re: Ducati 996 engine custom build Post by: buzzer on March 18, 2020, 09:48:38 AM Question... is bike building a form of self isolation?
As I am going to leave the belts open I thought it best to at least have a token grill to stop big stones flicking up… particularly off the front wheel. Its still a risk I know… I made this grill out of Stainless steel mesh, and 6mm stainless tube. I needed to cut a slot in the tube to make it neat, so I made a jig and used a 0.9mm cutting disk. it worked rather well! just got to polish it now. Also fitted new belts... I have used the app on my phone before for tensioning and its very good. takes any guesswork out of it. after fitting the belt on the horizontal cylinder I tensioned it using the app… and on the vertical cylinder I tensioned it to the good old trusted method of twisting it 90 degrees on the longest run to what years of experience told me felt right… when I checked it I was VERY close, which was quite pleasing. (https://jtccc.files.wordpress.com/2020/03/grill-2-copy.jpg) (https://jtccc.files.wordpress.com/2020/03/grill-3-copy.jpg) (https://jtccc.files.wordpress.com/2020/03/grill-copy.jpg) (https://jtccc.files.wordpress.com/2020/03/belt-tension.jpg) Title: Re: Ducati 996 engine custom build Post by: Mhanis on March 19, 2020, 09:58:21 AM That is a pretty cool guard!
Mark Title: Re: Ducati 996 engine custom build Post by: buzzer on March 20, 2020, 02:45:15 AM That is a pretty cool guard! Mark Thanks! Sometimes it doesn't go to plan... it would not start... I spent a good few hours trying to understand why... I had taken the tank off a few times to change things and had put a clamp on the fuel pipe.... and forgot! (https://jtccc.files.wordpress.com/2020/03/clamp.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on March 20, 2020, 02:58:11 AM ;D
Title: Re: Ducati 996 engine custom build Post by: buzzer on March 21, 2020, 04:28:36 AM here is a short video of how it sounds.... I did take it up the street and the throttle response is fantastic! [beer]
https://www.youtube.com/watch?v=ttwXvitwLT4 Title: Re: Ducati 996 engine custom build Post by: buzzer on March 25, 2020, 11:24:39 AM Made a stand today to keep it upright and safe in the garage… The wheels are idler bearing i changed on a car recently when I did a can belt... makes it roll nicely. Also fitted the seat badge and tank protector.... with all the Corvid 19 issues its looking like I won’t be riding it for a while…
(https://jtccc.files.wordpress.com/2020/03/side-stand-copy.jpg) (https://jtccc.files.wordpress.com/2020/03/stand-copy.jpg) (https://jtccc.files.wordpress.com/2020/03/top-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on March 25, 2020, 02:33:05 PM Bloody nice. [thumbsup]
Title: Re: Ducati 996 engine custom build Post by: buzzer on April 02, 2020, 07:15:31 AM Bloody nice. [thumbsup] Thanks! Scratching around for jobs to do now while I cant ride it! made some frame finishers… (https://jtccc.files.wordpress.com/2020/04/49727075328_28bd9cc198_c.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on April 02, 2020, 01:28:08 PM I appreciate your preference for a clean style. [thumbsup]
Title: Re: Ducati 996 engine custom build Post by: buzzer on April 04, 2020, 03:20:18 AM well I came to make the last frame finisher that was actually a different size to all the rest... then I noticed that Ducati had cut the frame at an angle! So I had to make an angled finisher... this took some setting up in the lathe to get the angle just right....
(https://jtccc.files.wordpress.com/2020/04/49734167566_dc7a0c5fe0_c.jpg) Title: Re: Ducati 996 engine custom build Post by: koko64 on April 04, 2020, 05:16:30 AM [clap] bravo.
Title: Re: Ducati 996 engine custom build Post by: Howie on April 04, 2020, 06:05:05 AM You did better than Ducati [thumbsup]
Title: Re: Ducati 996 engine custom build Post by: buzzer on April 04, 2020, 10:12:56 AM You did better than Ducati [thumbsup] [laugh] [laugh] [laugh] As an aside from working on the Ducati.... I have been busy doing a job on my Harley V-Rod today...I changed the oil and filter and in doing that took the opportunity to check on the timing bolt in the engine that can come loose on some bikes, which wrecks the engine! nice and easy job, just drain the oil and remove the alternator cover which comes off easily. I checked the torque of the bolt before I removed it and it was tight... However to be on the safe side I removed it and cleaned both the internal thread and the bolt, and used some high strength thread lock on there as advised by the factory... (https://jtccc.files.wordpress.com/2020/04/49735327201_808fde4542_c.jpg) (https://jtccc.files.wordpress.com/2020/04/49734783863_eaecab8650_c.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on April 11, 2020, 01:15:26 AM None Ducati this time, but with lockdown still in place I helped a mate out who needed some brake calliper pistons for a Norton Commando he is rebuilding...
I made two out of stainless steel for him as the originals were pitted quite badly... took a while to grind a tool to the correct angles and get the speed of the lathe right to get a nice finish, but I got there in the end... (https://jtccc.files.wordpress.com/2020/04/49758008976_f18faaa3bd_c.jpg) Title: Re: Ducati 996 engine custom build Post by: Duck-Stew on April 11, 2020, 05:30:20 AM You rock!!
Title: Re: Ducati 996 engine custom build Post by: Mhanis on April 11, 2020, 06:07:48 AM Ooohhhh, to have a talent...……….
But alas. Well done! Mark Title: Re: Ducati 996 engine custom build Post by: buzzer on May 10, 2020, 01:57:18 AM Been a while since I updated....early May, lockdown continues, still can’t ride, it’s very frustrating to have bikes on the drive and not ride them!!
done a few more jobs like programme the ignition advance to get a steady tick over, and importantly retard the ignition at cranking speed to give the starter motor an easier time. Also balanced the carbs. for years I used a mercury gauge for this but a mate borrowed them and broke it! so I bought a set of gauges, but noticed I could get it closer by ear! so I checked the gauges by connecting them to a single vacuum source and found they were all reading differently! hence the single gauge with 5 valves. the 5th valve provides damping to the gauge. I have found you can get a perfect tick over with this method. lets hope we can ride soon! (https://jtccc.files.wordpress.com/2020/04/49741938662_242ee9b722_c.jpg) (https://jtccc.files.wordpress.com/2020/05/49814064926_070062877b_o-copy.jpg) (https://jtccc.files.wordpress.com/2020/05/49814065111_9d5baba0ce_o-copy.jpg) (https://jtccc.files.wordpress.com/2020/05/49814065106_e16030be76_o-copy.jpg) (https://jtccc.files.wordpress.com/2020/05/laptop-copy.jpg) (https://jtccc.files.wordpress.com/2020/05/49777801783_2a0d769b86_o-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: Pinion on May 13, 2020, 06:13:24 AM Very nice build [thumbsup]
Title: Re: Ducati 996 engine custom build Post by: buzzer on May 23, 2020, 08:20:02 AM Very nice build [thumbsup] Thanks!Middle of may and lockdown has eased a little and I have been out doing a few miles... It runs REALLY well on the carbs! the throttle response is amazing and it feels very crisp and lively! made a few adjustments to the timing at low RPM, but the jetting feels OK, and a plug chop confirmed its not far out... just need to put a few miles on it now... its VERY loud though! will post a video soon as I can get someone to take it! (https://jtccc.files.wordpress.com/2020/05/49926122953_551ac1c7b3_o-copy.jpg) (https://jtccc.files.wordpress.com/2020/05/49915546252_c4fa352a01_o-copy.jpg) (https://jtccc.files.wordpress.com/2020/05/49912694786_5413300182_o-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: buzzer on May 28, 2020, 06:26:03 AM Been out and about the last few days bedding things in after the rebuild... one thing I noticed was its slow to turn over when you start it. I had upgraded the cables, and the starter itself was good, so I had another look at the timing. When I did the map, I had the first RPM point at 400 with 10 degrees BTDC and the second at 1000 again with 10 degrees... so i changed this to 5 degrees from 400 to 1000, so there is not so much advance at cranking speed.
I also configured the software so it did two full dead revolutions before it sparks... this means the engine is properly spinning before it fires... It really spins over now and starts MUCH better (https://jtccc.files.wordpress.com/2020/05/laptop-copy.jpg) Title: Re: Ducati 996 engine custom build Post by: Duck-Stew on May 28, 2020, 09:49:52 AM Man, this is SUCH a great build! I love all the updates, your attention to detail and obvious passion for it. [popcorn]
Keep up the good work! |