Ducati Monster Forum

Moto Board => Accessories & Mods => Topic started by: buzzer on January 03, 2023, 03:52:40 AM



Title: Ducati 1000 DS build
Post by: buzzer on January 03, 2023, 03:52:40 AM
December 2022 and my Guzzi build is finished, So onto the next project, a Ducati Multistrada 1000 DS.  I bought this as an unfinished project and it has some nice parts with it...  light wheels, 4 pad brakes, and many more nice parts.

I wanted to make this build a bit different. I have in my head what it will look like, and some criteria for the build. It must be light, single seat, less old school,  Carbs (I like carbs!) underslung exhaust... no tail piece, and above all minimal...  I will ask myself do I need to fit this!  Here is where it all starts!

(https://jtccc.files.wordpress.com/2022/12/52573574618_0c88cd1366_o-copy.jpg)

(https://jtccc.files.wordpress.com/2022/12/52573494245_3c690a27e9_o-copy.jpg)

I have ordered a load of stuff, but due to strikes and the time of year nothing will be here till the new year… It was also very cold in the main workshop, and with the cost of heating I don’t want to put the central heating on in there so the first job on this build was to make the throttle of all things. I can do this in the side workshop which is small and cheap to heat! As I am using flat slides I want some positive means of closing them, which means a pull to open, pull to close set up. I tried splitters in the past to do this but disliked the action, so decided on a 4 cable throttle. I made similar for the Guzzi build and it worked well, so this is an enhanced version of that with a slightly smaller cable wheel as the Guzzi throttle is a little too quick… I refined my silver soldering technique after watching the repair shop, and I have to say it worked rather well!



(https://jtccc.files.wordpress.com/2022/12/52587722923_7cb4de3077_o-copy.jpg)

(https://jtccc.files.wordpress.com/2022/12/52586835707_d0083057ab_o-copy.jpg)

(https://jtccc.files.wordpress.com/2023/01/throttle-3-copy.jpg)



Title: Re: Ducati 1000 DS build
Post by: RB on January 03, 2023, 04:16:43 AM
very cool prtoject, thanks for sharing.


Title: Re: Ducati 1000 DS build
Post by: Blackout on January 03, 2023, 09:02:04 AM
This should be good.


Title: Re: Ducati 1000 DS build
Post by: Howie on January 03, 2023, 10:04:39 AM
 [popcorn]


Title: Re: Ducati 1000 DS build
Post by: stopintime on January 03, 2023, 01:45:39 PM
I'm in  [thumbsup]



Title: Re: Ducati 1000 DS build
Post by: buzzer on January 04, 2023, 02:02:44 AM
As I wanted this to be different to the other builds, I tried several other tanks… I had an ST4 tank and a Monster tank that had too many holes to repair, so I cut these down… while I liked the ST tank, I couldn’t get the seat to tie in… I didn’t like the monster tank… So off to the bike breakers… he gave me the key to his storage unit...  and said "say hi to the ghost!"


I walked around looking at the hundreds of tanks in there, discounting the plastic ones, of which there were many… the slope of the frame makes the choices limited...  Nothing took my eye.  Its a VERY old building though, and I have to say it spooked me somewhat being in there on my own, lots of creaking noises, and scuttling sounds which were probably rats...  I didn't stay longer than I needed!

In the end I went back to the 999 tank I have used before. Another with some holes in the bottom where its rusted out.

(https://jtccc.files.wordpress.com/2023/01/52604526524_1f09c75a72_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: pitbull on January 04, 2023, 12:24:17 PM
 [popcorn]

This is looking super cool. Looking forward to seeing your progress.


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 05, 2023, 01:38:02 AM
While I love the look of a nice velocity stack they are not really practical for the road, hence while I make them for the photos I take, I like to use foam filters on the road. this of course means I need some suitable adaptors, which although you can buy them are REALLY expensive. these took a while to machine out of billet! I sometimes get asked where I get my material from for the lathe and miller. I am really lucky that there is a scrap yard locally that lets me hunt through the bins! They take scrap in from some of the aerospace companies so there are sometimes some nice bar ends in the skips. What is great about that is the bar ends are often etched with the material specification!

I don’t usually pay as I take my scrap in there and he writes the value in the back of his desk diary, and then as I take stuff, he takes the value off! he has done this for me for over 30 years! A few years ago I went in early in the year… he was no longer there as he had retired and I learned that his grandson had taken the company over. We chatted and I mentioned about the diary as I had a few pounds credit… The lad said he knew all about it and it was in the back of the book!

(https://jtccc.files.wordpress.com/2023/01/bells1-copy.jpg)

(https://jtccc.files.wordpress.com/2023/01/bells-2-copy.jpg)



Title: Re: Ducati 1000 DS build
Post by: buzzer on January 07, 2023, 09:48:38 AM
Time to start the fabrication of the back end. I decided to use some rose joints as I like the look they bring to a build. Experience has taught me to tack everything up first before welding fully! its going to be a very stubby back end, I have also used three 10mm LED as a stop and tail light. they are amazingly bright

(https://jtccc.files.wordpress.com/2023/01/rear-end-fab-7-copy.jpg)

(https://jtccc.files.wordpress.com/2023/01/rear-end-fab-2-copy.jpg)

(https://jtccc.files.wordpress.com/2023/01/rear-end-fab-3-copy.jpg)

(https://jtccc.files.wordpress.com/2023/01/rear-end-fab-9-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 09, 2023, 12:44:25 AM
Making the exhaust retaining flange out of 15mm alloy plate was quick and easy…

As an aside, that tin of marking blue is 50 years old, given to me by my Dad, along with one of my treasured possessions, a 0 – 1″ micrometre when I was 15 years old. Not much left in the tin now, but its still usable.

The stainless steel collar however took an absolute age to make! I should have really used some stainless pipe, but its an odd size and I couldn’t get any that would fit, so I ended up machining it out of a solid piece of bar stock. I hate working with stainless… everything you do with it makes your life hard, just like the material!

(https://jtccc.files.wordpress.com/2023/01/exhaust-1-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 12, 2023, 02:31:26 AM
I tried for a while to make a seat out of alloy sheet, and failed.  the shape is just to complicated!  in the end I decided on an alloy and glass fibre approach.  I lifted the tank slightly so the finished seat will have some clearance, and then covered it with duct tape, followed by some tin foil to act a a release.  This actually worked quite well!  Cutting the foam to shape took a while and is a dusty job, but with the fan blowing on me and out the door it wasn't too bad.  The key to using resin is the mix ratio...  I used 2.5% as it was a cold day, in the summer that would have gone off in 5 mins!  I will send it to the trimmer to do his magic...  this is one of the few jobs I send out.


(https://jtccc.files.wordpress.com/2023/01/seat.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 18, 2023, 02:47:22 AM
To get the tank low, and get rid of the large pump mounting hole I had to cut the bottom out of the tank. easy enough with one of those 1mm cutting disks which I seem to use a lot of these days! I needed to make the infill patch and contour this to fit the hole. to make this easier I profiled it to the right shape by cutting some wood and pressing it to shape in the vice, then a bit of planishing to get it to the final shape.

The aim is to get the gap as small as possible to facilitate a nice weld. I used some 1mm mild steel plate which matches the thickness of the tank, so TIG welding is no problem on a low amp setting. I used a couple of magnets to position it before adding a few tacks all round. At this point I ran out of Argon...  The last refill I bought was £65..  now its £104!

The outlet is made, but I need the filter fitting on the bike first so I can position it to get the pipe runs neat. Once this is welded on I can leak test.

(https://jtccc.files.wordpress.com/2023/01/tank-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 19, 2023, 10:37:40 AM
I picked up the headlight and fuel filter brackets today...  What a fantastic process waterjet cutting is!  They were profile cutting a 150mm thick block of alloy while I was there!  The jury is out on the brackets at the moment, but I am struggling to think of a better design

(https://jtccc.files.wordpress.com/2023/01/52637413883_cd4466a09d_o-copy.jpg)



Title: Re: Ducati 1000 DS build
Post by: buzzer on January 21, 2023, 01:58:56 AM
When i bought the bike it had a QD system on it… while I liked the concept, it was too big and heavy so I sold it on and decided to make an underslung exhaust of my own design. I wanted smaller and much lighter. I started with a mock-up of builders foam to get the shape and angles, and then moddled this in 3D. I did do a basic model on my iPad, but then found I had to pay to output it to a file! really frustrating! so I got my mate to do it and then had all the individual parts laser cut.

The baffle plates have staggered holes, which should quieten it down somewhat, but if not, I have a backup plan! Who knows if this will kill any performance? if I lose a few BHP so be it… but you never know!

here is a 1 min video of the process

https://www.youtube.com/watch?v=RgssU93IbPM

(https://jtccc.files.wordpress.com/2023/01/silencer-2.jpg)

(https://jtccc.files.wordpress.com/2023/01/silencer-3.jpg)



Title: Re: Ducati 1000 DS build
Post by: stopintime on January 21, 2023, 04:36:57 AM
Interesting.... hopefully this design will work better than the Ex-box... people complain about the tuning difficulties and performance and sound.

I hope you can make a video, side by side, one with two large (carbon) cans and this new bike  8)


Title: Re: Ducati 1000 DS build
Post by: greenmonster on January 21, 2023, 06:36:22 AM
Quote
.Who knows if this will kill any performance?


This Forum knows, do a search.
May look slim but looses power.


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 24, 2023, 02:05:07 AM
Interesting.... hopefully this design will work better than the Ex-box... people complain about the tuning difficulties and performance and sound.

I hope you can make a video, side by side, one with two large (carbon) cans and this new bike  8)

that's right..  the bike came with an EX box system, it sounded terrible, and was extreamly heavy...  I don't know about performance

Apart from a polish the exhaust is welded up and finished. I didn’t want to have distortion and burn through when attaching the baffles, so for these I used TIG braze which worked quite well.

The slip joints are held together with springs and to hold these I needed to make some spring hoops. These are actual quite difficult to make to get the bend just right and to a consistent shape. I made a little jig to make these.

(https://jtccc.files.wordpress.com/2023/01/silencer-4.jpg)


Title: Re: Ducati 1000 DS build
Post by: diamonddog-2 on January 26, 2023, 09:58:20 AM
So freaking interesting. Thank you for sharing.  More please!

       [popcorn]


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 29, 2023, 04:17:16 AM
So freaking interesting. Thank you for sharing.  More please!

       [popcorn]

There will be more, but this is my last post for a while, no bike related stuff for a month while we get some sun!

here is everything to go to be powder coated. The swinging arm will be just blasted though as I will be polishing that. In some ways it was a shame to strip the wheels as they were perfect, but black, and I want silver. The powder coater insists they are stripped of the powder coat before I send them, as its so difficult for him to blast it off… in the past I have used industrial paint stripper but its expensive, and a terrible job to do. This time I took them to a local car wheel refurbishes and they put then in their stripping tank for a couple of hours.. they came out fantastic, the pain literally fell of! I left the disks on and they came out without any paint on as well. I will be taking my engine cases in next!

(https://jtccc.files.wordpress.com/2023/01/ready-for-coating-1.jpg)



Title: Re: Ducati 1000 DS build
Post by: stopintime on January 29, 2023, 04:41:32 AM
There will be more, but this is my last post for a while, no bike related stuff for a month while we get some sun!
............

I dare you  8)


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 29, 2023, 08:26:29 AM
I dare you  8)

she has told me I had better not even think about bikes while we are away  [laugh]


Title: Re: Ducati 1000 DS build
Post by: buzzer on February 19, 2023, 03:07:10 AM
back from holiday, and the first job was a frame repair on a Triumph...  I don't do work for other people these days, but one of my best mates asked me if I could repair this Triumph frame for him.  How the hell do people think using rebar and welding like that is acceptable? 

all done now though and once its powder coated it will be like new.

(https://jtccc.files.wordpress.com/2023/02/triumph-frame-repair.jpg)


Title: Re: Ducati 1000 DS build
Post by: stopintime on February 19, 2023, 04:26:33 AM
You weren't quiet for a month, but well done anyway  ;D

... and the frame is well done as well, I'm sure [thumbsup]


Title: Re: Ducati 1000 DS build
Post by: buzzer on February 23, 2023, 10:18:38 AM
You weren't quiet for a month, but well done anyway  ;D

... and the frame is well done as well, I'm sure [thumbsup]

yes, we were away 2 weeks...  then back a month before we go again... I said I wouldnt have ang garage time and work on the kitchen in that month...  but then she couldn't decided on what she wanted... so here I am back in the garage until we go away again  ;D ;D

Started the engine build… these are simple engines to build, just a couple of points to remember… There is one special bolt in the crankcase that has an oil feed hole in it. Its also much easier to pop the piston into the bore, and then put the pin in, the rings are very fragile (and expensive!) make sure you have some rag in holes though, those pin circlips have a life of their own! in one of the pictures you can see a plate which holds the flywheel… this is necessary as the alternator nut and crank nut are VERY tight and need torqueing to 190 NM.

I would like to thank the local council for the steel to make the engine stand. Leaving a large sign in the hedge at the side of the road for 2 years, I felt I had to re-cycle it 🙂

(https://jtccc.files.wordpress.com/2023/02/52704422357_2ec3888591_o.jpg)


Title: Re: Ducati 1000 DS build
Post by: stopintime on February 23, 2023, 11:32:24 AM
Vite rosso  8)


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 03, 2023, 10:28:38 AM
Waiting for a few engine parts so I switched onto the hydraulics. Not sure which front callipers to use yet, so I built both sets. Everything was in great condition so I didn’t change the seals as they were all good.

(https://jtccc.files.wordpress.com/2023/03/hydralics-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: ungeheuer on March 03, 2023, 01:54:37 PM
can I come and be your apprentice?


Title: Re: Ducati 1000 DS build
Post by: greenmonster on March 04, 2023, 03:50:58 AM
Quite common mod to switch to 4pads.
I thought standard was ok but the 4pads I have now (w Brembo radial master 8)) its really good.


Title: Re: Ducati 1000 DS build
Post by: ducpainter on March 04, 2023, 01:48:16 PM
Quite common mod to switch to 4pads.
I thought standard was ok but the 4pads I have now (w Brembo radial master 8)) its really good.
I have the 4 pad calipers on my track bike with the old pee cup masters, and they're better than really good.

I love Tony's skill as a builder/fabricator. Too bad he's chromatically challenged. The orange masks all the good work because they all look the same at first view, and I look no further. Maybe that's a personality defect on my part. It's OK because my opinion doesn't matter, however, it's the only one I have. ;D


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 05, 2023, 02:05:40 AM
can I come and be your apprentice?


the fact I don't have an apprentice or anyone to pass my skills onto is one reason I document builds... at least it passes some of it on.  I have a son, but he is quite arty and not into what I do.  We also have a couple of granddaughters...  I am working on the youngest, but its not working just yet!


I have the 4 pad calipers on my track bike with the old pee cup masters, and they're better than really good.

I love Tony's skill as a builder/fabricator. Too bad he's chromatically challenged. The orange masks all the good work because they all look the same at first view, and I look no further. Maybe that's a personality defect on my part. It's OK because my opinion doesn't matter, however, it's the only one I have. ;D

I know, I know  ;D ;D  I just happen to like that look  [laugh]  I also decided after the Guzzi build I wouldnt  do another Duke for a while, then this one came along at a price I simply couldn't resist.  Next build will probably be a big capacity single, I am on the lookout for something.  it must have an electric start though.  I am conscious that my age means the I now struggle with heavy bikes, in fact I have just sold my Harley V-ROD for that very reason...  I was sad to see it go, it kind of closed a chapter on my life ...

I wanted the belts and pulleys to be on show, but I am not keen on open belts… all it takes is one stone! I have made these before out of the original covers. Start by cutting holes with a hole saw, and then cut the oval out. for this I use a saw in the dremel but a saw is OK. Then I marked the profile on some 3mm polycarbonate and cut that to shape. With that in the cut out, I drilled some 3mm holes half in the cover half in the poly. the windows are held in with some 3mm flanged bolts, washers and nylock nuts. I did ad a dab of high strength nutlock and some small neoprene washers as well.

I then hydrodipped them. I know that fake carbon is not everyone’s thing but I like it, and when covered with a lacquer its VERY durable and UV stable, unlike the real stuff! The actual process is easy, and the film and activator is cheap.

(https://jtccc.files.wordpress.com/2023/03/52727367153_0e169e911e_o-copy.jpg)

https://www.youtube.com/watch?v=jh6Hh1F0-Yg


Title: Re: Ducati 1000 DS build
Post by: diamonddog-2 on March 05, 2023, 07:46:35 AM
The hydrodipping video clip was really interesting. Thank you for posting all the things you do.

 [clap]


Title: Re: Ducati 1000 DS build
Post by: Howie on March 05, 2023, 11:37:48 AM
Is hydrodipping that easy or are you so good you make it look easy?


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 06, 2023, 02:42:04 AM
Is hydrodipping that easy or are you so good you make it look easy?

with a few tips its easy... 

you need a base coat, silver or gold works well with carbon

wet your fingers, pinch the film, the finger that sticks, that's the side that goes on the water.

water needs to be around 30 degrees

leave 1" around the film so it can expand in the tub

spray 12" away...

think about the dip angle, for air pockets and coverage don't go to fast

if you screw up, wipe it off with panel wipe and do it again

once dipped leave 5 mins and was the item under the tap.  keep going until all the slimy film goes, about 5 mins, gently touch the surface to see its all gone (important bit!)

let it dry a day, cover with a lacquer.  2K is best, and also now comes in aerosol




Title: Re: Ducati 1000 DS build
Post by: buzzer on March 06, 2023, 03:00:10 AM
Polishing day… I did the engine cases a few weeks ago. I then set a side a full day to polish the rest of the alloy… its a dirty, hard, and somewhat dangerous job! the swinging arm took ages! I used to do it in the workshop, but it made such a mess I now do it on the drive. I have a 2.5 HP 3000 RPM motor that I use that is an absolute beast and takes no prisoners if you get it wrong.

Its mentally draining to do actually, thinking about the angle you present the item to the wheel each time. I sand everything with 400 Mirka Abranet first (if you have not come across that product its a game changer, you will never use wet and dry again!) I use an 8"  closed stitched mop and medium compound, followed by a loose mop with fine compound. I use some very fine compound on the stainless.

That evening I had a bath as I was so filthy. I actually used fairy liquid to clean me off as ordinary soap doesn’t touch it. Next day I absolutely ached all over!

(https://jtccc.files.wordpress.com/2023/03/52727602926_a22d586296_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 08, 2023, 09:00:48 AM
the engine parts I had been waiting for came, and I finished off the belt covers.  I also made the housing for the hall effect triggers, the most accurate bit of machining I have done in years as I needed to locate the sensors exactly 135 degrees apart.  I will post some pictures later on that.  But for now here is the engine!

(https://jtccc.files.wordpress.com/2023/03/52734794468_667d534ab7_o-copy.jpg)

(https://jtccc.files.wordpress.com/2023/03/52734563999_5414589360_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 10, 2023, 06:05:41 AM
A nice part of the build is when you start to pull it all together. All that preparation of parts for months before all comes together quite quickly.  ;D

(https://jtccc.files.wordpress.com/2023/03/52737681132_f1d9525581_o.jpg)

(https://jtccc.files.wordpress.com/2023/03/52738687648_98b12c3841_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 12, 2023, 07:51:05 AM
One of the things that was missing on the bike when I bought it was a gear lever. No problem I though… until I saw the price! so I decided to make one, and while I was on, make it slightly longer to suit my big feet. I took the one off my other bike as a pattern. I milled it out of a solid piece of alloy plate, and then hand filed it all to shape, and gave it a polish, I was quite pleased with the result!

(https://jtccc.files.wordpress.com/2023/03/gear-lever.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 13, 2023, 09:42:14 AM
out in the daylight for the first time in a while  ;D

(https://jtccc.files.wordpress.com/2023/03/52744687262_221f51f336_o-small.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 16, 2023, 02:07:09 AM
One of the things I wanted on this build was a clean looking rear end.  I struggled to find a rear light that was suitable, so in the end I have fitted three 10mm superbrite LED’s as a rear light, and used a resister and diode so its bright and then brighter to act as a stop light.

https://www.youtube.com/watch?v=g6Mc2fn0_Kc



Title: Re: Ducati 1000 DS build
Post by: buzzer on March 19, 2023, 05:30:19 AM
I have made a few similar Hall Effect ignition pickups in the past and they have worked brilliantly. This is a refinement on those.  This time I have used an alloy cam wheel and put the magnets directly into that, rather than use a separate wheel.  the magnets are 3mm as opposed to the 4mm ones I have used in the past, lets hope they are OK!  I also swapped out the allen bolts for some none magnetic A4 ones just in case it picked those up.

Previously I have had a small discrepancy in the timing cylinder to cylinder, which is OK as I can compensate for that in the Ignitech software...  But it irritated me that I had to do that!  I put it down to my rotary table that is not the best and only measures degrees and its difficult to get the holes for the sensors precisely 135 degrees apart.  This this time I borrowed a mates table that is very accurate and can measure to minutes. It was a pleasure to use such a wonderful piece of quality kit!  Making the pickup plate took some time, probably the most accurate work I have done in a while!

I am not sure i needed the heat sink, but it looked aesthetically pleasing so I used it.

(https://jtccc.files.wordpress.com/2023/03/aa-ignition-3.jpg)

(https://jtccc.files.wordpress.com/2023/03/aa-ignition-2.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on April 14, 2023, 07:59:23 AM
I finished the throttle off...  I had to make the adjusters as they needed to be a custom size.  I also used cycle gear cable as the nice thing about it is the outer wire is longitudinal, which has several advantages, the one being that you can cut it so the inner liner can extend into the adjusters and into the throttle which makes the entire run of the inner cable within the liner.  I was very pleased with the light action, and only a 1/4 of a turn closed to open.  We all know a fast action throttle adds 20 BHP ;D

(https://jtccc.files.wordpress.com/2023/04/52804120023_8691b862ac_o-copy-1.jpg)

I know that I should use suppressed leads, but I prefer to use copper cored ones. they are easy to make up and you can make them to the spot on length. I have had that crimp tool 50 years!

(https://jtccc.files.wordpress.com/2023/04/52807624931_ec8e947555_o-copy.jpg)

one of the things I wanted to do was get rid of the rubber frame bungs… so I turned up some alloy ones. I needed some alloy bar, so I popped into my local metal recyclers… he had several skips of alloy round bar and machined square and oblong billets, all different sizes… many marked on the end with the material specification! They were just about to be taken away so I had to be quick, I really had to restrain myself though, it was like Christmas had come early!

(https://jtccc.files.wordpress.com/2023/04/52817386660_86e750f077_o-copy.jpg)



Title: Re: Ducati 1000 DS build
Post by: ungeheuer on April 14, 2023, 09:58:40 AM
As a reasonable spanner monkey, garage tinkerer, problem solver and (I like to think) innovative thinker... I feel so..... inadequate in the company of such skill.

Mate, will ya bugger off?  ;D



Title: Re: Ducati 1000 DS build
Post by: buzzer on April 15, 2023, 10:23:46 AM
As a reasonable spanner monkey, garage tinkerer, problem solver and (I like to think) innovative thinker... I feel so..... inadequate in the company of such skill.

Mate, will ya bugger off?  ;D



well if it makes you feel better...  it wouldnt start  :o

Things don't always go to plan...  I tried to starts it...  I had a spark, and lots of backfires, but it would not run.  I checked a few things and came to the conclusion it was the pickups...  I wasn't sure if it was the actual hall sensors, or the magnets and spacing.  I decided to try the magnets and spacing first, and it turned out to be that.  not sure if it was the strength of the magnets as they were tiny, or the spacing (I suspect it was the spacing) but either way I had to re design the rotor.  soon as I did this, it fired up and settled to a nice tickover.  I also breathed a sigh of relief as I had put a lot of effort into the exhaust and didn't know what it would sound like!  To me it sounded awesome!  here is a short video.

https://www.youtube.com/watch?v=t4z1kqUoEVk


Title: Re: Ducati 1000 DS build
Post by: buzzer on April 17, 2023, 01:01:53 AM
the fuel tap proved to be a challenge. It couldn’t go on the tank, but I also didn’t want to on show. In the end I made a small bracket and mounted it out of sight.


(https://jtccc.files.wordpress.com/2023/04/52817416095_07960f0fae_o.jpg)


I popped into the paint supplier where my mate works… he persuaded me to try some new lacquer which he said the customers were raving about… I reluctantly agreed to try it. Although I had prepped the tank, I thought I would try it on the mudguard first… I am glad I did! It was easy enough to spray, and gave a nice gloss from the gun, BUT it took almost two hours before it was dust free… That may be ok in a heated, dust free paint booth, but in my garage its a distinct disadvantage. So its back to what I know and I went back for some of the formula I always use!

(https://jtccc.files.wordpress.com/2023/04/52819705609_3244325911_o-copy.jpg)



Title: Re: Ducati 1000 DS build
Post by: buzzer on April 19, 2023, 12:21:15 AM
Here it is, finished...  I am pleased with the look, even though it divides opinion!

This will be the last full bike build for a while. This is my 12th bike build, they usually take me all winter to complete, and then I ride them over the summer.

I have no doubt there will be some tinkering, and I will post the results of that,  but I wont be doing another full build until September 2024. I will be doing a video on the build soon.

The plan is to spend the summer as we always do, Holidays, days out, and going for rides... Then in the autumn its time to do some work on the house, new kitchen, bathroom, general renovations and decorating. The last house purge was the year I retired...  14 years ago!  My wife has been very tolerant over the years!

(https://jtccc.files.wordpress.com/2023/04/52823269662_e877119b3f_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: Blackout on April 19, 2023, 04:50:18 AM
Another masterpiece. [thumbsup]


Title: Re: Ducati 1000 DS build
Post by: Howie on April 19, 2023, 05:08:17 AM
Ummm...WOW!


Title: Re: Ducati 1000 DS build
Post by: stopintime on April 19, 2023, 05:22:19 AM
....
This will be the last full bike build for a while.
...........

 [laugh] [laugh] [laugh] [laugh] [coffee]


Title: Re: Ducati 1000 DS build
Post by: buzzer on April 19, 2023, 10:30:11 AM
[laugh] [laugh] [laugh] [laugh] [coffee]

 [laugh] [laugh] [laugh] [laugh]


Title: Re: Ducati 1000 DS build
Post by: buzzer on April 21, 2023, 01:03:33 AM
I gave the garage a good clean out the other day, which meant getting all the bikes on the drive...  I thought it worthy of a picture.

I also did 80 miles on the new build, it ran very nice from the off...  I did however stop a couple of times to tweak the air screw on the carbs.  Its such a fun bike to ride!  I also took the Guzzi out for a 20 mile ride...  here's to a warm dry summer!

Here are some of the builds I have done over the years, yes there is an orange and silver theme, its what I like, and with all my builds, I build them for me!  I have done restorations in the past rather than custom builds and have kept these in original or period colours... 

One of my big regrets is not taking photos...   I have very few film photoes from the pre digital age which is a shame.

(https://jtccc.files.wordpress.com/2023/04/52834315075_66e44499c5_o-copy.jpg)

(https://jtccc.files.wordpress.com/2023/04/52830526371_8c6459ecd2_o-copy.jpg)

(https://jtccc.files.wordpress.com/2023/04/52834147004_025fcf2553_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: Monsterlover on May 01, 2023, 02:57:25 AM
Great work all around!


Title: Re: Ducati 1000 DS build
Post by: buzzer on May 04, 2023, 01:07:17 AM
well this and the Guzzi build comes to an end (that's if custom builds ever do!)

Have to say I am loving both bikes, they are very different to ride!  The Duke is so light and nimble at 168kg wet, with the Guzzi at 200kg

This will be my last build for 18 months...  I normally build a bike over winter, and ride all summer, so that's the plan this year...  then in September I will start work on the house... Happy wife, happy life! 

Hopefully I can start another build September 2024, so plenty of time to look around for anything that takes my fancy

for now here is a video that covers the build...

https://www.youtube.com/watch?v=tOb8nLGY9C8


Title: Re: Ducati 1000 DS build
Post by: greenmonster on May 04, 2023, 03:03:01 AM
And now you're a professional moviemaker as well. [thumbsup]

How`s the Guzzi running, any dips in power band, your exhaust works ok ?


Title: Re: Ducati 1000 DS build
Post by: buzzer on May 05, 2023, 10:51:25 AM
And now you're a professional moviemaker as well. [thumbsup]

How`s the Guzzi running, any dips in power band, your exhaust works ok ?

I am truly amazed how you can put a video like that together in a short time on you Iphone  ;D

The Guzzi is running great!  its very different to the Ducati...  it has a wall of torque and pulls like a train, no need for 5 gears, 3 would do!  I need to sort a few things...  its rather harsh on the rear, needs softer springs, and I got the gear lever ratio wrong and have had to fix that.

I am happy with how it runs, so much so I took a look at the jetting on the Ducati's and have made some good improvements there.  more of that later  [thumbsup]


Title: Re: Ducati 1000 DS build
Post by: buzzer on June 28, 2023, 03:53:55 AM
June, the weather has been great and I really am enjoying this bike and putting a few miles on it! however, every time I looked at the under slung exhaust I felt it didn’t suit the bike…  I know a lot of people liked it (some didnt...)  but for me it was wrong.  it was the long straight front pipe… So out came the welder and I made a new one! here it is!

this feels like a hooligan of a bike   The combination of the light weight, the torque delivery, the riding position, and the handling all bring out the hooligan

I have had the wheel come up a few times       

(https://jtccc.files.wordpress.com/2023/06/53000578666_74cb71e377_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: stopintime on June 28, 2023, 10:09:33 AM
I like it better than the box  [thumbsup]

... should the can be in line with the seat, rather than the seat support tube?


Title: Re: Ducati 1000 DS build
Post by: buzzer on June 29, 2023, 12:18:03 AM
I like it better than the box  [thumbsup]

... should the can be in line with the seat, rather than the seat support tube?

that's an interesting question...  for me it was no, I did mock it up that way but it sort of looked" stuck there"  Hence where it is now.  I also tried a megaphone on there, but the angle of that didn't look right either!


Title: Re: Ducati 1000 DS build
Post by: stopintime on June 29, 2023, 11:32:38 AM
that's an interesting question...  for me it was no, I did mock it up that way but it sort of looked" stuck there"  Hence where it is now.  I also tried a megaphone on there, but the angle of that didn't look right either!

Hmm.. what about a little lower then? What I think 'bothers' me is that the end cap is too close to the seat, visually.


Title: Re: Ducati 1000 DS build
Post by: Monsterlover on July 01, 2023, 03:13:13 AM
Hmm.. what about a little lower then? What I think 'bothers' me is that the end cap is too close to the seat, visually.

I'm with you now that you made me see it. Maybe split the distance between the rear hugger and the seat support tube?


Title: Re: Ducati 1000 DS build
Post by: buzzer on August 05, 2023, 09:27:42 AM
They say a custom build is never really finished… that’s a true statement! while the four cable throttle worked really well… it was just a little too slow for my liking, taking just more than a fist full from closed to open. Also, after buying a clutch cable from Venhill for the Guzzi and being impressed with how much lighter it made the clutch, I decided to buy some of their teflon lined conduit, and some of their flexible wire rope as opposed to cable. That has made a significant difference to the feel of the throttle, especially as I extended the liner into the adjusters and throttle housing. I also incorporated a positive stop for fully open on the throttle, save straining the cables. I always enjoy silver soldering and watching the solder flow into the gaps to make a seamless joint! I did have to buy some more sticks of solder as I was getting low… £10 a stick now! it used to be £1 last time I bought some!

(https://jtccc.files.wordpress.com/2023/08/53095816875_a6c13d1085_c.jpg)

(https://jtccc.files.wordpress.com/2023/08/53095910468_b57e532018_c.jpg)

(https://jtccc.files.wordpress.com/2023/08/53095597124_0547f77c02_c.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on August 14, 2023, 06:01:06 AM
had to be done!

if anyone is interested I have done a blog page on spraying at home...

https://jtccc.wordpress.com/projects-2/paint-spraying-at-home/

(https://jtccc.files.wordpress.com/2023/08/53105790498_4259849a46_c.jpg)

(https://jtccc.files.wordpress.com/2023/08/53105700880_d520560f25_c.jpg)

(https://jtccc.files.wordpress.com/2023/08/53105288851_de2ffdf72f_c.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on December 22, 2023, 07:28:23 AM
A custom build is never finished....

When I first built this bike I wanted an underslung silencer, which I did make… Unfortunately the bike ran like a bag of crap with it on, due to a silly design error i made in opposing the inlets from each cylinder into the silencer.. at 1/8 throttle, it ran rough. So this is MKll design!

I also wanted to put the British standard numbers on it, just in case the MOT man was in a bad mood… so I had some stencils made up and etched them on along with a Ducati logo. this is a very easy and simple process, here is a short video of how it’s done.

(https://jtccc.files.wordpress.com/2023/12/53413186032_5a4215bb5b_o-copy-1.jpg)

(https://jtccc.files.wordpress.com/2023/12/53414546325_9f36e0a148_o-copy.jpg)

(https://jtccc.files.wordpress.com/2023/12/53412940283_7b589130be_o-copy.jpg)

https://www.youtube.com/watch?v=8EUHDefIB7E



Title: Re: Ducati 1000 DS build
Post by: stopintime on December 22, 2023, 07:39:53 AM
A custom build is never finished....

....

... told you so  :D [thumbsup]

Video bookmarked!


Title: Re: Ducati 1000 DS build
Post by: Monsterlover on December 25, 2023, 07:33:44 PM
Nice


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 09, 2024, 07:25:44 AM
Probably my final post....


Well I said I wouldn't build another bike this winter, instead focusing on some house renovations which I started in September, planning to finish around March.  But I got my skates on and had them finished by Christmas, gaining me MANY brownie points...


Last week I got chatting to a mate who had this Honda SLR 650 at the back of the shed, not ridden for a few years.  Well I have always fancied doing a big single, and as this was Electric start, it fitted the bill perfectly!  I have gone to the dark side!


I like to have a design brief in my head before I start, In this case, as always it will be minimalist… As light as I can make it… Parts I do put back on I will ask myself, “can I make it?” The front wheel will be changed to a 17” to match the rear, which will entail a wheel building session, something I have wanted to do for years… we will see on that one!


I ordered the tank soon as I got it...  Brand new... off a CG125 Honda, great quality, came with a new cap and tap... £38 delivered, how do they do it for that little!


If anyone wants to follow this build it will be on my blog...I cant post links on here, but if you search @jtccc you should find it...  or I am happy to post on this thread if that's what people want?


(https://jtccc.files.wordpress.com/2024/01/53444842394_a95efcbb65_o-copy.jpg)


(https://jtccc.files.wordpress.com/2024/01/53443460707_86cb7353dd_o-copy.jpg)


(https://jtccc.files.wordpress.com/2024/01/53452147305_df9d80d002_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: stopintime on January 09, 2024, 08:05:03 AM
We often solve identity issues this way. Red tank "DUCATI"

I'd like it a lot if you post the build here [thumbsup]


(https://i.postimg.cc/zGwBhrWD/S6001339.jpg) (https://postimg.cc/NKMBhZpZ)


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 09, 2024, 08:24:53 AM
  [laugh] [laugh] [laugh] [laugh] [laugh]


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 12, 2024, 06:48:29 AM
first job has been to fabricate the rear subframe. I bought a pre bent hoop off Ebay and some Rod Ends. I did think about just welding it on, but I do like the industrial look of rod ends, and they make attachment point easy and adjustable. The bolts through the frame will be 8.8 high tensile and not stainless in this application. I will also be sleeving the frame where the bolts pass through and welding the bosses I have made on there.

(https://jtccc.files.wordpress.com/2024/01/53454984822_dcc593aa2e_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/01/53458068993_1177b7580f_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/01/53458350915_92ee2f9f63_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: Howie on January 12, 2024, 09:42:22 PM
This will be interesting [popcorn]  Thumper cafe racer?


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 13, 2024, 02:44:47 AM
This will be interesting [popcorn]  Thumper cafe racer?

more like a scrambler  :)


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 16, 2024, 05:28:52 AM
Next job took some thinking about and making… the footrest plates are structural to the frame as they support the ends of the swinging arm. I also wanted to move the pegs forward slightly… here is the result… more chunky than I usually make but they need to be!

(https://jtccc.files.wordpress.com/2024/01/53467781818_563e53b8e4_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/01/53467965439_1a6cd7c66e_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: stopintime on January 16, 2024, 11:44:02 AM
Do this  [thumbsup]

 [evil]


https://www.youtube.com/watch?v=nvMcFQqhbpM


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 19, 2024, 03:16:35 AM
I can see that lasting about 10 seconds!

I bought a new Keihin 41mm FCR carb for the bike… while it actually fits on the original manifold I wanted it to stick out a little more, so I decided to make a longer and different manifold. I am still not sure which one to use, but now have the option.

That plate of aluminium is aircraft quality and mills really well...  However, the milling chips are small and exceptionally sharp and I have received an official warning that I must shale my overalls off in the garage and remove my shoes before coming into the house  :'(

(https://jtccc.files.wordpress.com/2024/01/53473435463_061a61c7da_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/01/53471598492_87af34ab2e_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 27, 2024, 03:45:14 AM
now one of the more satisfying jobs… exhaust fabrication! the original headers were 28mm but its very hard to get any sorts of bends in that diameter so I went up to 32mm, which aesthetically I think looks better. 32mm bends are available in quite a few angles, its just deciding which ones you need, and that’s just an eyeball thing.

Its not that difficult to make a system, its more time consuming. Cuts are made using a 1mm cutting disk in the angle grinder, and if you wrap masking tape around the cut line you can get it very accurate. then it’s a matter of assembling it together, initially with Jubilee clips. I cut slots in these so I can tack it in situ. A tip about tacking is to double the amps on the welder to what you would use to weld… and then put the tiniest of tacks in place. A tiny tack also has the advantage that it does not pull a gap on the opposite side that you will get if you make big ones. Three tiny tacks are actually very strong, but if you make a mistake, can easily be broken by touching them with the cutting disk. 

Note the 2 way spirit level… this is a VERY useful (and cheap!) way of making sure build lines are correct. If you have the bike vertically (using a long spirit level on the wheel) and horizontal you can place the 2 way level on the bike and tape it there… that becomes your datum. To get it right on this bike I had to drop the stanchions through the yokes as I will be replacing the 19″ front wheel with a 17″ on soon.

(https://jtccc.files.wordpress.com/2024/01/exhaust-fab-4-copy.jpg)

(https://jtccc.files.wordpress.com/2024/01/exhaust-fab-2-copy.jpg)

(https://jtccc.files.wordpress.com/2024/01/exhaust-fab-1-copy.jpg)

(https://jtccc.files.wordpress.com/2024/01/exhaust-fab-5-copy.jpg)

(https://jtccc.files.wordpress.com/2024/01/exhaust-fab-3-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: Mhanis on January 30, 2024, 04:39:42 AM
 :o

Mark


Title: Re: Ducati 1000 DS build
Post by: buzzer on January 30, 2024, 11:58:52 AM
I have agonised over what to do about the number plate… In the end I decided to copy the current crop of bikes that hang it off a bracket off the swinging arm. I quite like how CCM do it so have sort of copied their design. I have used thin wall steel tube which is always difficult to bend, so to prevent kinking I fill the pipe with sand. First I block one end off, and weld a nut on the other. Then its filled with dry sand until its below the threads in the nut. I then hold the tube against the bench grinder and the vibration compacts the sand, so I fill it again. Finally a bolt is tightened onto the sand which compacts it furter.

Doing this means its far less likely to kink as its bent!

(https://jtccc.files.wordpress.com/2024/01/number-plate-ccm-2-copy.jpg)

(https://jtccc.files.wordpress.com/2024/01/number-plate-ccm-1-copy.jpg)

(https://jtccc.files.wordpress.com/2024/01/number-plate-ccm-3-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: Howie on January 30, 2024, 10:06:11 PM
Nice!


Title: Re: Ducati 1000 DS build
Post by: buzzer on February 01, 2024, 04:24:46 AM
I have used these GPS speedos on a few builds now, it makes things simple, neat and light. The hole for the ignition switch made a handy holder for the warning light LED’s!

(https://jtccc.files.wordpress.com/2024/02/53500789458_5624d5b236_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/02/53501055110_0d18343dcd_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on February 04, 2024, 03:29:22 AM
The rear number plate mounting looked OK, but it needed a hugger… I wanted to keep things as light as I could so I decided to try some carbon fibre.. first and probably last time as its a nightmare to work with! I had to buy a meter, so I decided to also make the battery tray as well… That’s currently drying, its nice and light but not that pretty, but its unseen so I will live with it. I used an old mudguard to make the mould and the hugger came out rather well! with what’s left I will probably make a front mudguard, we will see how that turns out, on this one I will try the vacuum bag approach.

The new 17″ front rim and new stainless spokes have also arrived. Expensive, but you can't  have rusty spokes, it spoils a build

there will be a short interlude in updates now as we are off for some sun for three weeks!

(https://jtccc.files.wordpress.com/2024/02/53508034518_fe40db181c_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/02/53508169034_767021328a_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/02/53506966582_4e42cfc350_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on February 24, 2024, 04:41:23 AM
I have wanted to try Cerakote for a while due to the great reports of its durability and finish. So I purchased a pint to see how it went… its not cheap! I read the instructions on their knowledge base and it seemed simple enough so I thought I would start with the wheel hubs.

First job was stripping the thick powder coat off, and for this I used some commercial paint stripper. As you can see this makes short work of removing it! the stuff you buy from DIY stores is next to useless for this.

Next prep for the coating. I gave the hubs a good blasting with aluminium oxide grit to give it a key, then cleaned then in hot water with some detergent in. I never use washing up liquid for things like this (or rubbing down paintwork) as it contains silicone, which kind of defeats the object of trying for a clean surface! I then popped them in the warm oven for two reasons…. one is to make sure they are completely dry, and secondly if you mask them while warm, the tape sticks MUCH better. With regard to masking, I put the tape on, and then brush the edges with a riffler file and then you can peel it off perfectly.

Next i gave them a single thin coat of Cerakote. I used a paper strainer as they suggested. Its very thin, but highly pigmented and covers really well. It flash dries in 45 mins, and is handleable in a few hours, but it takes 5 days to fully cure. I was impressed with the ease of application and the finish!



(https://jtccc.files.wordpress.com/2024/02/hubs-1-copy.jpg)

(https://jtccc.files.wordpress.com/2024/02/hubs-2-copy.jpg)

(https://jtccc.files.wordpress.com/2024/02/hubs-3-copy.jpg)



with the hubs now painted it’s time to try something I haven’t done before, and that’s wheel building. I watched a few videos on Youtube and managed to loan a jig off my mate, which actually proved really useful! I got special dispensation to do it on the dining room table as I knew it would take a while and I wanted to be able to sit down!

I was actually surprised how easy it was! I managed to get the correct offset, and up and down and side to side within half a mm.. here they are complete with new bearings and seals.

(https://jtccc.files.wordpress.com/2024/02/wheel-1-1-copy.jpg)



(https://jtccc.files.wordpress.com/2024/02/wheel-1-2-copy.jpg)





Title: Re: Ducati 1000 DS build
Post by: ducpainter on February 24, 2024, 06:55:54 AM
Did you use anything like Alodine on the bare aluminum before painting to avoid corrosion?


Title: Re: Ducati 1000 DS build
Post by: buzzer on February 24, 2024, 09:40:12 AM
Did you use anything like Alodine on the bare aluminum before painting to avoid corrosion?

no, Cerakote is a ceramic coating that goes straight on bare metal.  It needs a blast profile though using an aluminium oxide grit to get good adhesion.  at the same time I did the hubs I did on old water pump body as a test piece...  after 24 hours the coating was still quite soft, but after 5 days when it was fully cured it was hard and incredibly scratch resistant.  I was VERY pleased with the result! 


Title: Re: Ducati 1000 DS build
Post by: ducpainter on February 24, 2024, 10:57:38 AM
I'm familiar with cerakote, and it would be fine over bare steel. Aluminum, and more so magnesium, are different animals and require a conversion coating to chromate the surface to avoid corrosion under the topcoat. Aluminum begins to oxidize instantly in the presence of oxygen leaving aluminum oxide on the surface.

Don't be surprised if you see bubbling under the coating.


Title: Re: Ducati 1000 DS build
Post by: buzzer on February 24, 2024, 11:35:43 AM
I'm familiar with cerakote, and it would be fine over bare steel. Aluminum, and more so magnesium, are different animals and require a conversion coating to chromate the surface to avoid corrosion under the topcoat. Aluminum begins to oxidize instantly in the presence of oxygen leaving aluminum oxide on the surface.

Don't be surprised if you see bubbling under the coating.

people have been using it on bare alloy for years with great results...  even the aerospace industry use it on bare alloy. no need for an etch primer, it's designed as a single coat process.


Title: Re: Ducati 1000 DS build
Post by: buzzer on February 25, 2024, 02:05:34 AM
headlight brackets took some thinking about, but I had plenty of time to do it lying in the sun! thank goodness for the Ipad and Ipencil!. I sent the drawing off to the water jet cutters and they cut them out of some nice 25mm plate, they came out well. I also designed them so i could mount the custom made indicators.

(https://jtccc.files.wordpress.com/2024/02/headlight-2.jpg)

the carbon battery tray came out OK, I initially made an alloy one, but it hung down too low and spooled the lines, so I made the carbon one stepped so the battery can sit in a recess to the side. its going to be tight with the electrics!

(https://jtccc.files.wordpress.com/2024/02/headlight-3.jpg)

(https://jtccc.files.wordpress.com/2024/02/53548912808_8e521501ca_o-copy.jpg)

Here it is inprofile, not long before i can take it all apart for painting!  At this stage its really important to try to mount everything...  you don't want to get it all painted/ powder coated and then find you are missing a bracket for say a horn!  I also wheeled it around and found that the forks hit the tank...  the lock stops are not adjustable on this so I am gong to have to extend them before painting...

I played around for hours trying to decide on high, low, beak type mudguard, but decided in the end to go low with a carbon one... with the advantage of a nice fork brace as well. Just ordered some orange fork gaiters, will see what that looks like!

(https://jtccc.files.wordpress.com/2024/02/53547848702_e90a7a59ca_o-copy.jpg)



Title: Re: Ducati 1000 DS build
Post by: buzzer on March 02, 2024, 03:41:09 AM
one of the few items on the bike that needed real attention was the swinging arm bush and needle roller bearing. it was badly rusted and seized… I checked and the bush is no longer available. I made one out of good quality steel, and case hardened it several times to build up the depth of the hardened layer. I also did a test piece and was pleased that I could not touch it with a file! I have not done case hardening for a LONG time!

(https://jtccc.files.wordpress.com/2024/03/case-harden.jpg)

I finished welding up the frame and parts. Where I had modified the frame tubes I put an internal tube so it didn’t crush it when I tightened the bolts, then I welded the support bushes on. Then it was off to the powder coaters, along with a big box pf parts to be plated.

(https://jtccc.files.wordpress.com/2024/03/sss-copy.jpg)

Its always stressful pulling an engine apart… you never know what you are going to find! I was really pleased as it came apart. there is no discernable wear on the bore, all bearings are nice and smooth, so its just gaskets, seals, and a new cam chain. I can see why these engines do mega miles, it’s VERY well built!

(https://jtccc.files.wordpress.com/2024/03/engine-1-copy.jpg)


(https://jtccc.files.wordpress.com/2024/03/engine-2-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: stopintime on March 02, 2024, 08:34:48 AM
What is "case hardening"? Or rather, how is it done?


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 02, 2024, 10:03:30 AM
What is "case hardening"? Or rather, how is it done?

it's where you heat steel to cherry red (720 ish degrees) and then immerse it in a carbon rich compound.  the steel absorbs some of the carbon into its structure.  you do it a couple of times then quench it to harden it.  it gives a very hard layer to the steel.


Title: Re: Ducati 1000 DS build
Post by: stopintime on March 02, 2024, 10:45:16 AM
 [thumbsup]

Is that some of the same principle as when iron becomes steel?


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 04, 2024, 01:24:27 AM
[thumbsup]

Is that some of the same principle as when iron becomes steel?

yes, if you add carbon to iron it becomes steel, the more carbon, the easier it is haren by heating and quenching.  Lots of components are case hardened... it has the advantage of a hard wearing surface, with a core that's not brittle.


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 04, 2024, 01:26:01 AM
the engine build is well underway…its a nice and simple engine to build, I do like the way honda gets all the tolerances spot on! While I was on I polished the ports, and matched the inlet manifold to the head. I also did a bit more Cerakote, and I have to say its easy to apply, and gives a superb finish, I would say that its easily up to factory standard! I have used the air dry titanium colour on the side case for a bit of contrast and will also be using this on the oil lines.

(https://jtccc.files.wordpress.com/2024/03/53564672502_ef3bfa9776_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/03/53566914643_d24f2eaf7f_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 05, 2024, 04:40:24 AM
Onto rebuilding the forks, boy the oil was black in there! they were all OK though so new seals and dust covers, and some new oil. I often hear of people replacing fork seals and still having them leak afterwards…. This is often because people install the seals by tapping them in with a punch! this invariably damages the seal lip, hence they leak. the best way to install them is with a nylon collar supported in the vice… that way you can tap them in nice and square and get then seated on the bottom of the land.

(https://jtccc.files.wordpress.com/2024/03/53567768011_f3e51bb3a2_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/03/53567767961_1e3333f04d_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: greenmonster on March 06, 2024, 04:21:55 AM
Good tip.


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 07, 2024, 11:00:22 AM
The engine is all back together now and I am pleased with the results.  There will be a break in posts for a while...  I need a bit more sun!

(https://jtccc.files.wordpress.com/2024/03/53572243967_54e41b232a_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/03/53572243952_a5ee30c74b_o-copy.jpg)


Title: Re: Ducati 1000 DS build
Post by: ducpainter on March 07, 2024, 03:42:06 PM
The engine is all back together now and I am pleased with the results.  There will be a break in posts for a while...  I need a bit more sun!

(https://jtccc.files.wordpress.com/2024/03/53572243967_54e41b232a_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/03/53572243952_a5ee30c74b_o-copy.jpg)
Are you leaving England? [evil]


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 11, 2024, 07:11:14 AM
Are you leaving England? [evil]

yes  [wasn't]  few days in Dubai, and now Maldives...  [thumbsup]


Title: Re: Ducati 1000 DS build
Post by: stopintime on March 11, 2024, 07:17:38 AM
Couldn't you just take vitamin D and keep buiding?


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 11, 2024, 09:25:17 AM
Couldn't you just take vitamin D and keep buiding?

I could...  But then I would miss sitting by the infinity pool and shower, with a beer... watching the pretty girls  [wine] [laugh] [laugh]


Title: Re: Ducati 1000 DS build
Post by: stopintime on March 11, 2024, 11:42:56 AM
Ok - that's importanter.


Title: Re: Ducati 1000 DS build
Post by: ungeheuer on March 11, 2024, 12:41:54 PM
Couldn't you just take vitamin D and keep buiding?
[laugh]


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 16, 2024, 07:56:05 AM
Ok - that's importanter.

it was :)  All I can say is thank goodness for mirror sunglasses  [evil]

but back to reality... and bike building!

painting day… I debated on painting some of the parts satin black, but I actually like the fake carbon, plus its very durable. The fuel filters came as well.. I bought an 8mm and a 6mm one and swapped the parts over to compensate for the fact the fuel tap is a smaller pipe than the carb!

(https://jtccc.files.wordpress.com/2024/03/53586335985_b437acdff5_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/03/53585890211_b9a9fed71f_o-copy.jpg)

I was going to put a standard Honda decal on the tank, but then I saw these and liked them… not from the usual supplier, but the seller also sent me some samples so i could test the compatibility with the laquer. It was fine thank goodness. When painting over decals there are a few tips… first off I always do a first coat of laquer and let it dry, i never put them on the base coat. then I wet sand with 1000 wet and dry and then stick the decals in place. Now the important bits… Always wipe the area with panel wipe… this is for two reasons. Firstly, there is always some adhesive on the edge of the decal, and secondly they often have silicon on them and that makes the paint cess. I always give a mist coat over the decal and let it tack off, the reason for this is if you hit it with a full coat first you end up with runs off the horizontal edges of the decal.

I looked at the filler cap that came new with the tank and decided it looked crap, so I took it apart and made a new on incorporating a breather.

(https://jtccc.files.wordpress.com/2024/03/53591433735_53d08e9a29_o.jpg)

(https://jtccc.files.wordpress.com/2024/03/53591113656_f0cd3a1b2d_o.jpg)


Title: Re: Ducati 1000 DS build
Post by: stopintime on March 16, 2024, 08:15:39 AM

....so I took it apart and made a new on incorporating a breather.

Of course you did  [thumbsup]


Title: Re: Ducati 1000 DS build
Post by: buzzer on March 17, 2024, 09:20:29 AM
I have come to a standstill now until the powder coater finishes my frame and parts, which is quite frustrating! Like so many business these days he just can't get good reliable staff so has a backlog...

I have also finished the wiring diagram ready to do the electrics.

(https://jtccc.files.wordpress.com/2024/03/53593821825_4511b67638_o-copy.jpg)

(https://jtccc.files.wordpress.com/2024/03/honda-wireing-digram-v3.jpg)



Title: Re: Ducati 1000 DS build
Post by: DucHead on March 20, 2024, 04:09:29 AM
Fantastic stuff!!  8)

I have a few engine covers (Suzuki) that I stripped, blasted, and applied Cerakote with no underlayer.  They look great after a few years, but I'll keep an eye on them.  I've also Cerakoted a few sets of carburetors.


Title: Re: Ducati 1000 DS build
Post by: ducpainter on March 20, 2024, 05:22:57 AM
Hey, maybe it works, it just goes against my training. I suspect a lot of it depends on handling, and timing.


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