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Ducati Monster 900 restoration

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buzzer1955
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PostPosted: 10:47 - 12 Dec 2020    Post subject: Reply with quote

Paddy. wrote:
Do you do more other than just Ducati, or is it because of the familiarity?


over the years I have done many... but of course in the old days I didn't take any photographs to record the builds! just the odd ones! i used to do cars as well...

here are a few from recent years, but take a look at my blog.... www.jtccc.wordpress.com


https://jtccc.files.wordpress.com/2020/10/0000aaaaa-4-copy.jpg

https://jtccc.files.wordpress.com/2018/04/ducati-multistrada-custom-2.jpg

https://jtccc.files.wordpress.com/2019/01/aadsc01466.jpg

https://jtccc.files.wordpress.com/2020/05/49926122953_551ac1c7b3_o-copy.jpg

https://jtccc.files.wordpress.com/2018/07/a-ducati-monster-small-2.jpg

https://jtccc.files.wordpress.com/2015/11/suzuki-gt500-t500-cafe-racer-2.jpg

https://jtccc.files.wordpress.com/2016/05/ducati-st4-1.jpg

https://jtccc.files.wordpress.com/2014/02/1.jpg

https://jtccc.files.wordpress.com/2014/02/bike-on-ramp-1.jpg

https://jtccc.files.wordpress.com/2014/02/a-harley-2-reg1.jpg

https://jtccc.files.wordpress.com/2014/02/yamaha-rd.jpg
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arry
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PostPosted: 17:09 - 12 Dec 2020    Post subject: Reply with quote

Just had a look at your blog. You've had some mega cars Cool
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buzzer1955
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PostPosted: 17:56 - 12 Dec 2020    Post subject: Reply with quote

arry wrote:
Just had a look at your blog. You've had some mega cars Cool


Very Happy yes, my all time favourite was the Clio Trophy... but I had to sell it as it made my wife sick Crying or Very sad

Did a bit of painting and polishing today… painted and lacquered the clutch cover, and rear spring, and put a coat of lacquer on the cam belt covers which I had decided to carbon effect dip… not everyone’s cup of tea I know, but I like the look… The silencers came up really well! there were a few marks on them that would have niggled me so I decided to polish them.

as an aside, while the spray gun had some lacquer in, I finished off some cheese boards I have been making as Christmas presents for friends... its got me a few brownie points.. the fruit and spices are encapsulated in clear casing resin.

https://jtccc.files.wordpress.com/2020/12/polishing-copy.jpg

https://jtccc.files.wordpress.com/2020/12/chopping-boards-copy.jpg
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Shaft
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PostPosted: 23:17 - 12 Dec 2020    Post subject: Reply with quote

buzzer1955 wrote:
arry wrote:
Just had a look at your blog. You've had some mega cars Cool


Very Happy yes, my all time favourite was the Clio Trophy... but I had to sell it as it made my wife sick Crying or Very sad



Given your penchant for Italian iron, I'm surprised you didn't pick one of your Lancias - the Monte was a bit 'difficult', but Themas were great cars, I did very well with them (and Cromas) when I was trading, so much cheaper than Saab 9000s.

Having said that, I do have a soft spot for Scimitars, in fact pretty much anything with a 3.0 Essex, except for my Gilburn Invader, which was a dog with fleas Laughing
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buzzer1955
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PostPosted: 19:07 - 14 Dec 2020    Post subject: Reply with quote

[/quote]

Given your penchant for Italian iron, I'm surprised you didn't pick one of your Lancias - the Monte was a bit 'difficult', but Themas were great cars, I did very well with them (and Cromas) when I was trading, so much cheaper than Saab 9000s.

Having said that, I do have a soft spot for Scimitars, in fact pretty much anything with a 3.0 Essex, except for my Gilburn Invader, which was a dog with fleas Laughing[/quote]

I had a couple of Scimitars, a 3.0 and also a 2.5 straight 6 with a raymond hayes head and triple SU carbs.. my other favourite car was the BMW 7 series...

Started the rebuild… first job was to put the frame on the engine, easy job, I held it, my wife popped the bolts in! I then fitted the headstock bearings, which I have replaced as there were small sighs of pitting, and they are cheap. I pulled them in rather than use a hammer, which also means you can give them a good tighten and bed them in nice and hard against the register. Its starting to come together… Was also playing around with the image of the engine…


https://jtccc.files.wordpress.com/2020/12/50716400947_c5ed40a295_o-copy.jpg

https://jtccc.files.wordpress.com/2020/12/head-stock-copy.jpg

https://jtccc.files.wordpress.com/2020/12/50720213611_0717096a72_o-copy.jpg
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buzzer1955
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PostPosted: 18:49 - 15 Dec 2020    Post subject: Reply with quote

my wife will often say I am definitely on the spectrum... today I fitted the side stand and noticed there was more play than I liked... so I made a new bush, and bronze thrust washer as I knew it would niggle me if I didn't!

https://jtccc.files.wordpress.com/2020/12/50723736042_1ce1ee0937_o-copy.jpg
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buzzer1955
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PostPosted: 11:00 - 18 Dec 2020    Post subject: Reply with quote

Its funny how to me progress seems slow, but when you come to put it all together you realise that all the little jobs you have been doing over the months are now paying off as it becomes an assembly job! One thing I have done in the last few days is to check the loom over… its in great condition apart from one area… It looks like someone has fitted an alarm at some point…, and someone has subsequently removed it! they didn’t do a bad repair, but I hate the tape over bare wires, and I wanted to check the integrity of the joints, so I pulled the soldered wires apart and re-soldered them, and covered the join with shrink wrap. To finish it off nicely I took the terminals out of the blocks with my terminal removal tool. this is a fantastic little set of tools, and very cheap to buy.. I have lost count of the times I have used them over the years! that meant I could use some braided expandable sheathing which most cars seem to use these days. it means it can go over the terminals and then fit tight on the wires. this is finished off with some hear shrink, and if you use the glue lined stuff it makes a good repair.

probably my last update this side of the holiday... Merry Christmas!

https://jtccc.files.wordpress.com/2020/12/wireing-copy-small.jpg

https://jtccc.files.wordpress.com/2020/12/engine-in-frame-3-small.jpg

https://jtccc.files.wordpress.com/2020/12/engine-in-frame-1-small.jpg

https://jtccc.files.wordpress.com/2020/12/engine-in-frame-4-small.jpg
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struan80
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PostPosted: 15:18 - 18 Dec 2020    Post subject: Reply with quote

Shocked Cool Nice mate.
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Easy-X
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PostPosted: 16:26 - 18 Dec 2020    Post subject: Reply with quote

https://media.giphy.com/media/huyVJYSKcArLiu8J5g/giphy.gif
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buzzer1955
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PostPosted: 12:17 - 26 Dec 2020    Post subject: Reply with quote

back after the break... I did relent and have a few hours in the workshop Mr. Green next the hydraulics … I stripped everything down and cleaned the callipers and master cylinder up. the callipers came up well, but the anodizing on the master cylinders were poor… so I bead blasted them and have decided to leave them silver… All the seals were perfect, so I have reused these. I cleaned the callipers up in petrol with some very fine scotchbrite, being very gentle, they came up a treat.

looked at the switchgear and although its in great condition, the plastic sleeving was tatty… so I used some of the braided stuff, and some glue lined shrink wrap to finish it off… the braided stuff expands a lot, so no need to remove the terminals off the wire which is a bonus.

https://jtccc.files.wordpress.com/2020/12/hydralics-copy.jpg

https://jtccc.files.wordpress.com/2020/12/50750513308_79f484eae3_o-copy.jpg
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buzzer1955
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PostPosted: 14:36 - 29 Dec 2020    Post subject: Reply with quote

starting to go back together, I am pleased with the way the exhaust and silencers polished up… Polishing always hurts my wrists these days… must be getting old 😟

https://jtccc.files.wordpress.com/2020/12/wheels-2-copy.jpg
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buzzer1955
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PostPosted: 15:28 - 13 Jan 2021    Post subject: Reply with quote

Time to start up soon… I am always aware that a rebuilt engine needs oil at first start-up, and while I always fill the filter before I screw it on, the oil cooler and pipes are empty, as are the oil ways, and the oil pump. I have therefore always used this method of giving the engine the best start in life I can and inject some oil into the system via the oil pressure switch port.

I used to do it on many of the race engines I have built in the past and it was always satisfying to take the oil filler cap off and see oil seeping out the rocker shafts or cam bearings. Either way I always turn it over until the oil warning light goes out… which unless you prime the oilways can be a worrying amount of time!

https://jtccc.files.wordpress.com/2021/01/oil-fill-copy.jpg
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buzzer1955
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PostPosted: 12:47 - 15 Jan 2021    Post subject: Reply with quote

well it started first time! I screwed in my oil pressure gauge and it went up straight away… sounded nice! I like to start builds on a dummy tank if I can…. I made that tank over 40 years ago, its started a few engines! its still got an original laverda tap on it!

https://jtccc.files.wordpress.com/2021/01/oil-presure-copy.jpg

https://jtccc.files.wordpress.com/2021/01/dummy-tank-copy.jpg
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buzzer1955
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PostPosted: 16:59 - 28 Jan 2021    Post subject: Reply with quote

been out of action for almost 2 weeks... strained my left hand, taking off a lid off a jar of all things, so thought it better to rest it... getting there now... sigh of getting older I guess...

Started preparing the tanks and bodywork for painting… I know the tank hinge on the monster is a weak point, and it did show evidence of being strained… I didn't want to paint the tank and find out it soon failed, so I decided to take the bracket off and strengthen the area and TIG weld the bracket back on… I normally have tanks blasted but the guy who does it for me is off with Covid at the moment, so it may be a while before he is back, and I don’t trust anyone else after having some shocking jobs done in the past….

https://jtccc.files.wordpress.com/2021/01/tank-repair-copy.jpg

https://jtccc.files.wordpress.com/2021/01/50884995047_09d1c77c07_o-copy.jpg
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buzzer1955
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PostPosted: 17:06 - 29 Jan 2021    Post subject: Reply with quote

things didn’t go well with the painting… the seat cowl had rattle can paint on it by the look of it... and it reacted badly to the base coat. going to have to do it all again. the other parts came out well though… two coats of clear on the mudguard and fairing, one coat on the tank before I put the decals on and then hit it with one and a half coats…

https://jtccc.files.wordpress.com/2021/01/50887295223_1e1c7db056_o.jpg
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arry
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PostPosted: 17:26 - 29 Jan 2021    Post subject: Reply with quote

Wow that's come on amazingly Cool
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buzzer1955
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PostPosted: 11:19 - 01 Feb 2021    Post subject: Reply with quote

arry wrote:
Wow that's come on amazingly Cool


thanks!

Painting is all finished and I am happy with the results... I love the way 2k just comes out with a gloss from the gun... here is a 25 second video...

https://www.youtube.com/watch?v=fgFTyJd4fQs



just ordered a new battery...
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buzzer1955
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PostPosted: 17:44 - 04 Feb 2021    Post subject: Reply with quote

One of the few fabrication jobs I have done on this bike… I have decided to fit an ignitech ignition… Most people seem to fit them next to a smaller battery, or move the coils over, but I wanted to keep the unit away from the heat of the engine… So I made a bracket to fit it under the LH side panel. it just fits nicely…

https://jtccc.files.wordpress.com/2021/02/ignitech-mounting.jpg
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buzzer1955
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PostPosted: 15:14 - 06 Feb 2021    Post subject: Reply with quote

well apart from a few snagging jobs, and replacing the rear brake hose which is too long… its finished. I need to tweak the ignitech unit and enable one of the output channels to limit the revs to 2500 when the stand is down… When I was 19 a good mate rode away from the pub with the stand down… just up the road he came off, and the accident resulted in him losing an arm… those things stay with you…

Need to find another project now! if anyone in the UK has anything... let me know!

https://jtccc.files.wordpress.com/2021/02/side-2-copy.jpg

https://jtccc.files.wordpress.com/2021/02/side-1-copy.jpg
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Easy-X
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PostPosted: 16:41 - 06 Feb 2021    Post subject: Reply with quote

Fancy a CBR1000F from the '80s? Laughing

Stunning work on the Ducati Thumbs Up
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buzzer1955
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PostPosted: 10:34 - 16 Feb 2021    Post subject: Reply with quote

Easy-X wrote:
Fancy a CBR1000F from the '80s? Laughing

Stunning work on the Ducati Thumbs Up


not one I fancy to be honest... struggling for inspiration for the next build...

They say a build is never finished… in some ways true! I am still finding little jobs to do like making some frame bungs as none came with the bike…

https://jtccc.files.wordpress.com/2021/02/frame-bungs.jpg
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arry
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PostPosted: 10:38 - 16 Feb 2021    Post subject: Reply with quote

buzzer1955 wrote:

not one I fancy to be honest... struggling for inspiration for the next build...


What are you doing with the Monster when the new project comes in? Shifting it on?
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buzzer1955
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PostPosted: 11:12 - 16 Feb 2021    Post subject: Reply with quote

arry wrote:
buzzer1955 wrote:

not one I fancy to be honest... struggling for inspiration for the next build...


What are you doing with the Monster when the new project comes in? Shifting it on?


I am going to keep this one... I was reflecting the other day about a day in 1994 when I went to work on My Laverda Jota...it was such a nice day I rode past work and went to Slater Brothers the Laverda importers at Collington. When I got there I parked next to a red 900 Monster... It was the first time I had seen one in the flesh... I was looking around it when Richard Slater came out with the keys and said take it for a spin! I was really impressed, much lighter and agile than the Jota... I have always wanted one since then!

I am however going to move the 996 engine bike on soon as the weather picks up and I can get it MOTed...
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buzzer1955
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PostPosted: 12:06 - 22 Feb 2021    Post subject: Reply with quote

I was looking at the picture of the bike the other day and thought” those silencers are too long”… and its too quiet… Well I had the original silencers which were quite marked, So I looked at shortening them and removing part of the baffle… not a bad job… by removing the bracket I was able to slide the sleeve down enough to remove the end with a cutting disc. I then cut 100mm off the inner and sleeve (both ends to preserve the stampings) , and welded it all back up again. One thing I learned many years ago when welding exhausts is to clean the carbon off the inside… or it leaches through the weld and the joint cracks! They polish up really well…you just have to remove the original finish with a DA sander with some 120 grit, followed by some 400, then polish…

https://jtccc.files.wordpress.com/2021/02/silencer-h.jpg

https://jtccc.files.wordpress.com/2021/02/silencer-i.jpg

https://jtccc.files.wordpress.com/2021/02/silencer-a.jpg
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buzzer1955
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PostPosted: 15:51 - 23 Feb 2021    Post subject: Reply with quote

well my builds have come to an end for this year... and one must go to make way for a new project which I will hopefully start next winter. not sure what it will be yet... time to think, and find something suitable...

https://jtccc.files.wordpress.com/2021/02/4-bikes-copy.jpg
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