Pictures of my Ducati Winter build 2019/20

[buzzer1955]

Hi guys. First post here...

Every winter i do a project, sometimes a car, but for the last few years a bike. This year its been a Ducati, same as last year, and the year before it was a Suzuki.

So my thoughts are turning to the next project... which i want to be a scrambler style bike. With that in mind, i will be looking for a donor, so i am looking for suggestions and insparation!

The criteria is...

Air cooled
Spoked wheels
500cc or bigger
Must have a strong reliable engine
Budget of about £2000

Any suggestions?

[Robby]

XL600R ticks your boxes.

[buzzer1955]

Well I missed all but one of my criteria... Only managed to get below £2000... here are a few photos that tell the story of this winters build...

https://jtccc.files.wordpress.com/2019/02/aadsc01482.jpg
https://jtccc.files.wordpress.com/2019/03/33391376238_fe6f919109_o.jpg
https://jtccc.files.wordpress.com/2019/04/manifold-1.jpg
https://jtccc.files.wordpress.com/2019/08/tank-fab.jpg
https://jtccc.files.wordpress.com/2019/09/brracket-die.jpg
https://jtccc.files.wordpress.com/2019/11/crack-2.jpg
https://jtccc.files.wordpress.com/2019/11/ducati-996-engine-paint-1.jpg
https://jtccc.files.wordpress.com/2019/11/diy-plating-3.jpg
https://jtccc.files.wordpress.com/2019/11/finished-zinc-plating.jpg
https://jtccc.files.wordpress.com/2019/11/top-yoke.jpg
https://jtccc.files.wordpress.com/2019/12/frame-on-engine-3-small.jpg
https://jtccc.files.wordpress.com/2019/12/img_0894-copy.jpg
https://jtccc.files.wordpress.com/2019/12/49187760423_b63409eb06_o-copy.jpg
https://jtccc.files.wordpress.com/2019/12/side-1-copy.jpg
https://jtccc.files.wordpress.com/2019/12/leads.jpg
https://jtccc.files.wordpress.com/2019/12/wiring-1.jpg

[stinkwheel]

I'm going to move this to Show and Tell so it doesn't drop off the bottom so quickly.

You might want to edit the title of the original post so people can see what the project is?

I like your mudguard bracket mandrel. Wish I had the machining expertise to make stuff like that. I landed up brazing tabs onto mine.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[buzzer1955]

[stinkwheel]

Loving the birds-nest on the floor in this picture:
https://jtccc.files.wordpress.com/2019/12/wiring-1.jpg

Did you buy a used car loom or is that what you ripped out of the bike? Car loom is a good way to get lots of different colour wires cheaply.

What's the little PCB with the LED readout on it?
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[buzzer1955]

yes, I went to the scrap yard and got some bits of car loom for the wire, its a good source...

the digital readout is for the fan... The fan was originally switched by the old ECU but the new ignition does not have that function... this is a cheap and easy way around it, the little unit is less than £5 and they are quite reliable and can be set to switch at any temperature. the temp probe fits in the original sensor plug with some araldite... the unit is now in a little plastic box...

I like to draw the circuits of the wiring as I do it, and write the colours on the print out as I go along... nice to give any new owner some help for the future, otherwise it would be a nightmare to fault

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

[buzzer1955]

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

[Pete.]

That's simply awesome Tony, I have a ton of questions and every time I look at the pics another one pops up.

Love the DIY plating setup. What is it copper then zinc? Did you have any trouble with the spindle diameters growing?

Did you roll the cones for the cans yourself? They look very neat.

What happened to the lobster-back ends on the cans? Change your mind?

Carbs from what?

Can't place the lathe. Looks very "South-bend 9 clone" but the countershaft tensioner lever I can't place that at all. Early non-underdrive Boxford? I love that you're using the original rocker post, I wouldn't have the patience for that.

Frustratingly, I can't place that bench-top milling-machine with the funky jig-bore-style sliding head either.

How many times did you have to go round the tank to get all the pin-holes?

Totally inspirational really. I'd like to see much more.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[buzzer1955]

Thanks Pete!

the plating came out well... it was a zinc kit and I did the blue pasivate to get the bright colour. its microns thick, so there were no problems with threads and spindles.


to roll a cone is very difficult... I bought the silencers with the lobster back quite cheaply (£20 each) off ebay... and cut the ends off and used the front cones, and made the end cone. I can pop some restrictive baffles in there to keep the mot man happy.

The carbs ar 48 mm CV off a honda VTR... the biggest cards fitted to any bike I could find... the original throttle bodies were 50mm so they should be OK....

The lathe is a Boxford... I bought it 40 years ago... it came with lots of tooling, and imperial and metric change wheels which I still have, and even the original handbook with the commissioning installers sheet, all filled in! its a lovely machine

the milling machine is VERY old, there is no name on it, but it dates from the early 30's. again its a robust machine. Last year I replaced it... with a Clarke machine. it lasted a week, it was pathetic compared to the one you see in the pictures. I quickly sold it and went back to the old one!

as for welding the tank... I had two leaks... I use a dye penetrant kit which is brilliant! spray on the dye, leave for a min, and then spray the developer on there. any leaks show immediately. you then spray on a cleaner, and weld up the leak. picture below. I have made a couple of alloy tanks in the past, but used fibreglass covers on them.

https://jtccc.wordpress.com

you can always look at my blog, link above, if you want to see more....




https://jtccc.files.wordpress.com/2019/08/leak-detection.jpg

https://jtccc.files.wordpress.com/2015/11/tank-14.jpg

https://jtccc.files.wordpress.com/2015/11/tank-16.jpg

https://jtccc.files.wordpress.com/2015/11/tank-stree-1.jpg

https://jtccc.files.wordpress.com/2015/11/tank-styree-3.jpg

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





[img][/img]

[Easy-X]

Nice! Love the leak-dye idea
____________________
Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[Pete.]

[Easy-X]

"This one weird trick will increase the range of your bike!!!"
____________________
Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[buzzer1955]

[Easy-X]

The "one weird trick" I do know for tanks that have recently had fuel in: pipe the exhaust from a car into the tank and that purges all the petroleum fumes out after running for a bit.
____________________
Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[Pete.]

[Easy-X]

Dammit, I get educated every day on here
____________________
Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[buzzer1955]

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

[A100man]

Very impressed. Only wish I had the skills and the necessary commitment...
BTW T500 Suzuki? Did you make the expansions??

Cheers
____________________
Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600

[buzzer1955]

[dekip]

Great, man.

As a electronics/programmer geek, i like the use of thermocouple. These cold joints makes me crazy these days as i am in designing custom board for high temperature measuring. Eventually, it works.
____________________
Long time reviewer in computer magazine.
That include all wireless devices, SBC and microcontrollers. When my brain get stuck, all that helps is ride.
My bikes: MZ 175SE (1967), Yamaha Virago XV535 (1993) and TVS Apache (2008)

[buzzer1955]

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


https://jtccc.files.wordpress.com/2020/02/primer-small.jpg

[Easy-X]

Maybe these would be of help:

https://i.imgur.com/3gD8m0b.jpg
https://i.imgur.com/kRVilkU.jpg
https://i.imgur.com/Gd6AAB8.jpg
https://i.imgur.com/HJ9ZfPJ.jpg
https://i.imgur.com/Tz06z5J.jpg
https://i.imgur.com/R2kZl8R.jpg
https://i.imgur.com/DLDGarJ.jpg
https://i.imgur.com/UtAPCzS.jpg
____________________
Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[stinkwheel]

Red ones go faster. Well known fact.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[buzzer1955]

Easy-X that's brilliant! Thank You!! i like several... I am going to ponder while we are away...