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Another Ducati 1000 build...

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buzzer1955
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PostPosted: 16:20 - 27 Aug 2020    Post subject: Reply with quote

started work on the seat base. I have cut it to shape and added the Rivinuts to hold it on. I have used aluminum ones as these are much easier to pull in with a nut and bolt if you don’t have the special tool to draw them in…

Also a picture of how its looking... I know this build will finish well before Spring next years so I have bought another project to see me through the dark months of winter... watch this space!

https://jtccc.files.wordpress.com/2020/08/rivinuts-seat-copy.jpg

https://jtccc.files.wordpress.com/2020/08/progress-copy.jpg
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DownHillMania...
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PostPosted: 17:26 - 28 Aug 2020    Post subject: Reply with quote

Wow dude, this looks amazing! How did you learn to do it? I could never do so much on my own... You must be some kind of wizard, right?
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buzzer1955
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PostPosted: 23:59 - 31 Aug 2020    Post subject: Reply with quote

DownHillManiac86 wrote:
Wow dude, this looks amazing! How did you learn to do it? I could never do so much on my own... You must be some kind of wizard, right?



Mr. Green definitely not a wizard Embarassed I learned many skill in my early years as a Bentley and Bristol mechanic... that ages me somewhat... I moved into IT programme management in later years, but always been an engineer at heart Very Happy

more of my stuff on my blog.... www.jtccc.wordpress.com
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DownHillMania...
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PostPosted: 07:21 - 02 Sep 2020    Post subject: Reply with quote

buzzer1955 wrote:
but always been an engineer at heart Very Happy


Yes, i can definitely see that. Great job man Very Happy Thumbs Up
And you have a nice blog as well, you're really into it. Very cool Smile
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buzzer1955
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PostPosted: 15:35 - 02 Sep 2020    Post subject: Reply with quote

Still in the middle of a build of a multistrada special when a bike i have always wanted came up at a bargain price… an early Ducati Monster. With the prospect of limited going out and no holidays due to Corvid, and the fact the current build will be finished before winter, I decided to buy it! here it is… It's a bit tatty, but it runs well and sounds sweet. Ripe for restoration its going to the back of the garage for a while… this will be a straight restoration though, probably red as I like red monsters!

https://jtccc.files.wordpress.com/2020/09/ducati-monster-900-restoration-1.jpg

https://jtccc.files.wordpress.com/2020/09/ducati-monster-900-restoration-3.jpg
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buzzer1955
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PostPosted: 17:07 - 02 Sep 2020    Post subject: Reply with quote

On the last couple of builds where I have converted from EFI to carbs I have used an Ignitech ignition unit that utilised the original induction sensor. While the bikes ran OK, I had to make adjustments in the software to compensate for the fact that the values in the software differed from what was actually happening on the bike, plus the tick over was not as steady as I would have liked… This irritated me, and Ignitech themselves refused to answer emails for advice… so I investigated a hall effect setup.

I read about it on the fastbikegear website (Liam has been VERY helpful) and decided to give it a go… The sensors are tiny, and sense two small magnets in the cam wheel through a couple of 3mm holes in the alloy plate. South Pole switches it on, north off, so it’s important to get them the right way round, hence the magnet and phone! Here is how I made it, took a while! The values in the software now match the actual advance when checked with a strobe, and the tick over is rock solid! I have shown it here on the 996 engine as that bike is on the road…


https://jtccc.files.wordpress.com/2020/09/ignitech-hall-effect-ignition-4.jpg
https://jtccc.files.wordpress.com/2020/09/ignitech-hall-effect-ignition-1.jpg
https://jtccc.files.wordpress.com/2020/09/ignitech-hall-effect-ignition-3.jpg
https://jtccc.files.wordpress.com/2020/09/ignitech-hall-effect-ignition-2.jpg
https://jtccc.files.wordpress.com/2020/09/ignitech-hall-effect-ignition-5-small.jpg
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buzzer1955
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PostPosted: 13:23 - 06 Sep 2020    Post subject: Reply with quote

well its running really well now, and its got a very stable tickover... dry clutch always sounds like a bag of spanners through!

here is a short video...

https://youtu.be/M_b45UEcvsA
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buzzer1955
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PostPosted: 16:37 - 13 Sep 2020    Post subject: Reply with quote

Now for the part I actually enjoy doing… the wiring! I am building this loom completely from scratch, save for things like the handlebar switches, although I am replacing the outer sheathing as it was tatty. I know this is something a lot of people struggle with but over the years I have developed a system… I start with a design in my head and I put it down in rough on my Ipad, using an Ipencil which I find brilliant. then I transfer it to visio, which I print out and add the colour of wires on as I go along. I don’t try to it all on one diagram like in workshop manuals, but keep separate pages for different circuits like lights, indicators, ignition… I also create tables of key components where they have pin outs.

All this is put into the build folder which I always pass on when I sell the bikes.

I have a nice crimp tool which is normally sufficient, but if I am in any doubt I put a dab of solder on the joint. I also don’t use pre insulate connectors, instead I put 20mm of heat shrink on which makes a nice joint, and the heat shrink also supports the joint. If you use the glue lined heat shrink, it also makes the joint waterproof. this is of course if I am not using super seal connectors which are not only excellent, but also cheap! and finally, I use the most useful little kit, which has tools for removing all types of pins from connectors!


https://jtccc.files.wordpress.com/2020/09/wireing-1.jpg
https://jtccc.files.wordpress.com/2020/09/ignitech-wire-diagram-1.jpg
https://jtccc.files.wordpress.com/2020/09/hall-sensor-dia.jpg
https://jtccc.files.wordpress.com/2020/09/connector.jpg
https://jtccc.files.wordpress.com/2020/09/terminal-tool.jpg
https://jtccc.files.wordpress.com/2018/11/crimp.jpg
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buzzer1955
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PostPosted: 09:59 - 21 Sep 2020    Post subject: Reply with quote

Run out of a few wire connectors so moved onto the cam belt covers till they come… I made some of these a few years ago and they worked well… but this time I have made the holes oval and I think they look better. used a hole saw to cut the circles, and a saw in the dremel to cut the straight bits. just got to carbon dip them now and make the polycarbonate windows…

Also mounted the plate that holds the hall sensors

https://jtccc.files.wordpress.com/2020/09/cambelt-cover-1-copy.jpg

https://jtccc.files.wordpress.com/2020/09/cambelt-cover-2-copy.jpg
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buzzer1955
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PostPosted: 17:37 - 23 Sep 2020    Post subject: Reply with quote

for some parts of the loom I have used this braided sheathing... its a bit fiddly to do but the results are good. I notice a lot of cars use this now on the loom.

Another job I have been meaning to get around to... The FCR carbs need a one into two cable setup. I was going to use a junction box off an old British bike, but all the ones I could see were either too short on the pull distance, or terrible quality, so I decided to make one. I was going to make it out of aluminum but had difficulty getting nice threads, probably due to the grade of alloy bar I had. so brass it is. It also allowed me to put longer holes to retain the cables, all the ones I looked at only had short holes.

https://jtccc.files.wordpress.com/2020/09/50375900692_f9832008d5_o-copy.jpg

https://jtccc.files.wordpress.com/2020/09/50375900557_1d4a174f20_o-copy.jpg

https://jtccc.files.wordpress.com/2020/09/50375900677_ec910c216a_o-copy.jpg
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P.
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PostPosted: 17:59 - 23 Sep 2020    Post subject: Reply with quote

If you and Pete. worked together... there would be some serious weaponry on the roads...

Loving this.
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buzzer1955
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PostPosted: 17:49 - 24 Sep 2020    Post subject: Reply with quote

Paddy. wrote:
If you and Pete. worked together... there would be some serious weaponry on the roads...

Loving this.


Thanks!

here is the plate to hold the ignition switch. It didn't look right just flat, so I made a small press tool to add a raised ring where the switch goes.

https://jtccc.files.wordpress.com/2020/09/ignition-1-copy.jpg

https://jtccc.files.wordpress.com/2020/09/ignition-2-copy.jpg
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buzzer1955
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PostPosted: 18:49 - 26 Sep 2020    Post subject: Reply with quote

Finished the wiring apart from the horn as it didnt seem to like being bead blasted!

https://jtccc.files.wordpress.com/2020/09/finished-wireing-copy.jpg
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buzzer1955
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PostPosted: 19:37 - 28 Sep 2020    Post subject: Reply with quote

Been carbon fiber decorating my belt and clutch covers today... not decided if its going to be gloss or matt clear coat yet...

I like this hydrographics, I may do my helmet soon, there are some nice films out there! here is a link to a 2 min video of how its done in the back garden with an Ikea box! if you don't like fake carbon... don't click the link!

https://www.youtube.com/watch?v=jh6Hh1F0-Yg
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Easy-X
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PostPosted: 11:58 - 29 Sep 2020    Post subject: Reply with quote

What? They're not real carbon fibre parts?! Illusions shattered Laughing Laughing Laughing

How many goes did it take to get your technique down pat? Wink
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buzzer1955
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PostPosted: 17:18 - 29 Sep 2020    Post subject: Reply with quote

Easy-X wrote:
What? They're not real carbon fibre parts?! Illusions shattered Laughing Laughing Laughing

How many goes did it take to get your technique down pat? Wink


sorry to disappoint! Mr. Green

I have done the dipping a few times now... the key seems to be get the water to 65-70 degrees... make sure the film is the right way up (don't ask me how I know that!) and don't spray too close, and wet it out until it shines like glass and stop. Oh, and think about the angle of dip to prevent voids. here is the results now they are clear coated...



https://jtccc.files.wordpress.com/2020/09/50397865326_a113460bf0_o.jpg
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buzzer1955
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PostPosted: 16:06 - 02 Oct 2020    Post subject: Reply with quote

Done a few jobs in preparation for the start… put the jets in the carbs, started with what I think will be rich to be on the safe side… made a stay for the oil cooler, and made the ignition leads. I have had that crimp tool since I was 20… so its 45 years old! it does make nice crimps on the leads though. I have used copper core leads, and resistor plugs to keep the neighbours happy! *The hydro dipping came out quite good...


https://jtccc.files.wordpress.com/2020/10/50398740871_b4cd3bb067_o-copy.jpg
https://jtccc.files.wordpress.com/2020/10/50408551826_b728926682_o.jpg
https://jtccc.files.wordpress.com/2020/10/50408707402_a7c31b195f_o.jpg
https://jtccc.files.wordpress.com/2020/10/50407847908_4a23c936d9_o.jpg
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buzzer1955
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PostPosted: 10:09 - 04 Oct 2020    Post subject: Reply with quote

Try as I might I just couldn’t get the fuel pipes to run correctly with a standard flat “T” piece… the bends in the pipe were too tight. so I ended up making a custom one out of brass… took a few hours… Very Happy

https://jtccc.files.wordpress.com/2020/10/fuel-junction-copy.jpg
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buzzer1955
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PostPosted: 17:24 - 05 Oct 2020    Post subject: Reply with quote

My clutch covers plates are back from the laser cutters… he turned it around in a day... he said he has hardly any work as all his customers are having a hard time... its tough out there... Over the last couple of years I have been learning CAD… Its not an intuitive package and I get frustrated, but get there in the end!

https://jtccc.files.wordpress.com/2020/10/clutch-cover-cad.jpg

https://jtccc.files.wordpress.com/2020/10/clutch-cover-copy.jpg
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buzzer1955
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PostPosted: 12:40 - 09 Oct 2020    Post subject: Reply with quote

The seat pad came back from Aldridge trimming and as usual Karen did a fantastic job… she said she was not asked for orange stitching very often! next job was to make the fuel filter holder… this took some thinking about due to the position, and the fact I wanted it to be secure… In the end I machined a clip out of nylon. there is an annular grove which stops the filter moving, its very secure

started it up yesterday… it actually started first time!… but it didn’t run well… A quick check on the timing revealed it was significantly out. Looks like I made a calculation error in placing the magnets. rather than re-make the timing wheel, I slotted the mounting holes on the miller. A simple job, but it took ages to set it up! This of course meant that I had to turn off the original timing marks and scribe some new ones. I used a pointer and timing disc in the lathe to do this. the marks were scribed using a sharp tool, drawn across the surface with the cross slide. I think that way they are pretty accurate! here is a short video of it running.


https://jtccc.files.wordpress.com/2020/10/fuel-filter-web-2.jpg

https://jtccc.files.wordpress.com/2020/10/fuel-filter-web-1.jpg

https://jtccc.files.wordpress.com/2020/10/seat-1.jpg

https://jtccc.files.wordpress.com/2020/10/timing-wheel-web-4.jpg

https://jtccc.files.wordpress.com/2020/10/timing-wheel-web-3.jpg

https://jtccc.files.wordpress.com/2020/10/timing-wheel-web-2.jpg

https://www.youtube.com/watch?v=iy-3sPlFi-A
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struan80
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PostPosted: 17:21 - 09 Oct 2020    Post subject: Reply with quote

Cool Really top notch work there.

it's not often you find mechanical techs up to speed with electrical schematics and electrical work In general

Not sure I like the look of the end product though, sorry about that. I'm still liking sports bikes.


Best of luck Very Happy
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buzzer1955
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PostPosted: 13:43 - 11 Oct 2020    Post subject: Reply with quote

struan80 wrote:
Cool Really top notch work there.

it's not often you find mechanical techs up to speed with electrical schematics and electrical work In general

Not sure I like the look of the end product though, sorry about that. I'm still liking sports bikes.


Best of luck Very Happy


yes, not many people do both... lots of people say I build bikes with carbs because I don't like technology... that's not true... I love new technology and worked in the industry for the last 20 years of my career..

yesterday’s job was to make some velocity stacks for the FCR’s… first time in many years I have done some free hand turning (just like wood turning) to get the shape of the curved entry right. took ages to bet both to match the plastic one… the new ones will enable me to use filters as its important on the road in particular as the carbs face forward…

https://jtccc.files.wordpress.com/2020/10/velocity-stack-fcr-2-copy.jpg

https://jtccc.files.wordpress.com/2020/10/velocity-stack-fcr-copy-1.jpg
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buzzer1955
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PostPosted: 14:19 - 21 Oct 2020    Post subject: Reply with quote

first time out in the daylight for a while… its running OK, just need to change the carb needles which are on order, then a road test...

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

https://jtccc.files.wordpress.com/2020/10/0000aaaaa-3-copy.jpg

https://jtccc.files.wordpress.com/2020/10/0000aaaaa-1-copy.jpg
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Easy-X
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PostPosted: 15:08 - 21 Oct 2020    Post subject: Reply with quote

https://media.giphy.com/media/VPV0CVtbU6ZKU/giphy.gif

The "this post is cool" isn't sufficient Thumbs Up
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P.
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PostPosted: 10:17 - 23 Oct 2020    Post subject: Reply with quote

I love the work thats gone in to this, I just feel its missing the back end...and I think its breaking C&U regs, otherwise its stunning and I'd love to have a go on that.
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