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Ducati Multistrada Scrambler project

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buzzer1955
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PostPosted: 19:24 - 08 Jun 2021    Post subject: Ducati Multistrada Scrambler project Reply with quote

June 2021 and I have been mulling over doing another special, rather than a Restoration, which I did last time with an early Monster 900 . I have been riding around the last project I built, the Multistrada with the FCR carbs on it, which goes really well! My favourite bike to ride! One of the problems with it though is the single seat, my wife likes to come out on pillion sometimes… So I decided to build a scrambler/flat track/adventure type bike, with a dual seat on.

I looked around for another 1000 DS Multistrada and this red one turned up at the right price. These are cheap to buy as many are suffering leaking and bubbling tanks, and faded LCD screens. I am still formulating ideas at the moment, but I have made a bit of a start so I have stripped it of all the parts I wont use so I can sell these on.

but below is a rough mock up with a borrowed seat. Also a picture of the last 4 specials I have built over the last few years. This will be a slow build as I want to enjoy the summer!

https://jtccc.files.wordpress.com/2021/06/ducati-8-1-copy.jpg

https://jtccc.files.wordpress.com/2021/06/ducati-8-2-copy.jpg

https://jtccc.files.wordpress.com/2021/06/me-holding-bike-copy.jpg

https://jtccc.files.wordpress.com/2021/06/test-seat-copy.jpg

https://jtccc.files.wordpress.com/2021/06/4-builds-copy.jpg
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Easy-X
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PostPosted: 21:34 - 08 Jun 2021    Post subject: Reply with quote

Wow! From bloated pig to Grom level svelteness Laughing Laughing Laughing
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struan80
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PostPosted: 22:09 - 08 Jun 2021    Post subject: Reply with quote

Very nice. One day I'll get a Ducati Very Happy
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jeffyjeff
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PostPosted: 10:50 - 12 Jun 2021    Post subject: Reply with quote

I like the blocks holding the seat up. Gives literal meaning to the term "wooden brakes". Wink
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MarJay
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PostPosted: 11:53 - 12 Jun 2021    Post subject: Reply with quote

Am I the only one who likes the original Multistrada?
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buzzer1955
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PostPosted: 13:32 - 12 Jun 2021    Post subject: Reply with quote

MarJay wrote:
Am I the only one who likes the original Multistrada?


its a great bike... just a bit ugly Laughing
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MarJay
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PostPosted: 13:55 - 12 Jun 2021    Post subject: Reply with quote

buzzer1955 wrote:
MarJay wrote:
Am I the only one who likes the original Multistrada?


its a great bike... just a bit ugly Laughing


I actually think it looks great. I'm one of the people who really liked the MH900e and I think this might even be an improvement...
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Robby
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PostPosted: 21:18 - 19 Jun 2021    Post subject: Reply with quote

I also like the original multistrada. I can't say why, because I don't really like any of the other adventure bikes. Maybe I just like supermotos and lego. and red.
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carbon90
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PostPosted: 06:50 - 29 Jun 2021    Post subject: Reply with quote

Totally cool Ducati! Nice
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buzzer1955
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PostPosted: 11:15 - 08 Jul 2021    Post subject: Reply with quote

Sometimes I just sit for a while and look at the silhouette of a build in the garage with the lights out… I did this the other night (my wife thinks I am mad!) and I kept coming to the conclusion that the tank is not what I want… So off to the bike breaker who lets me wonder around his BIG unit. I took a cardboard cut out of the shape I wanted with me, and some measurements… of the hundreds of tanks I looked at (surprising how many are now plastic!) , none were suitable, mainly due to the angle of the frame.

On the last build I used a 999 tank which worked well, so I decided to try a shortened version on this build. I didn’t feel bad cutting this up as its so badly corroded, and it just goes to show what leaving a bike for a long period with ethanol based fuel in it does inside the tank. you can see from the light I am holding behind it that its actually perforated on the top! So its off to the blasters with it to see what state its in when it comes back…. I have a fall back, but its a perfect 999 tank, be a shame to cut it up... If the one comes back from the blasters and its too bad, I will probably use it to mock up, and see if I can find a dented one.

https://jtccc.files.wordpress.com/2021/07/tank-2-copy.jpg

My FCR 41's came this morning

https://jtccc.files.wordpress.com/2021/07/fcr-carbs.jpg
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buzzer1955
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PostPosted: 11:16 - 10 Jul 2021    Post subject: Reply with quote

well the tank came back from the blasters… Surprised as you can see its full of pin holes, and for the first time in over 40 years of repairing tanks I feel I have been beaten! there is no point in trying to repair this! I put a light inside to shop the extent of the corrosion. look after your tanks guys!


https://jtccc.files.wordpress.com/2021/07/tank-22.jpg
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GSTEEL32
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PostPosted: 17:33 - 10 Jul 2021    Post subject: Reply with quote

buzzer1955 wrote:
who lets me wonder around his BIG unit


WTF is wrong with me, when my inner voice reads this in the style of Kenneth Williams ?????????????
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buzzer1955
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PostPosted: 14:33 - 12 Jul 2021    Post subject: Reply with quote

GSTEEL32 wrote:
buzzer1955 wrote:
who lets me wonder around his BIG unit


WTF is wrong with me, when my inner voice reads this in the style of Kenneth Williams ?????????????


obviously your age Mr. Green

Started the frame modifications, just tacked up at the moment. On this build I want to keep the seat height right for me, but also allow for an under seat exhaust and a seat long enough for a pillion. I have replaced the shocker with a strut at the moment so I can see what things look like at max and min travel.

https://jtccc.files.wordpress.com/2021/07/51305730462_b492fd8e16_o-copy.jpg
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G.Mantis
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PostPosted: 19:47 - 14 Jul 2021    Post subject: Reply with quote

Seriously nice mod. Congrats. What made you get into it? tired of touring?
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buzzer1955
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PostPosted: 12:51 - 19 Jul 2021    Post subject: Reply with quote

G.Mantis wrote:
Seriously nice mod. Congrats. What made you get into it? tired of touring?


I tend to do a bike build every year, over the winter, but with COVID I have been busy most of the time in the garage!

on my last build I run a pair of FCR carbs, it runs really well so for this build I chose the same carbs, but this time decided to bolt them together, and use a common split spindle to control the slides. this means I can use a single pull/ pull throttle arrangement, instead of the 4 cables system I used before. It also means I can run a TPS on the end of the spindle.

I thought it would be easy, I got some 8mm silver steel for the spindle, and a couple of new bearings with seals instead of the closed cup bearings… unfortunately the threads on the locating pins into the spindle is an unusual thread and I couldn’t find a tap… so I had to make some new pins as well… All done now though, including a linkage in the middle so I can balance the carbs .

I have also made some new velocity stacks to accommodate some foam filters… there is a few hours work in those! and a pile of swarf!

Short video to demonstrate how I hand turn the bellmouth on the stacks!

https://www.youtube.com/watch?v=Ot4jIKXcFuI

https://jtccc.files.wordpress.com/2021/07/fcr-carbs-and-stacks-2.jpg

https://jtccc.files.wordpress.com/2021/07/fcr-7-copy.jpg

https://jtccc.files.wordpress.com/2021/07/fcr-carbs-and-stacks-1.jpg
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buzzer1955
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PostPosted: 10:04 - 23 Jul 2021    Post subject: Reply with quote

To mount the carbs I needed to make some alloy custom manifolds. I made these using the pie /lobster cut method. I set the chop saw to 7 degrees and cut off a selection of pieces and tape them together until I have the right shape… I then mark the position of each and weld them together, ensuring I have good penetration, which I then grind off inside to make them smooth. the long bur in the picture is a beast to use!

https://jtccc.files.wordpress.com/2021/07/manifold-1-copy.jpg

https://jtccc.files.wordpress.com/2021/07/manifolds-2-copy.jpg

Onto the tank. I managed to source a very clean 999 tank, but of course this is too long for the build… so out came the angle grinder and off came the back! measure twice cut once!. I then fabricated a new back end and welded it into place. When welding stuff like this, everything needs to be clean for a good half inch either side of the weld, so I clean both sides with emery paper, and use to carb cleaner to ensure there is no grease… also wipe the welding rod with some as well…

Once the back/side piece was in place I planished the sides so the new piece had the same radius as the tank. then I welded the bottom in. to test for leaks I use two methods… some dye penetrant and developer, and if it passes this test, I do a final check with air at just 3 PSI and squirt it with soapy water.

https://jtccc.files.wordpress.com/2021/07/tank-modifications-copy.jpg

https://jtccc.files.wordpress.com/2021/07/tank-modifications-2-copy.jpg
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A100man
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PostPosted: 10:13 - 23 Jul 2021    Post subject: Reply with quote

Impressive skills! That old tank looks horrendous sure it wasn't stored in brine?
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buzzer1955
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PostPosted: 10:16 - 23 Jul 2021    Post subject: Reply with quote

A100man wrote:
Impressive skills! That old tank looks horrendous sure it wasn't stored in brine?


its the result of storing it for 3 years half full of E5... lots of tanks are suffering with this, its not like the old days when you could store a tenk for 30 years with fuel in Sad
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buzzer1955
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PostPosted: 20:17 - 24 Jul 2021    Post subject: Reply with quote

one of the most difficult things I find to make on a bike is the seat… this one i have used a different approach as (a) its a dual seat and (b) I am making the base out of aluminium. I mocked up what I wanted in cardboard first, and then transferred the patterns onto some 3mm aluminium. Then I seam welded it… It came out ok, be interesting to see what its like once its to the final shape and the foam and cover is on!

https://jtccc.files.wordpress.com/2021/07/seat-1-copy.jpg

https://jtccc.files.wordpress.com/2021/07/seat-2-copy.jpg
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struan80
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PostPosted: 21:37 - 24 Jul 2021    Post subject: Reply with quote

Very nice sir. But a waste of a good bike. Well in my eyes.
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buzzer1955
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PostPosted: 10:52 - 01 Aug 2021    Post subject: Reply with quote

struan80 wrote:
Very nice sir. But a waste of a good bike. Well in my eyes.


They are not a good bike these days... the tanks swell with the ethanol in the fuel, and leak, there is no long term fix for that... and its only going to get worse as we move to E10 fuel. Its so bad that many people end up cutting the frame x member to remove the tanks! Also the LCD screens go dim so you cant see the display... and the circuit boards in the clocks corrode, and you lose the indicators... Many are suffering ECU issues.

Next job will be the exhaust system but to do this I needed a silencer to get the mock up right… I wanted a small slim silencer, that was re-packable, and that I could fit a baffle come MOT time… and a bit retro/old school. I searched but couldn’t find any suitable, they were all too wide as I want an under seat, side mounted setup. so I modified a cheap (£16!) stainless steel one off eBay. I would have loved to have made one from scratch but don’t have a cone roller, and to buy a ready made stainless cone is expensive. the hardest part of making this was actually drilling three holes for the bolts to hold the end cone in. the stainless is incredibly hard! after blunting 3 new drills, and buying a cobalt drill and that not touching it, I ended up making a punch and die and punching the holes!

https://jtccc.files.wordpress.com/2021/08/silencer-1-copy.jpg

https://jtccc.files.wordpress.com/2021/08/silencer-2-copy.jpg
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buzzer1955
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PostPosted: 19:00 - 02 Aug 2021    Post subject: Reply with quote

With the silencer finished I mounted it on the frame. I decided to make it rubber mounted to keep the vibrations down a bit. The collector was challenging… first one I made I was not happy with, so the second one I welded it on the inside with the TIG, which came out well and should flow OK. Stuck for a few days now as I need a couple of mandrel bends to finish it off.

https://jtccc.files.wordpress.com/2021/08/exhaust-12-copy.jpg

https://jtccc.files.wordpress.com/2021/08/exhaust-1-copy.jpg

https://jtccc.files.wordpress.com/2021/08/exhaust-123-copy.jpg
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Easy-X
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PostPosted: 12:47 - 03 Aug 2021    Post subject: Reply with quote

buzzer1955 wrote:
With the silencer finished I mounted it on the frame. I decided to make it rubber mounted to keep the vibrations down a bit.


N00b question: if one end of the exhaust system is rubber mounted and can therefore move a teeny-weeny bit how does that square with the other end that is solidly bolted to the engine?

I know on a car (which relatively speaking has a massively long system) one might have a flex joint near the engine side or is the rubber mount only enough to cut down higher frequency vibrations with not enough movement to stress other points in the system?
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buzzer1955
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PostPosted: 17:26 - 03 Aug 2021    Post subject: Reply with quote

Easy-X wrote:
buzzer1955 wrote:
With the silencer finished I mounted it on the frame. I decided to make it rubber mounted to keep the vibrations down a bit.


N00b question: if one end of the exhaust system is rubber mounted and can therefore move a teeny-weeny bit how does that square with the other end that is solidly bolted to the engine?

I know on a car (which relatively speaking has a massively long system) one might have a flex joint near the engine side or is the rubber mount only enough to cut down higher frequency vibrations with not enough movement to stress other points in the system?


although the front pipes are bolted to solid to the engine. they go into push in joints that hold together with two springs, and there are going to be three such flexible joints in the system, so there is some flec everywhere. its important as without it it all cracks!
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Easy-X
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PostPosted: 18:27 - 03 Aug 2021    Post subject: Reply with quote

Ah, that makes sense as the last time I mentioned this topic to someone they were "oh no! it needs to be a solid mount!!!" but that was for a single piece exhaust on an old bike.
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