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Ducati Multistrada Scrambler project

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buzzer1955
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PostPosted: 15:23 - 05 Aug 2021    Post subject: Reply with quote

the speedo/ rev counter I am going to use has a plastic case... which does not look good. I tried to get some tube the right diameter but it was too big or too small, so I cut 12mm out of some bigger stuff and seam welded it back up, using a piston ring clamp to pull it together to weld it. I knew it wouldn't look right with a flat bottom so I made a conical one by spinning it in the lathe. The alloy needs to be soft for this so I annealed it by heating it up to temperature, and letting it cool. A neat trick to know when its the right temperature is to use a Sharpie pen, and when its burn off and has disappeared, its the right temperature! a bearing on the end of a bar makes it easy! here is a short video...

https://jtccc.files.wordpress.com/2021/08/51359638684_d869d74bf1_o-copy.jpg

https://www.youtube.com/watch?v=EzapW5hnO3I
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buzzer1955
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PostPosted: 21:19 - 08 Aug 2021    Post subject: Reply with quote

The seat base is finished, added the rivinuts to hold it on, and made a bracket so it only bolts on at the rear so it comes off easily. The last build is a pain to remove the seat. just need to add the foam and sand it to shape. I am happy with the mock-up but cant decide if the front mudguard needs to go central or biased to the front, but that can wait a while. the exhaust is all but finished apart from polishing and adding the hoops for the springs.

https://jtccc.files.wordpress.com/2021/08/seat-base.jpg

https://jtccc.files.wordpress.com/2021/08/mockup-1-copy.jpg
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buzzer1955
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PostPosted: 19:22 - 14 Aug 2021    Post subject: Reply with quote

many (many!) years ago I modified the frame on a Bultaco for a race seat. I put a complete back end on, much like what I have done here. I made very careful measurements using various fixings as datums, and welded it all up. soon as it was finished, and the seat on, it was evident that it didn’t sit straight on the bike. I was gutted as I had painted the frame. No one else noticed, but it bugged the hell out of me for years! I learned from this, these days, here is how I do it… I get the bike dead upright to a spirit level on the wheel, and then make sure the seat is level. seems to work!

I have also made a new purchase... an auto darkening welding mask... why the hell I didn't buy one years ago I just don't know! its so much easier! Laughing

https://jtccc.files.wordpress.com/2021/08/is-it-straight-copy.jpg

https://jtccc.files.wordpress.com/2021/08/frame-hoop-copy-2.jpg
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Shaft
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PostPosted: 23:43 - 14 Aug 2021    Post subject: Reply with quote

buzzer1955 wrote:
The seat base is finished, added the rivinuts to hold it on, and made a bracket so it only bolts on at the rear so it comes off easily. The last build is a pain to remove the seat. just need to add the foam and sand it to shape. I am happy with the mock-up but cant decide if the front mudguard needs to go central or biased to the front, but that can wait a while. the exhaust is all but finished apart from polishing and adding the hoops for the springs.

https://jtccc.files.wordpress.com/2021/08/seat-base.jpg

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


Personally, I would leave it where it is and extend the front half a little, maybe even straighten it up, to echo the silencers and give it some balance.
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buzzer1955
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PostPosted: 10:09 - 19 Aug 2021    Post subject: Reply with quote

With the new seat the rear foot pegs were too far back, and uncomfortable for her legs, so important to get this right! I have made some new hangers out of 10 and 12mm steel tube. I made a jig first so all the angles and bolt holes were correct, and it wouldn't move as I brazed it. this is my first time TIG brazing and I was worried about strength, so I did a test piece first and tried to break the joint... the parent metal broke before the joint so all is well there!

https://jtccc.files.wordpress.com/2021/08/rear-footrest.jpg
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buzzer1955
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PostPosted: 20:39 - 07 Sep 2021    Post subject: Reply with quote

been taking a few days off and getting about a bit on the bike and in the car. I have to say Covid and the restrictions to normal life have got to me a bit! I got my parts back from the water jet cutter, another superb job! while I was there he was cutting through a 150mm block of exotic alloy! I designed the number plate bracket, the headlight brackets, and the number plate backing on CAD and sent it to him… a few days later I picked this up. I could have cut it by hand bit this is so easy. I was going to sell the number plate, but I have decided to keep it… L90 fits the engine configuration! below is a short video of him cutting the plates

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

https://jtccc.files.wordpress.com/2021/09/51433264262_9d04efcccf_o.jpg

https://jtccc.files.wordpress.com/2021/09/51434186364_9c59abcc86_o.jpg
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buzzer1955
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PostPosted: 13:26 - 25 Sep 2021    Post subject: Reply with quote

Strip down begins… the bike is now all in pieces and the frame and wheels are at the powder coaters. The engine is all in pieces as well ready to have the cases vapour blasted. Engine wise its all good apart from the exhaust valve guides which is a common problem on these engines… I need to replace the guides. Its easy to check if they are worn, here is a little video to show how to check them… the valve needs to “just” off its seat.

Here is a puller I made to remove the gearbox bearings. I know you can buy blind bearing pullers (I have a set) but for the gearbox bearings on the Ducati engine they don’t work well as there is no inner race to pull on, and you end up pulling the rollers out and breaking the plastic cage! They are also expensive bearings to replace at £60 each…. This puller expands fully into the rollers as the bolt rides up the internal taper. Also a primary gear puller I made a few years ago, along with the dimensions for that. I know you can buy them also (£150… where is the fun in that) but this cost me £20 for the laser cutter to knock me out 5 sets! Happy to share the CAD drawing…

https://jtccc.files.wordpress.com/2021/09/strip-down.jpg
https://jtccc.files.wordpress.com/2021/09/gearbos-bearing-puller-copy.jpg
https://jtccc.files.wordpress.com/2021/09/gearbox-bearing-puller-3-copy.jpg
https://jtccc.files.wordpress.com/2021/09/gearbox-bearing-puller.jpg
https://jtccc.files.wordpress.com/2021/09/puller-1.jpg
https://jtccc.files.wordpress.com/2021/09/puller-3.jpg
https://jtccc.files.wordpress.com/2021/09/primary-gear-puller.jpg


checking for guide wear...


https://www.youtube.com/watch?v=0rV2OPrxpNw
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buzzer1955
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PostPosted: 12:48 - 02 Oct 2021    Post subject: Reply with quote

Collected the frame and wheels from Redditch shotblasting… another superb job! its a 50 mile round trip for me, but well worth it for his quality work! Very Happy

https://jtccc.files.wordpress.com/2021/10/frame-and-wheels-2.jpg
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pepperami
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PostPosted: 09:46 - 03 Oct 2021    Post subject: Reply with quote

Impressive Thumbs Up
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buzzer1955
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PostPosted: 16:05 - 04 Oct 2021    Post subject: Reply with quote

My engine cases are back from the vapour blasters… another superb job from SP Vapour Blasting who are meticulous and I completely trust to do a good job! When I get them back, the first thing I do is clean them of any media that is left from the cleaning process. They were VERY clear of media, but I like to be sure! I then inspect all the threads. No point in building the engine up to find you have suspect threads, as at this stage its easy to rectify any that are poor. As it happens the only two that needed attention were the ones that hold the stand bracket on. This is a common failure point and I have seen a few cases cracked in this area due to lose bolts. I drilled the hole out and used a M10 x 1.5 helicoil. As these are a couple of really stressed bolts I use a double depth helicoil inserts (see picture for comparison) , just to make a good job of it.

https://jtccc.files.wordpress.com/2021/10/helicoil-3-copy.jpg

https://jtccc.files.wordpress.com/2021/10/helicoil-5.jpg
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buzzer1955
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PostPosted: 10:05 - 06 Oct 2021    Post subject: Reply with quote

Starting to assemble the heads. New exhaust guides fitted as the originals were badly worn. I heated the heads up to remove and replace the guides, and made a tool to knock them in up to the register. It’s long enough to go through a guide in which is a snug fit in the valve seat so I can ensure it all goes in perfectly straight. Also I have a tool to fit the valve stem oil seals… if you use a socket it damages the rubber on the seal. Two of the rockers had started to peel the hard surface off… I have replaced with good second hand ones. My Dad bought me that tin of grinding paste 50 years ago…. I can vividly remember him sitting in the chair in our back room with a BSA Gold Star cylinder head on his lap grinding the valves in for me…. My mother looking on with disapproval Mr. Green it’s done well, only recently run out!


https://jtccc.files.wordpress.com/2021/10/51556847598_d5c8cc3cd6_o.jpg

https://jtccc.files.wordpress.com/2021/10/heads-build-copy.jpg

https://jtccc.files.wordpress.com/2021/10/worn-rockers-copy.jpg

https://jtccc.files.wordpress.com/2021/10/grinding-paste-copy.jpg
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buzzer1955
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PostPosted: 11:32 - 08 Oct 2021    Post subject: Reply with quote

when people say to me Ducati bikes are expensive to service I ask them if they have ever done the valve clearances Laughing ! on this engine there are 8 clearances to set, on the 4V there are 16! at £12 a shim and with the time involved no wonder its expensive!

https://jtccc.files.wordpress.com/2021/10/valve-clearances-copy.jpg
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buzzer1955
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PostPosted: 11:14 - 11 Oct 2021    Post subject: Reply with quote

Build-up of the engine commences… The tool for holding the flywheel is essential. This one is home made, but they are cheap anyway. When people say wedge a penny in the gears I cringe!

One important thing to remember is there is one special bolt in the cases that acts as an oil feed to the LH case. This needs to go in a certain hole!

The bottle of oil is strategically placed... I am so ashamed of the welding on that engine frame!

I had a little help bead blasting the other day!

https://jtccc.files.wordpress.com/2021/10/flywheel-tool-copy.jpg

https://jtccc.files.wordpress.com/2021/10/special-bolt-copy.jpg

https://jtccc.files.wordpress.com/2021/10/kaitlin-copy.jpg
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A100man
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PostPosted: 12:27 - 11 Oct 2021    Post subject: Reply with quote

https://jtccc.files.wordpress.com/2021/10/grinding-paste-copy.jpg

Henry Cole will give you 50 quid for that one on the left.
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buzzer1955
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PostPosted: 15:10 - 12 Oct 2021    Post subject: Reply with quote

for £50 he can have it Mr. Green

There is something satisfying about doing the hydraulics. I pulled everything apart and gave it all a good clean, bead blasted everything and put it all back together with a smear of rubber brake grease and brake fluid. I didn’t replace any of the rubbers on this build, all seems to be in nice condition, so they just got a quick wash in methylated spirits.

Last update for a few days... I will be 66 tomorrow... a Pensioner! Another milestone reached! My wife is treating me to a few days away and we have family things planned!


https://jtccc.files.wordpress.com/2021/10/brake-rebuild-copy.jpg

https://jtccc.files.wordpress.com/2021/10/brake-rebuild-2-copy.jpg


Last edited by buzzer1955 on 15:52 - 12 Oct 2021; edited 1 time in total
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Fat Angry Scotsman
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PostPosted: 15:36 - 12 Oct 2021    Post subject: Reply with quote

First time I have ever checked this thread and I am not disappointed. Those brake components all shiny gave me a bit of a chubby Embarassed
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buzzer1955
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PostPosted: 10:46 - 17 Oct 2021    Post subject: Reply with quote

I took a good look at the forks, and while the sliders were perfect, the anodizing on the legs was past its best. I popped them in the lathe and used some 240 paper to remove the anodising, then followed it up with some 800, and then a polish. they came up a treat! I did consider re-anodizing them but there is so much to polish anyway! I fitted a couple of new seals, and some new oil. all in all not a difficult job!

https://jtccc.files.wordpress.com/2021/10/forks-4.jpg
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Easy-X
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PostPosted: 12:56 - 17 Oct 2021    Post subject: Reply with quote

buzzer1955 wrote:
I took a good look at the forks, and while the sliders were perfect, the anodizing on the legs was past its best. I popped them in the lathe and used some 240 paper to remove the anodising, then followed it up with some 800, and then a polish. they came up a treat! I did consider re-anodizing them but there is so much to polish anyway! I fitted a couple of new seals, and some new oil. all in all not a difficult job!

https://jtccc.files.wordpress.com/2021/10/forks-4.jpg


Lacquer to preserve the finish?
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buzzer1955
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PostPosted: 19:35 - 18 Oct 2021    Post subject: Reply with quote

Easy-X wrote:
buzzer1955 wrote:
I took a good look at the forks, and while the sliders were perfect, the anodizing on the legs was past its best. I popped them in the lathe and used some 240 paper to remove the anodising, then followed it up with some 800, and then a polish. they came up a treat! I did consider re-anodizing them but there is so much to polish anyway! I fitted a couple of new seals, and some new oil. all in all not a difficult job!

https://jtccc.files.wordpress.com/2021/10/forks-4.jpg


Lacquer to preserve the finish?


I hate it to be honest and never found it to be any good... besides, I like a good polish Mr. Green

Started the rebuild of the engine… a tip I picked up years ago is its sometimes best to pop the piston in the bore with a ring clamp from the top, and then push it down far enough so you can get the piston pin in from the side… this saves broken rings and that’s important when a set for one piston is over £200! Put some rag in the open crankcase before putting the circlip in though!

https://jtccc.files.wordpress.com/2021/10/engine-364.jpg
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buzzer1955
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PostPosted: 14:59 - 22 Oct 2021    Post subject: Reply with quote

I couldn’t resist modifying the clutch cover… I guess that the clutch is going to be even more noisy now!

https://jtccc.files.wordpress.com/2021/10/clutch-housing-copy.jpg
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Easy-X
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PostPosted: 19:44 - 22 Oct 2021    Post subject: Reply with quote

N00b question: I get that Ducatis often have dry clutches but by opening them up are they not affected by dirt & dust?
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buzzer1955
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PostPosted: 10:38 - 23 Oct 2021    Post subject: Reply with quote

Easy-X wrote:
N00b question: I get that Ducatis often have dry clutches but by opening them up are they not affected by dirt & dust?


they don't seem to be... they create enough dirt and dust of their own! some people love the dry clutch sound... I find it irritating to be honest and it sucks of poor engineering Rolling Eyes I was at the traffic lights a while ago and a guy pulls alongside me with his window open... he sat there listening... looked at me and said "that needs looking at, sounds like a bag of spanners" Mr. Green

Next job has been to make the plate and trigger wheel for the hall sensors for the ignition. I have made some modifications from the last couple I made, the trigger wheel bigger and i have fitted a heat sink to the plate. I tried to order the same hall sensors as I used the last few times, but everyone seemed to be out of stock, with a delivery date of sept 2022! Fortunately a good friend found me some in Germany, so they are on the way!

The hall sensors are triggered by two tiny magnets in the rim of the trigger wheel, south pole turns the hall on, north off.

https://jtccc.files.wordpress.com/2021/10/51620219952_a4286ed4ca_c.jpg

https://jtccc.files.wordpress.com/2021/10/51621050871_0ce82bf5a0_c.jpg
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buzzer1955
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PostPosted: 13:57 - 24 Oct 2021    Post subject: Reply with quote

Finished making the belt covers… they cut easily with a hole saw and a diamond wheel in the Dremel… as does the 3mm Polycarbonate. not everyone like the fake carbon look... but I like it, and its very durable when coated with some 2K clear. In fact, more durable than the real thing in some case! Its cheap and easy to do as well... here is a short video of the process...

the engine is now finished, time to start assembly soon!

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





https://jtccc.files.wordpress.com/2021/10/belt-covers.jpg

https://jtccc.files.wordpress.com/2021/10/51624862821_619944e51b_o-copy.jpg
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Easy-X
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PostPosted: 17:37 - 24 Oct 2021    Post subject: Reply with quote

C'est magnifique!

Another point against dry clutches though: at least with a wet clutch the particles are captured by the oil which one would obviously dispose of responsibly when it's changed out.
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buzzer1955
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PostPosted: 10:14 - 27 Oct 2021    Post subject: Reply with quote

started to pull it all together now, its amazing how quickly it all comes together once the engine is finished... it must be the easiest bike to put the engine in!

https://jtccc.files.wordpress.com/2021/10/51630295137_b1e26dc37d_o-copy.jpg
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