View Full Version : My 996 build has finally started. :D
Bodybag
06-12-2008, 09:47 PM
I know its not Monster related but I thought I'd share my fun day with you!!
I finally got my 996 build started this afternoon.
The bike started in October 2007 with just a frame and a plan to build a trackbike from ebay parts. Unfortunately due to me writing off my 749S earlier this year I had to rethink things. I'm now building a road legal 996 as my main bike.
I managed to buy a 748 rolling chassis for less than £700 during the summer, stripped it and sent various parts away to be sorted out. The frame and subframe were sent to Darrenpalm Powdercoaters in Leicester who did an outstanding job. The coating is so well done on the headstock that you can still see the impression of the frame number. The engine went to Jeff Green at G-Tech in Stoke Albany to confirm what I already knew, that the Crank had gone in the 748 motor.
I'd already purchased a 996 engine ready for the rebuild so that also went to Jeff and he's given it a good service and fitted some parts including the clutch and generator for me.
I haven't done much rebuilding yet but as you can see from the photos below, I have finally pulled my finger out and started!!
This is how the rolling chassis looked when it arrived with the 748 engine still in place.
http://i165.photobucket.com/albums/u79/monster_budd/11062008164.jpg
The 996 engine as it looks now that Jeff Green has sorted it out.
http://i165.photobucket.com/albums/u79/monster_budd/06122008349.jpg
This is the engine, swingarm and rear shock offered up to the frame. but not yet bolted in tight.
http://i165.photobucket.com/albums/u79/monster_budd/06122008352.jpg
Apologies for the poor quality of the photos, but as you can tell, I'm working in rather tight conditions!!
Better photos will follow as I do more work to the bike.
Wish me luck.
Phil
Albie
07-12-2008, 12:10 PM
Good luck then not that you will need it. What colour body work.Pearlecent white like the 848
Bodybag
07-12-2008, 06:14 PM
Hello mate,
No, I'm thinking of Senna. Black frame, red wheels and grey bodywork. Understated but still looks the nuts. :D
ricky
07-12-2008, 06:21 PM
lookin good so far mate, cant wait to see the finished article!!
paul33
07-12-2008, 07:06 PM
looking good so far like the black frame :)
Well you've overtaken me on the road to progress :dizzy:
Shandy
08-12-2008, 07:39 PM
He's got way past me too and my 916.............damn credit crunch............
Looking good though mate and heading in the right direction :thumbsup:
I have to say though i am disapointed with one thing though, is that a fan heater............
http://i165.photobucket.com/albums/u79/monster_budd/06122008352.jpg
Ya big poof..................lol
Its not a proper winter rebuild unless you freeze your nuts off in the garage!!!! Mind you saying that i usually use the lounge to get over the cold :)
Cheers,
Shandy
Bodybag
09-12-2008, 12:04 AM
Yes it is a fan heater. My mum would kick my head in if I brought any of it into the house!! Although I did manage to get the frame in but that was only after it had been shotblasted and powdercoated so it was all lovely and clean, even then, it only stayed till I'd cleared enough space in the garage to store it!! Mums eh?! :D
Albie
09-12-2008, 08:31 PM
Just noticed your flooring. Its looks like the interlocking stuff. Im after some when when my mother moves her stuff into her new house in new year. Did you lay it and how much per m2.
littlejimmy12
10-12-2008, 04:26 PM
god.....bike porn......lots of lovely shiny recently powder coated bits of metal OOOoooo, good luck with the 996 I would love one of those
littlejimmy12
10-12-2008, 04:28 PM
interlocking flooring can be found from a lot of Gym/Fitness club equipment suppliers - we used these guys in our club recently
http://www.softfloor.co.uk/
Bodybag
10-12-2008, 07:06 PM
I think I used Maplins last year. Its workbench flooring. They were doing packs for £15 each. Its only 10mm thick foam but, as Albie said, its the interlocking stuff and covers about 2 square metres a pack. Ideal as a quick fix for a garage floor. Hope this helps.
Bodybag
12-12-2008, 10:14 PM
I managed to pull my finger out this evening and cracked on with some more of the build. I'm still wrking in sub-zero temperatures but that just adds to the fun. Rigger boots seem to help!!
Today I've managed to get the bike to the point where its on its own wheels and put the sub-frame back on too. It took me nearly three hours to get the headstock sorted out as the powdercoating was inside the steering tube. I ended up using really rough sandpaper to sand out the insied of the headstock. Then I used a good old fashioned wooden persuader to get the eccentric steering unit into place. It took me several goes to line up the stem properly as its an interference fit and I couldn't find my steering adjuster tool!! :scratch:
Ah well, all sorted now.
First pictures are of the headstock after 2 and a half hours of faffing about!!
http://i165.photobucket.com/albums/u79/monster_budd/12122008369.jpg
http://i165.photobucket.com/albums/u79/monster_budd/12122008367.jpg
This is the bike after I managed to get it up onto its wheels. And yes I know the front wheel is on the wrong way round. I was struggling and figured that for the time being, as long as its on, I'm happy. It needs to come off anyway as I don't have the speedo gear on the spindle yet.
http://i165.photobucket.com/albums/u79/monster_budd/12122008371.jpg
A random gratuitous porn shot... lol
http://i165.photobucket.com/albums/u79/monster_budd/12122008374.jpg
And finally a shot of the rear of the bike with the sub-frame in place.
http://i165.photobucket.com/albums/u79/monster_budd/12122008375.jpg
There's still a long way to go but I'm happy that its starting to look like a bike at last!! :D
emily's driver
12-12-2008, 10:42 PM
Nice work Bodybag. I have only one criticism though. Since you are going to such lengths to restore the bike, are you going to replace the OEM fasteners and bolts? The really odd ones you can have silver nickel plated if need be.
Bodybag
12-12-2008, 10:53 PM
Hello mate, yes I am. All the main engine bolts have been changed already. I have a huge pack of new frame and fairing bolts but I needed to get the bike into a sensible state in a hurry as I had no room to do anything. Tomorrow I'll be changing all the rusty and tarnished crap for decent replacements. I need to order some fresh fasteners too as I'm not happy with some that I've already used such as the sub-frame bolts and I'm sure there'll be plenty more that I'll get annoyed with if I put them on the bike!! :D
gary tompkins
12-12-2008, 11:36 PM
... I have to say though i am disapointed with one thing though, is that a fan heater............ Ya big poof..................lol
Its not a proper winter rebuild unless you freeze your nuts off in the garage!!!! Mind you saying that i usually use the lounge to get over the cold :)
Cheers,
Shandy
I agree... fan heaters are gay
A real man keeps his spanners in the fridge
Bodybag
13-12-2008, 12:00 AM
I was freezing my nuts off in the garage. I turned the heater off tonight becasue I realised it was doing nothing other than increasing the electricity bill!! I had to stop work tonight in the end, not due to the cold but due to the amount of condensation I was laying on everything!! lol
Albie
13-12-2008, 09:12 AM
looking good mate.
gary tompkins
13-12-2008, 10:08 AM
I was freezing my nuts off in the garage. I turned the heater off tonight becasue I realised it was doing nothing other than increasing the electricity bill!! I had to stop work tonight in the end, not due to the cold but due to the amount of condensation I was laying on everything!! lol
I built the trike between October and March. At mid point of fabrication in January I was welding (full of man flu) at -5 degrees. Had to have a break every hour as I couldn't feel my fingers or any of my five remaining toes.
Stop winging and get on with it :chuckle:
Bodybag
13-12-2008, 12:41 PM
Stop winging and get on with it :chuckle:
Sorry boss. I'm getting on with it, honest. :D
I see the stand but not bolted up??
Bodybag
13-12-2008, 02:28 PM
No, not yet. I neede to get the bike on wheels to give myself some room to move in the garage. It'll go on the stand soon as i need to get both wheels back off again.
emily's driver
13-12-2008, 08:43 PM
Hello mate, yes I am. All the main engine bolts have been changed already. I have a huge pack of new frame and fairing bolts but I needed to get the bike into a sensible state in a hurry as I had no room to do anything. Tomorrow I'll be changing all the rusty and tarnished crap for decent replacements. I need to order some fresh fasteners too as I'm not happy with some that I've already used such as the sub-frame bolts and I'm sure there'll be plenty more that I'll get annoyed with if I put them on the bike!! :D
I was not being picky (well OK yes I was!) but I am sure it will look the biz when it's done. I know these seem to be minor points but IMHO they make the finished project look a million times better. I have lost count of the number of rebuilds I have seen, where people have gone to inordinate lengths to restore a bike and then used the old corroded or tarnished bolts and nuts. As you know the plating on OEM fasteners from Ducati is SHI*E so I have always replaced mine with a combination of stainless steel and titanium, as was the case with Nonnie's bike. As I said all those special parts and brackets which are not readily available I simply had silver nickel plated (ie the fuel tand rear bracket, rear seat cowl brackets to name but a few etc etc etc) Judging by your photos you are doing a very thorough job. Be interested to see the end result.
Bodybag
14-12-2008, 11:41 PM
Today I hit my first snag. I've fitted the complete clutch (including the master cylinder, lever, slave cylinder and the pushrod) from my 749S onto the bike. The clutch isn't responding and the lever is very soft. DO I need to bleed the clutch or have I done something wrong? Is the pushrod the same length etc.?
Any help would be appreciated.
Thanks.
Do you have the other push rod to compare it with?
Bodybag
15-12-2008, 12:51 AM
No. the engine didn't have any clutch components when I got it.
Is the pressure plate properly seated? It is possible to mis-align it slightly so it looks OK but snags on the edge of the basket.
Bodybag
15-12-2008, 02:04 PM
Is the pressure plate properly seated? It is possible to mis-align it slightly so it looks OK but snags on the edge of the basket.
Everything is seated correctly. The clutch is all in place. Problem I have is that when I pull the lever, nothing happens. It might be that I need to bleed the system but I want to make sure the pushrod is the right length too.
Mine is at JHP otherwise I'd measure it. I will be going there in a couple of days so if you don't have a solution by then I'll do the measurement & call you.
Bodybag
15-12-2008, 06:55 PM
That would be great. Thanks. :D
gary tompkins
15-12-2008, 11:00 PM
The push rods are different lengths - depends on age of motor
Aftermarket slave's come with a spacer to take up the slack
Bodybag
15-12-2008, 11:38 PM
The engine is a year 2000 996. The slave is off a 2003 749S.
Panther
16-12-2008, 12:13 PM
When I changed the engine in my 620ie (03) for a 750ie (02) from a SS. I had the same problem. Because I was using the push rod and slave cylinder from the old 620 engine, the lever was like a sponge.
I changed the push rod for the one from 750 one and it all worked fine.
I did not realises it was longer for the 750 :fou:
:)
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