Project Eric - The Rebuild.

[Paranoid Dave]

As many of you probably know over the last year I've been playing with my wife's (steady now, stop laughing at the back) monster, the lovely Eric. He was a first bike with what we think was a sad background and years of neglect, but who cares, we still liked him.

In the couple of years he was used before Shirley (my wife and Eric's owner) used him he did his job perfectly, only breaking down once when a throttle cable snapped coming home from lincolnshire, after that he has been Mr dependable.

Knowing he was now redundant in the garage, he needed some attention, and neither of us wanted to see him go. Having recently (at that point) sold my beloved Kylie I was keen to keep a classic 600 monster in the garage as a bit of a retro thing. Eric was to become a classic, but not exactly standard monster....

With a pig ugly screen as his only modification when I started there were a few good reasons to strip him down.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_2861.jpg

He was showing some signs of age to say the least.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_2864.jpg

Again...
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_2866.jpg

the rocker covers were so bad, while wearing latex gloves I rubbed my nail up it and peeled a strip of it off, and didn't even break my glove!
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_2892.jpg

[Paranoid Dave]

The casings would need some work too.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_2895.jpg

So finally I began to take things apart. Now I've read enough rebuild threads on here to know how something so 'easy' doesn't need notes and photo's and 6 months later you haven't got a clue what bolt is what, so being Paranoid i took lots of photo's...
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3720.jpg
I have about 20 pages of these so if anybody needs to know what bolt is what on an early 600 i'll probably be able to help.

If it was wirey and could be tagged it was, roll out the tape and sharpie pen..
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3729.jpg

I was amazed how quick and easy it was to get a monster sown to this size.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3763.jpg
And there's no law against an idiot like me being allowed to do it.

[jezzamondo]

Well impressed with innovative use of camera & whiteboard!

[chris yeatman]

good start, keep the pic's coming.

[Paranoid Dave]

So my first mission is to get all the metal off to the powder coaters. Two main colours chosen and a third for the wheels. This was all carried out by Maldon Blasting and Coating, the wheels would be a one off colour made by them and stunning if a little odd (in a good way) I still don't know what colour it is?
The Frame and brackets all a funky shade of something and the engine cases and footrest bits in a sparkle silver.

With that out the way it's on with painting the engine. Looking closely there's no way you can paint under the top cylinder without removal so stupidity takes over from bravery and out comes a spanner that won't fit. Who the hell has a 15mm spanner? So while Shirl's in town buying me a spanner I'm taking small bits apart and taking more photo's.
Once the heads are off I mask everything, strip as much as I can (the bike not me), thinners, wet and dry, soap and water, you name it... A final clean with thinners and an etch prime later, silver engine paint goes on. I did this in 3 or 4 sections, do a side, tip the engine and do the next...
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3796.jpg

[Paranoid Dave]

Heads are much easier to work on as I can lift them without making grunting noises. Same cleaning methods, paint goes on and the same to the barrels only original black colour kept for those.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3800.jpg
The tricky bit for me is putting things back together, at the time of writing this I still don't know if I have done it right but all seemed to be OK, looks so much better now the paint's not flaking off the engine. :D
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3914.jpg
Those pesky head bolts require a special tool but a nice friend (thanks Berty) made one for me using a long spanner bent into a C shape with a socket welded on top. I had the fixings re-plated so they look good now, not a nasty yellow gold.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3916.jpg
Every fixing that couldn't be replaced with stainless was re-plated. Even some that aren't seen, the axles and quite a few that it would appear aren't needed. (There's always some left in the box, a bit like an IKEA wardrobe).
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3917.jpg

[Paranoid Dave]

With the engine in a reasonable shape, I head off to Maldon to pick up the frame, Oh boy did I have a smile on my face that day. Eric's certainly not going to be a standard monster any more.
Step 1, stop smiling long enough to put frame on engine.
Step 2, Smile again.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3918.jpg
I wanted to get the engine cases on and get the block sealed up, but being me I broke an oil glass when I took it out the casing and needed to replace it. I also needed a gasket set. I ordered them all from ducati and the lovely italian company put me on back order so 6 weeks later I was till waiting. Asking on the forum I was sent to classic gaskets who had a full set which arrived next day.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3926.jpg
The sight glass was in stock at another ducati branch (UKMOC tip off) so one phone call later and 2 were in the post, arrived next day.
The day after that both glass and gaskets arrived from ducati - SOD's LAW.
So put it all together, belts too (my first time fitting them) and I'm wondering if I've done it all right?
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3927.jpg

[Paranoid Dave]

I can't get over how pretty things look when they get together. I had every single part re-plated here.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3930.jpg

Some nice new rocker covers for the horizontal head, powdered with the cases. The paint and powders a good match.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3932.jpg

Starting to take shape and you can see the colour of the wheels now. It's not gold, It's not copper, It's not orange, It's not brown, It is a little metalic and it does depend on the lighting??
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3933.jpg

The original forks were leaking badly so I replaced them years ago with a pair from Gilps. Scruffy gold bits with good bottoms on one pair and scruffy chrome in good legs on the other. One game of mix and match later...
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3934.jpg

WIRING
Oh how I was not looking forward to this. I'd taken advice and cleaned the loom, dried it, fixed some parts, self amalgamating tape here and there, all seems good but how the hell do you fit the spaghetti back in the frame. Probably best just to wear it as a scarf?
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3935.jpg

This bike is still Shirley's and so one reason for the strip was to make it more useable. Wider higher bars and a higher seating position were a must. So renthal bars at the front and a luigi moto jack up kit at the back. I wanted to replace the suspension arch with a billet one and Gary T had one in the loft... thanks Gary, it looks right at home it do.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3942.jpg

[Paranoid Dave]

More pretty bits
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3943.jpg

The fuel line is on show with the old 600's and the fuel tap on the side highlights it so I thought braided hose. When I fitted it though it was so over the top it was too much and it rubbed on the belt covers so I thought classic bike and went for a 'different' look that would hopefully be complemented by the tank.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3963.jpg
Call me Paranoid but I figure a pair of bungs in case of a driveway drop would be a good idea. I'm not a huge carbon lover but my service man said to me a year or two back "oh please don't do it black, there are so many other colours" and so I have tried not to use a single black object or paint (barrel excluded) on the project. For this reason the carbon bungs work.

Calipers front and rear have stainless bolts, nipples and banjo's. Caliper mounting bolts I was advised not to use stainless so they are re-plated.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3964.jpg

One part of the original bike that I have always hated is the sprocket cover. As far as I can tell they never made an after market one for the early model so some drawings and a dremel later.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3976.jpg
I've cut the plastic down to the bolt holes, the rest is made of ali sheet, being powdered and when I rivet the two together, it should look a lot prettier.

TIME TO TURN THE ENGINE
1, out with plugs
2, select gear
3, fit chain and wheel
4, turn wheel by hand.

Two problems, firstly I can't bleed the clutch, it hates me and I hate it. So for the time being neutral is fine.
Secondly I put a spacer in the sprocket carrier the wrong way and when I turned it around and hammered it home I was a little heavy handed and, well, you can see...
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3977.jpg

SO today with another carrier in the post I do some odd jobs, like polish up the pipes a bit.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3979.jpg

Polish up the spacers for the pipes, work out bolt lengths ready for shopping this week and start to hang them and fit footrests. I can't do it fully as I have made an ali undertray to hold the fuse box and ditch the nasty black plastic bit.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3994.jpg

As it stands this is how I left it tonight. Things are slowly taking shape, more in the post and some at the powder coaters. I'm sure I'll be back when there's more to show.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_3997.jpg

[gregski]

wow that is awsome

[Gunsoku]

Holy jingleberries. That's awesome.

<- Subscribed.

[Nonnie]

hee heee you crazy dudes!

Just can't wait til I see it all. Hard work and design is proper ace when it comes to Monsters eh?

See you Friday!

xxxxxxx

[benson]

WoW!!!!! you is well nang innit peeeedeeeee!

[benson]

Seriously impressed PD - it looks amazing - the colour of that frame!!!!!

[Pedro]

Nice work there Dave

[He11cat]

like the frame...
making my glittery plans look sad!!

[uksurfer]

good work, looking forward to the next pictures, great to see another detailed rebuild, that is going to be such a one off!

[benson]

In the daylight the pics look even more sparkly!!!!!

[Paranoid Dave]

In the daylight the frame looks even more sparkly but I cant bring the sun into the garage.

[BluprintZ]

Very nice Dave, wouldn't bother fitting lights though mate, it'll be dazzling enough!:cool:

G ; )

[gary tompkins]

OMG!!!

That frame colour is just awesome :cool:

PD you are the man :hail:

[emily's driver]

Looks very chic Monsieur Girling and very sparkly. Shirl is gonna love it! See you tomorrow.

[benson]

She loves him already...:mand::mand::mand:

[scrapps]

Mmm shiny....... keep it out of Hellcats and my reach or bits may go missing :chuckle:
Top work and a great colour.

[Mand]

oowww that is dead nice! I mean proper dead nice. :mand:

[Paranoid Dave]

I know it's the norm to say 'tha camera don't do it justice' but in this instance the camera doesn't capture the colour at all. The frame is not red or even sparkly red, but the flash makes it look like that. the real colour is even more incredible and unusual, I showed Nonnie and the response was "wow - what colour is it".

Maybe in months to come when I can wheel it outside the garage I'll be able to get a photo of it without the flash?

Thanks for the positive vibes all, at this point in a build things slow down and motivation to finish is helped by such things. I've also watched many rebuild threads over the years and been inspired and learnt a hell of a lot from them so hopefully this will continue the trend and give someone else an idea.

[mintyhit]

Wow! Very nice indeed! You will be so proud of your work when you first fire it up.

Question: How did you get your front callipers so clean? I really struggled with mine as anything tough enough to remove 10 years of ingrained break-dust also tended to remove the gold plating!

[Paranoid Dave]

a toothbrush, some brake cleaner and running water.

[Albie]

Looking great Dave. Looking forward to seeing the final result and then in the flesh. Maybe you can show it at Pomps august lunch meet on the bank holiday.

[Mand]

a toothbrush, some brake cleaner and running water.

and a great deal of patience!

Gosh I remember the days when I used to polish my pipes/exhausts weekly! :chuckle:

Can't wait to see the finish result Dave, perhaps the Cakes can "go east...." for a special viewing. :mand:

x

[w108rna]

Can't wait to see the finished job. Are you a professional mechanic or just someone who likes tinkering? It looks like you have taken lots of care.

[RODUC]

I'm impressed looks amazing

[Darkness]

Seriously impressed PD - it looks amazing - the colour of that frame!!!!!

I'm waiting to see the tank on it: something that complements translucent green..........

Translucent green perchance?

:cool:

[rac3r]

Now that is the definition of BLING! :cool:

[yantheman]

amazing work! :thumbsup: :hail:

[Paranoid Dave]

I am a total novice. No training and that i'm sure will become evident when I try to start it. I did lots of tinkering with my old 600 and now 900 and taken most bits apart just not all in one go. After that its two bolts and off comes the frame.

If I was good I wouldn't have smashed the sprocket carrier like an idiot. having done so I purchased another from ebay, it turned up and is the wrong one. I got another one to replace the replacement but it was not in great condition. As you can see...

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4008.jpg

Thankfully the seller (breaker) is sending me a replacement for the replacement to the replacement for the one I broke.

Benson, translucent tank like a buell would be great but not the answer. Green is a feature and so is a ducati stripe but like everything I do it has to be a bit different.... and once again the colour will be questionable?

All in good time.

[giler]

like the frame...
Making my glittery plans look sad!!

ding dong!

[Paranoid Dave]

WOW what a day. I'm not called paranoid for nothing, I worry about things and when it comes to deigning anything I tinker to the limit. So when it came to designing a colour scheme for the paint, i've drawn pages and pages of sketches, i've photoshop'd image after image, and when after best part of a year I was almost sorted, I changed it all again.
A few weeks ago I took the paint to DJ Spray in norfolk, I warned him I was going to be a pain and a little picky but when an idea's in your head what else can you do. Well I got the message yesterday that it was ready and lucky for me today is my day off.
My paranoia was churning my stomach and an hours drive is not a help, but I arrive and poke my head through the doorway, there on the table are the 3 main parts in all their glory as my body shouted "aaand realx". :D :D :D

I'm really really really happy with the work, so this weekend will see me back in the shed for the next installment. I'm a happy man today.:D

[Paranoid Dave]

So here's a couple more pics:

Andy P, you're bleedin great you are!

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4001.jpg

So back to the paint. As I said I went through many ideas and directions, all trying to bring colour and something a bit different. This one was done during an early Art Nouveau period.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/NouveauTricolore.jpg

And from there:
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/greenidea.jpg

Or this:
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/redidea.jpg

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4014.jpg
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4015.jpg

Maybe this:
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/side.jpg
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/TankTop.jpg

I'll let you decide what direction the idea went from there, but it's not white I can tell you that.

[pooh]

Dave
looks amazing mate when will it be done?

Ian

[giler]

I like the top version, just not sure about the astro-turf belly pan:chuckle:

[benson]

I'm seriously loving the story here Dave and I just wish I was peering over your shoulder this weekend - can't wait to see the glorious finished paint!

[Nonnie]

Well...I have seen it!

It's a very unusual thing it is.

You're teasing them Davey.

[benson]

Oh but we likes a tease.....

[emily's driver]

Any update Dave...pics?

[Paranoid Dave]

Well after a couple of months waiting around for replacement parts and powder coaters to do their thing, once again I find myself in the garage updating Eric (or Erica we're just not sure).

Two things I have always hated about the monster are the undertray and the front sprocket cover (old style), both scruffy, grotty and impossible to do anything with without serious effort. Well I like a challenge so some sheet Ali, careful drilling, bending and a dose of powder later I now have these lovely objects.

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4161.jpg
UNDERTRAY

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4162.jpg
Bracket for ohlins can, front sprocket cover and indicator bracket for the tea tray.

And... most importantly the part I broke, replaced on more than one occasion, then powdered again is finally here. (Fanfare please at the back).
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4167.jpg

Unfortunately I couldn't fit the sprocket on it because it would seem at some point the casting took a knock and one of the bolts is off line a fraction too much. I wonder if it damaged the casting. I remember brake levers bend once when you drop a bike but never bend back.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4171.jpg
Sprocket holders it would appear are the same. :Furious:

Oh great!

So I have another one in the post and when it arrives I'm banned from touching the bike as I need some surgery and will not be allowed to lift ANYTHING for a month. :hissy:

So that's it for a bit longer. Here's the finished sprocket cover, personally I think its a vast improvement on the original and uses all the original fittings.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4176.jpg

And the new undertray is much smarter and easier to clean.
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4180.jpg

And if you were wondering what the bodywork looks like, here's the pictures you've been waiting for....

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4178.jpg
http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/100_4179.jpg

[utopia]

Oooh Dave, you're such a tease.
Novel mounting for the rear no plate btw.

[pooh]

Dave looking good mate
Ian

[benson]

You spangly paint whore!!!! I so love the sprocket cover - Ericaaaahhhh is going to be one hot bike!!!

So - not allowed to lift anything for a month - thank god for internet and typing messages to monster friends!

XXX

[Nonnie]

We will keep you entertained Davey Sprockett.

x

[benson]

Oh yes indeed - I can see it now...PD captive inside his own home and visitors from hell!!!!!

[benson]

We would never need to go home!!! Be afraid Davey!!!

[gary tompkins]

Get that cack foam and ducktape off dammit!!!

We wanna see the bling :hissy:

[Darkness]

Get that cack foam and ducktape off dammit!!!

You mean that isn't the final finish?

:spin::spin:

[Julie]

Lovely! I enjoy postes like this PD!

[Paranoid Dave]

Ok so three years after Eric was parked up with 'project' intentions, 2 years after I started work and 1 year after I had ever planned on finishing, thanks to my bodily needs and Pudding-Head's encouragement today Eric made one big leap forward...

He was so close to being done and the plan is that until I can sell my Milla, this will be much kinder to me so I need to get him finished. Today ticked off the majority of little jobs and I plan to pass it on to the expert to bleed, fuel, fix my many likely mistakes and MOT it.

With the Sun shining down I couldn't resist wheeling it out of the garage and letting it glisten and show me his true colours, and what colours! No literally, what colours is he?

And so to his new name, P-H said he is wonderful (just as well as it's her bike) but "I think a lot of people will either love it or hate it" just like Marmite. So from here on he will forever be My Mate Eric

Sadly he will not be appearing near a mill pond any time soon so you'll have to make do with these pictures.... so hoping you Love him and not Hate him, I would like to introduce you to My Mate Eric.

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/IMG_0399.jpg

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/IMG_0400.jpg

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/IMG_0402.jpg

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/IMG_0408.jpg

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/IMG_0405.jpg

[Paranoid Dave]

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/IMG_0407.jpg

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/IMG_0409.jpg

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/IMG_0410.jpg

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/IMG_0412.jpg

http://i1029.photobucket.com/albums/y359/paranoidphotos/Project%20Eric/IMG_0413.jpg

He looks a bit tidier than he did at the start I think you'll agree. I'll finish the thread when he's tested and finally seen tarmac. :D

[benson]

Very very shiny and green and orange and geometric - I like Marmite!

[gary tompkins]

Nice one PD - looks fantastic :biggrin:

Pity it won't be at Arrow Mill

[pooh]

PD
Very nice mate hell of a job. Not sure about the sparkly bits but every one to there own. Pity you ain't off to the Mill but hopefully meet up soon. By the way like the Ducati graphics were they transfers or painted directly onto the tank?

See you soon
Ian

[Paranoid Dave]

The logo and the stripes over screen, tank and tail are vinyl that changes colour from red to green to gold. The bodywork is dark green almost black and changes colour depending on viewpoint. Oh and the frame changes colour from brow to red to green so every angle makes the bike look very different.

[sbhumphrey]

Just about to embark on the stripdown and rebuild of my m900 and this really gives me inspiration to make it a more personal machine. Fantastic job!

[emily's driver]

Very nice Dave. I know how much hard work rebuilds are or can be, so all credit to you. Bet Shirl will be fighting to get the keys off you. I like Marmite too and as a collaboration of the spread you either love or hate and Ducati, Eric's more like "Marmaduke" now! Or is that an animated large dog? Either way well done fella.

[Albie]

It looks great PD. As rod said it takes a lot of work and patience to get results like that. Whilst its not everyones cup of tea it has to be said its a work of art. I love the tank colours and would like to see it in the flesh. I dont think the pics will do it justice

[Cutter]

Nice one - great to see something different! I just know photos can't do this bike justice - bet those colours even cooler in real life....