Another build thread - Ducati 1000 - Page 10

buzzer · 08-08-2021, 08:19 PM

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.

PPuxley · 08-08-2021, 09:02 PM

Looking Great, Tony!

slob · 08-08-2021, 09:23 PM

biased to the front, to improve airflow to the oil cooler?
isn't the silencer going to hamper access to the r/h seat securing bolt?
as ever, impressive work nonetheless!

buzzer · 14-08-2021, 06:18 PM

Quote:

Originally Posted by slob

biased to the front, to improve airflow to the oil cooler?
isn't the silencer going to hamper access to the r/h seat securing bolt?
as ever, impressive work nonetheless!

yes, I have had to put one bolt to the side so I can get to it with a ball end allen key

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!

buzzer · 19-08-2021, 09:08 AM

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!

PPuxley · 19-08-2021, 01:26 PM

Great fabrication skills, Tony! Brazed steel frames look so good you dont want to put a finish on them, do you!

buzzer · 07-09-2021, 07:38 PM

Quote:

Originally Posted by PPuxley

Great fabrication skills, Tony! Brazed steel frames look so good you dont want to put a finish on them, do you!

yes its almost a shame to paint them!

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

buzzer · 25-09-2021, 12:26 PM

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…

checking for guide wear...

https://www.youtube.com/watch?v=0rV2OPrxpNw

buzzer · 02-10-2021, 11:48 AM

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!

buzzer · 04-10-2021, 03:04 PM

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.

buzzer · 06-10-2021, 09:04 AM

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 �� it’s done well, only recently run out ��

PPuxley · 06-10-2021, 10:31 AM

Tony, are those the AV&V stem seals from Canada or do you have a UK source?

buzzer · 06-10-2021, 04:57 PM

Quote:

Originally Posted by PPuxley

Tony, are those the AV&V stem seals from Canada or do you have a UK source?

they are genuine... they were in the head gasket kit

buzzer · 08-10-2021, 10:31 AM

when people say to me Ducati bikes are expensive to service I ask them if they have ever done the valve clearances! 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!

buzzer · 11-10-2021, 10:13 AM

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!

08-08-2021, 09:02 PM	#137
PPuxley Registered User Join Date: Apr 2021 Location: Reading Bike: M900 Posts: 600	Looking Great, Tony! __________________ Golf-My favourite game. While my wife plays I'm in the workshop.

19-08-2021, 01:26 PM	#141
PPuxley Registered User Join Date: Apr 2021 Location: Reading Bike: M900 Posts: 600	Great fabrication skills, Tony! Brazed steel frames look so good you dont want to put a finish on them, do you! __________________ Golf-My favourite game. While my wife plays I'm in the workshop.

06-10-2021, 10:31 AM	#147
PPuxley Registered User Join Date: Apr 2021 Location: Reading Bike: M900 Posts: 600	Tony, are those the AV&V stem seals from Canada or do you have a UK source? __________________ Golf-My favourite game. While my wife plays I'm in the workshop.

08-08-2021, 08:19 PM	#136
buzzer Registered User Join Date: Jun 2018 Location: Wolverhampton Bike: M900 Posts: 392	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.

08-08-2021, 09:23 PM	#138
slob . Join Date: Jul 2003 Location: East London Bike: Multiple Monsters Posts: 9,713	biased to the front, to improve airflow to the oil cooler? isn't the silencer going to hamper access to the r/h seat securing bolt? as ever, impressive work nonetheless!

19-08-2021, 09:08 AM	#140
buzzer Registered User Join Date: Jun 2018 Location: Wolverhampton Bike: M900 Posts: 392	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!

25-09-2021, 12:26 PM	#143
buzzer Registered User Join Date: Jun 2018 Location: Wolverhampton Bike: M900 Posts: 392	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… checking for guide wear... https://www.youtube.com/watch?v=0rV2OPrxpNw

02-10-2021, 11:48 AM	#144
buzzer Registered User Join Date: Jun 2018 Location: Wolverhampton Bike: M900 Posts: 392	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!

04-10-2021, 03:04 PM	#145
buzzer Registered User Join Date: Jun 2018 Location: Wolverhampton Bike: M900 Posts: 392	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.

06-10-2021, 09:04 AM	#146
buzzer Registered User Join Date: Jun 2018 Location: Wolverhampton Bike: M900 Posts: 392	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 �� it’s done well, only recently run out ��

08-10-2021, 10:31 AM	#149
buzzer Registered User Join Date: Jun 2018 Location: Wolverhampton Bike: M900 Posts: 392	when people say to me Ducati bikes are expensive to service I ask them if they have ever done the valve clearances! 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!

11-10-2021, 10:13 AM	#150
buzzer Registered User Join Date: Jun 2018 Location: Wolverhampton Bike: M900 Posts: 392	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!