Carbon bodywork fitment - Ducati.ms

twowheelcossack · Oct 4th, 2006, 12:16 pm

I have scoured the internet for some basic guidelines for the drilling/fitment of carbon bodywork on motorcycles, including this great forum and have yet to find any (let me know if you need to know how to fit a carbon hood to any import car however, no shortage of that in cyberspace...). I realize most of it is patience, relatively slow drill/tool speeds, endless removal and replacement of bodywork and the "measure twice (thrice?), cut once" philosophy. I would like some info/sage advice/previous horror stories a little more specific to Ducati 916-748 models. I have a '01 996sps with DP bodywork (minus tail) which, for the most part is drilled, except for the upper mounting/windscreen holes and the mirror mount. After starting the rudimentary work so far I have learned that there seems to be a logical way/order of things to happen so it actually fits and that the end result doesn't look cobbled together like some rolling disasters I've seen at track days/club races (no offense if that was your ride, I realize this stuff isn't easy...) Some specific questions that center around which parts to drill and fit on or off the bike, then fit to the next part:

1. Do I fit upper to lowers with lowers on or off the bike?

2. Do I fit/drill windscreen holes with upper on or off the bike? Should I do
the windscreen before fitment to lowers? If so, when do the mirror/
bottom wellnut holes get drilled?

3. None or all of the above?

4. Are you as confused as I appear to be so far?

It seems sure that the success of one panel fitting is dependent on all the other panels and their fitment. Local paid professionals around here are reticent to do the work in fear of the replacement costs of botched carbon, so I figured I'd get as much of your input as possible before warming up the Dremel and attempt to avoid amassing unusable carbon "wall hangings" for the ol' garage. DIY is more enjoyable anyway. Thanks in advance.

Sith · Oct 5th, 2006, 9:46 am

Don't have a lot of specific advice for you other than to suggest you're on the right track already which is to take your time and think things out logically. I've done quite a bit of piecing together and painting drag cars in the past and although a car is not a bike some issues remain the same; especially when dealing with "aftermarket" or one off bodywork/panels. Due to variations of the panels during the manufacturing process I'd suggest fitting them on the bike. May be awkward and require another set of hands but that way flexing of the panels/size variations can be addressed and everything can be adjusted as it will actually lay on the bike. Conversely if you do everything off the bike you may find it's not quite right once you try and mount it on the bike. Also suggest getting a roll of the blue, low-tack painters tape (available at Lowes, Home Depot, etc.), maybe 2" wide and place that over panels/pieces that are liable to be easily scratched when moving them around and over panels that will need to be drilled and make your marks where to drill on the tape and drill pilot holes through the tape as well. Will also work well to find the mirror placement points on the fairing.

Again, like you suggest; take your time and think things out. Trust me, you'll do a much better job then the so called professionals out there. Good luck!

twowheelcossack · Oct 5th, 2006, 11:01 am

Thanks for your encouraging words, Sith. The blue tape is a great suggestion and one I had not considered. You're right, after a little more consideration, 90% of the work is pretty much sitting and staring at the bike in order to find out the logical order of things. That coupled with trial and error with fitment before making any permanent cuts/holes will get me through. I'll post pics after the paint gets shot.

Sith · Oct 5th, 2006, 11:18 am

Sounds like a plan to me! Looking forward to seeing the finished product!

jamesmorgan · Oct 5th, 2006, 12:22 pm

just tackled the body work on a 67 mustang and i would assume the same principals would apply. when doing a car you would start with the pieces that line up against a body part that cant be adjusted ,ie the doors becouse the rear gap is "fixed" as you cant adjust the rear quarter panel. then work your way forward from there lining everything up against the priveious panel. that said, pick a panel that buts up against something that you cant move, ie the gas tank, line it up, drill it and mount it. then everything else should "fall into place". The main thing is to take your time, remembering that once the hole is drilled, its perminant. measure 3 times, test fit even more, then drill and be happy. good luck!!!

desmofetish · Oct 5th, 2006, 1:29 pm

For the windscreen, I would suggest starting with the lowest, center hole. Then after it is drilled, you can mount it and mark the remaining holes from there. Remember, the fairing will have to bend in slightly to meet the windscreen holes (at least with my MS production carbon it did). As for the mirror mounts... you really just have to take the chance and go for it...as I did. Hold it to the fairing stay and mark your holes to the best of your ability. Just be as detailed as possible, measure, measure and measure again, then take the chance. Mine turned out great!

twowheelcossack · Oct 5th, 2006, 1:54 pm

Quote:

Originally Posted by jamesmorgan

just tackled the body work on a 67 mustang and i would assume the same principals would apply. when doing a car you would start with the pieces that line up against a body part that cant be adjusted ,ie the doors becouse the rear gap is "fixed" as you cant adjust the rear quarter panel. then work your way forward from there lining everything up against the priveious panel. that said, pick a panel that buts up against something that you cant move, ie the gas tank, line it up, drill it and mount it. then everything else should "fall into place". The main thing is to take your time, remembering that once the hole is drilled, its perminant. measure 3 times, test fit even more, then drill and be happy. good luck!!!

Great suggestions jamesmorgan, there are a few places where there is no room for error (such as where the dzus backing plates reside and connect upper to lower, a crucial junction that would make it easy to screw up the lines of the bike...) and places where there is allowance for +,- such as the bottom wellnuts underneath the air-runner intake. Big thanks.

twowheelcossack · Oct 5th, 2006, 2:11 pm

Quote:

Originally Posted by desmofetish

For the windscreen, I would suggest starting with the lowest, center hole. Then after it is drilled, you can mount it and mark the remaining holes from there. Remember, the fairing will have to bend in slightly to meet the windscreen holes (at least with my MS production carbon it did). As for the mirror mounts... you really just have to take the chance and go for it...as I did. Hold it to the fairing stay and mark your holes to the best of your ability. Just be as detailed as possible, measure, measure and measure again, then take the chance. Mine turned out great!

Good ideas, and you're right. Upon making a "dry run" fitting I did notice that the mirror stalk stays didn't meet well with the upper; it appearing to be too wide. Doing the shield first in the manner you describe would tighten up the whole piece for it's next step. I'm confident your suggestions will help me pull it off better than the stock ABS items. It took much patience/expletives/Coors Light to attach the shield last time I attempted it years ago, and those teeny little torx/wellnut items must have a defense department spec. rating based on their violently high cost (is that real gold or just an anode finish. Sheesh...) Thanks again for your help.

desmofetish · Oct 5th, 2006, 6:33 pm

Quote:

Originally Posted by twowheelcossack

It took much patience/expletives/Coors Light to attach the shield last time I attempted it years ago

Ahhhhhhh, there's your problem... you ride a Ducati but still drink Coors Light as if you're trying to get drunk before the high school prom... How about you try something more selective, say Pilsner Urquell... Czech it out!!!!

twowheelcossack · Oct 5th, 2006, 6:55 pm

Quote:

Originally Posted by desmofetish

Ahhhhhhh, there's your problem... you ride a Ducati but still drink Coors Light as if you're trying to get drunk before the high school prom... How about you try something more selective, say Pilsner Urquell... Czech it out!!!!

Very observant and very true, desmofetish. My date did complain about my dirty fingernails... I've since switched to something more respectable.