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Discussion Starter #41
Onto the wiring...* I looked at the existing loom and realised SO much had changed that it was redundant...* So I am going to wire this from scratch, using my own design of loom.* I priced up the wire new and it was a LOT of money , and although I had some wire from past rebuilds it was limited in different colours.* So off to the scrap yard with a big pair of side cutters.* I came away with this lot for £5!* should keep me going.* it took a while to separate it into single strands of wire, but there is now a right mix of colours!

its bigger than it looks in the picture

 

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Discussion Starter #43
December and progress has been a little slow due partly to the holiday, but mainly as my wife has broken two fingers which means garage time is limited! I am having to do jobs I don’t normally do!

I have managed a couple of small jobs… made some adaptors for the manifold for the vacuum fuel tap, mounted the speedo sensor on the back wheel in place of the original hall sensor (hope the magnets stay in place!) and finally made a new “T” peice for the carbs as I didn’t like the very short connector on the original plastic one.

This needed to be accurate, so out came the micrometer, which my Dad gave me when I was about 16… that was 47 years ago. I have more modern measuring stuff, but this is still the default measuring tool I go to. its still checks out accurate!

I have started the bike, but I have a problem in that I only have a spark on the vertical cylinder... this seems to be a problem with the Ignitech ignition. the guys there are looking at it for me at the moment







 

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Discussion Starter #44
Managed to sneak in the garage for a while... still some wiring to finish off, and I have replaced the ignition leads with some new copper core wire. Been years since I made some up, they seem to last well on today's cars and bikes.

as I need to get the pins out of some of the loom connectors, in particular the handlebar switches I used this set of removers... they were only a few pounds but over the years they have been used time and time again! They fit the majority of connectors and allow you to remove and replace the connection pins without damage.


 

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Discussion Starter #46
A little bit more progress... the original mudguard protected the chrome stanchion from stone chips... hence the new alloy protectors. I have also made up some alloy frame plugs in place of the black rubber ones.



 

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Discussion Starter #47
Now the bit I am not too keen on… painting the tanks and seat. not because I don’t like that actual work, its the mess it makes in the garage. There are two tanks as I initially bought a Carbed Monster tank, but it simply didn’t fit, which is a pity as I prefer the shape. Thought I would paint it at the same time and sell it on. Its almost new, the guy I bought it off said when his monster was new it fell over and dented the tank, so he bough a new one. this has been in his loft for almost 20 years! The monster tank will be red… I already have some paint… As for the tank and seat… we will see!

 

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Fantastic build. Great job . I too have drilled out jets in the past . The most difficult part is remembering what size jet they are if you move them around. Can I ask, why did you go with a vacuum carb as opposed to a pumper carb like the Fcr?
 

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Discussion Starter #49
Fantastic build. Great job . I too have drilled out jets in the past . The most difficult part is remembering what size jet they are if you move them around. Can I ask, why did you go with a vacuum carb as opposed to a pumper carb like the Fcr?
sure, it was just the expense of the FCR's... I picked up the 900 Mikuni CV's for £35 as the air screws were seized, but I managed to free them off. they are 38 mm and I know some 900's make good power with these on, plus its a road bike and torque is more important to me than outright power. I am going to see how it goes.

I do have some 42mm carbs of a Honda V twin as a fall back position
 

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Discussion Starter #50
Thanks!

I decided that as I had not used this particular paint system before I would do the Monster tank first as I wont be using that... Have to say the paint is really good and goes on really nice! anyone want a Monster tank, its up for sale soon!

 

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Discussion Starter #51
finally decided on the colour after much deliberation.... Orange. The tank and seat divide opinion, some like it, some hate it... may as well do the same with the colour! have to say this paint is really good... but so is my new spray gun...

When I was 20 my dad bought me a second hand Binks Bullows 230, which I have used for over 40 years. I must have bought 5 different guns over the years to replace it, but always came back to it. then last year my mate loaned me a gun to try. Fantastic! I was shocked to learn he paid £18 for it new, complete with three different nozzles!! So I bought one, its brilliant!





 

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finally decided on the colour after much deliberation.... Orange. The tank and seat divide opinion, some like it, some hate it... may as well do the same with the colour! have to say this paint is really good... but so is my new spray gun...

When I was 20 my dad bought me a second hand Binks Bullows 230, which I have used for over 40 years. I must have bought 5 different guns over the years to replace it, but always came back to it. then last year my mate loaned me a gun to try. Fantastic! I was shocked to learn he paid £18 for it new, complete with three different nozzles!! So I bought one, its brilliant!
Bike turned out great, want to share the details on the new spray gun?
 

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Discussion Starter #58
Love this build!!!!!........except for the tank. The proportions are just not there, but the rest is very impressive and the color is surprisingly nice. Maybe this guy could build you a one off aluminum

https://www.ducati.ms/forums/42-monster/719121-ducati-monster-alluminium-tank.html
I would have liked to have made the tank.... but i dont have an english wheel, yet! Work is in progress on that and I have plans to make one. So for now its has to stay with the ST4 tank as there are no viable alternatives. I tried the Monster tank on there and it simply does not fit, i think some of the other later bike tanks might be better, but they are plastic, and i want to stay away from that and the associated problems with them...
 

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Discussion Starter #60
I have been unhappy with the silencer... and decided to make one in Stainless Steel, out of one I bought off Ebay, this time re-packable, and also with a removable baffle for MOT time. Even without the baffle, its acceptable (with my ears!!) with just the resonator now its packed properly.



 
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