Ducati.ms - The Ultimate Ducati Forum banner

41 - 60 of 322 Posts

·
Premium Member
Joined
·
579 Posts
Discussion Starter #41
Mmmmm Carbon Fibre

Making carbon parts involves mixing your resin and hardener (50:1) getting an initial tacky layer in your mould and then laying down and wetting layers of carbon fibre (or fibreglass) and resin until satisfied.

This the plate for my electrics. The mould, the finished layers, what it looks like once its come out of the mould and then after having attacked it with a coping saw and various sanding implements to get it into shape.

This is my first effort and clearly John Britten I am not, but you get the idea.
 

Attachments

·
Premium Member
Joined
·
579 Posts
Discussion Starter #42
Fun stuff.

I have to admit, making stuff out of carbon fibre is a bit of a pain. It's expensive and hugely time consuming and takes ages to get a result, especially as I'm only doing bike stuff on Saturdays (plus I think my f-ing around is driving Muzza mad!). I'd much rather do stuff which is more instantly gratifying.

Last week Muzza (or at least one of his off-siders) painted my wheels. They needed a scuff and sand afterwards, during the course of which, one of the rims made a dash for freedom. (Earthquake maybe? We're still having the occasional small tremor) When it fell of the bench the rim got a ding in it so I wasn't having a good day. At least it only needed a visit to a local engineer to repair.

This week, when I turned up at the Muzzabikes workshop, my wheels were all finished, resplendent in a fresh coat of satin black, I have to say they look amazing; even better than I thought they would! I had bought some late model Duke disc carrier bolts off eBay, bolted my discs on and Muzza fitted some nice new Michelin Pilot Powers. Result!
 

Attachments

·
Registered
Joined
·
463 Posts
Your doing a cracking job Hamish, I ran a set of Vee2 cams ages ago and they ruined me rockers. Didn't really improve the bike either.

Keep it up mate!

Cheers Pablo
 

·
Premium Member
Joined
·
579 Posts
Discussion Starter #44
I mentioned planning to have the coils hanging off the lower frame rail. In order to do that we needed to make some new tabs and weld them on.

A bit of furniture framing turned out to be spot on, then it simply a case of making them pretty. (Last pic)
 

Attachments

·
Premium Member
Joined
·
579 Posts
Discussion Starter #45 (Edited)
A pretty much standard '89 Supersport came into the Muzzabikes shop the other day. Here's a quick comparison of the frames. As well as the differences I note some additional frame bracing on mine.
 

Attachments

·
Premium Member
Joined
·
579 Posts
Discussion Starter #46
I'd decided that in order to get the battery box situation resolved quickly, I should get one made in aluminium, and guess what, when I put it on the bike, the plate at the front doesn't cover the holes needed to secure it. :(

At least it tells me angle of the tabs needed to secure it, meaning Muzza could paint the frame. So, several swear words later, after a quick etch prime of the shiny bits, that’s now done. Great! With a finished frame I can put in the steering head bearings, then forks, and swingarm, then wheels...WHEELS!!! WHEEEEEELS!!!! (you get the picture) :crazy:

I bought an old STM slipper clutch off my mate Todd, or at least most of an STM slipper clutch as it turned out. :mad: Grrrrrrrr. Parts cost 250% of the component cost, if you can get em, i.e. IF STM can be bothered answering your email to sell them to you. Of course now they want to go on holiday for a month! (Cos they're worn out from answering emails right??) Anyway, it's probably not worth throwing good money after bad, as the clutch is the apparently less reliable older design.

Back to Plan B. I installed the Barnett Clutch Basket I originally bought (or at least the second (black) one, (the first one I purchased had a very pink hue which I didn't fancy), then the clutch plates, (including some lovely lightweight aluminium sintered alternates I got from Germany), topped by a Rizoma Pressure Plate, with techy spring covers and (TPO) titanium screws. Fine bling!

Finally I put some red paint in the timing marks on my lightened 400SS flywheel (makes em easier to see) and buttoned down the motor.

Next weekend is going to be an exciting one. :D
 

Attachments

·
Premium Member
Joined
·
579 Posts
Discussion Starter #47 (Edited)
The next week wasn't quite as exciting as I'd hoped. There's always a lot of fiddly stuff that I realise I need to do before the more exciting (bolt on) stuff gets done.

Last time I made some more stuff out of carbon fibre, but after making it too thick last time, this time it was too thin; may need some bracing. Will see when it's trimmed to shape. (Pic1) This part is a support for my carbon 916 Corsa tail fairing (which is unique in having a round hump).

Other fiddly stuff is more satisfying. After having my heads ported, it seemed important to port-match my Malossi inlet manifolds, and get an inside surface that promotes the right sort of swirl characteristics. (Pics 2&3) Luckily Muzzabikes has the right tool for the job. Done.

Needing some gratification I thought I'd bolt on the swingarm. Alas, the shim box was with another customer so we didnt have enough shims...

Last pic is my custom chain adjuster, complete with race stand bobbins.

And that's another Saturday gone!
 

Attachments

·
Premium Member
Joined
·
579 Posts
Discussion Starter #48 (Edited)
Bolting on stuff!

So THIS week things got a bit more exciting. First to go on were the manifolds and carbs, then the swingarm, rear wheel and brake, carbon sprocket cover, Oberon slave cylinder, then the frame (YAY!) oil lines on the side of the motor, custom mounted S4R oil cooler, S2R oil lines and the coils. I even put the rear-sets on. Lastly, before a well deserved beer, I bolted the Ohlins shock in. Finally, it actually 'looks' like a motorbike!

With that we moved the bike to the next work-station. Replacing it "on the production line" is a motor out of a much neglected 996S that Muzza is going to make like-new for a customer. "I know!!", he said, "We could put THAT in your bike! =)" Yeah...yeah...very funny.
 

Attachments

·
Premium Member
Joined
·
2,478 Posts
It's coming on nicely! Are you planning to make it street legal? :cool: ...and if so, should you be getting it checked by a LVVTA ( Low Volume Vehicle Technical Association) inspector as you go? I'm totally unsure as to that requirement - I know you DO if you're building a car...

Here's a link to their website Low Volume Vehicle Technical Association Incorporated ...so you can wade through the guff yourself. ;)

I had a quick look, and noticed that they DO have some requirements for motorcycles - at least in respect of noise. Yours will need to be under 100dBA at 2500 rpm... So you should have a 'bit' of wriggle room...

Sorry - not trying to rain on your parade - more along the lines of 'forewarned is forearmed'... I hate surprises that appear just when you think it's all done!

Reckon you'll have it done by mid November? If so, I'd love to check it out in person - I'm supposed to be meeting some mates in Christchurch on my/our way down to the Burt Munro festival around the 18th...
 

·
Premium Member
Joined
·
579 Posts
Discussion Starter #50
It's coming on nicely! Are you planning to make it street legal? :cool: ...and if so, should you be getting it checked by a LVVTA ( Low Volume Vehicle Technical Association) inspector as you go? I'm totally unsure as to that requirement - I know you DO if you're building a car...

Reckon you'll have it done by mid November? If so, I'd love to check it out in person - I'm supposed to be meeting some mates in Christchurch on my/our way down to the Burt Munro festival around the 18th...
Yep, it's my intention to ride it on the road. If I was starting from scratch and took it to an inspector I'm sure he'd take one look at it and say "No way!" However, it managed to get a new VIN prior to the new rules coming out and had registration and a WOF until it fell over after the Feb earthquake. To the guys at the testing station, it wont look much different to what it did before.

In its previous iteration, with ZXR forks and a steering stem spaced with bearing shells, *I* wouldn't have given it a Warrant of Fitness! Now, with pretty much every part replaced replaced or reconditioned, it's a much better, safer bike.

If the worst comes to the worst and they start inspecting all vehicles in a detailed fashion, the build has been carried out by an A Grade Mechanic (Muzza) and inspected by an Engineer Surveyor (my Dad) and we've documented the entire build... but I'm not about to go looking for trouble. And if it finds me, then I guess I'll have a very competitive race bike.

The mufflers I've got have been re-packed so I cant imagine it'll be super loud (more's the pity). If its a bit OTT we can always make some db Killers.

It bloody well better be finished! It's my plan to take it to the Burt Munro Rally! Look forward to seeing you there!. :D
 

·
Premium Member
Joined
·
2,478 Posts
Yep, it's my intention to ride it on the road. If I was starting from scratch and took it to an inspector I'm sure he'd take one look at it and say "No way!" However, it managed to get a new VIN prior to the new rules coming out and had registration and a WOF until it fell over after the Feb earthquake. To the guys at the testing station, it wont look much different to what it did before.

In its previous iteration, with ZXR forks and a steering stem spaced with bearing shells, *I* wouldn't have given it a Warrant of Fitness! Now, with pretty much every part replaced replaced or reconditioned, it's a much better, safer bike.

If the worst comes to the worst and they start inspecting all vehicles in a detailed fashion, the build has been carried out by an A Grade Mechanic (Muzza) and inspected by an Engineer Surveyor (my Dad) and we've documented the entire build... but I'm not about to go looking for trouble. And if it finds me, then I guess I'll have a very competitive race bike.

The mufflers I've got have been re-packed so I cant imagine it'll be super loud (more's the pity). If its a bit OTT we can always make some db Killers.

It bloody well better be finished! It's my plan to take it to the Burt Munro Rally! Look forward to seeing you there!. :D
Sounds like you've got your bases pretty much covered! Especially as it was already rego'd/WOF'd before the 'quake.

I wouldn't worry too much about the noise level - mine passed at the local VTNZ without the dB killers in. Mind you - there was a Harley there the first time I took it in with the new pipes on. It was quiet by comparison. :D

Yeah - I'm looking forward to the ride. Be my first decent ( >1000km) ride for a few years! They've all been 500-600 kms, then back... I don't know if my body is going to appreciate it though. :( Not too ride fit... ;)

Keep an eye out for a yellow SL with a red tank, and a pack rack...

Looking forward to more pics of yours as it completes!
 

·
Registered
Joined
·
221 Posts
.

haha funny where things turn up............I made those axle adjuster/track stand blocks a few years ago. sold them on trademe an here they are on your bike !! awesome job Hamish
 

·
Premium Member
Joined
·
579 Posts
Discussion Starter #53 (Edited)
haha funny where things turn up............I made those axle adjuster/track stand blocks a few years ago. sold them on trademe an here they are on your bike !! awesome job Hamish
Hi Rick

Classic. The ironies of a small community in a small country eh. :D (a bit like finding out I slept with your sister. I didnt! Probably.) I've seen a few of my old bits and pieces turn up in funny places too. Bloody good idea you had with those! :) See I've rounded off the backs of them and scribed a mark so you can line up the marks on the swingarm.

Speaking of swingarms, I know where your old one is too. On a another early SS. :cool:

Hope all is well.
 

·
Premium Member
Joined
·
579 Posts
Discussion Starter #54
This Saturday I mucked around with steering stops, bolted on some more things, packed the top head bearing and installed the triple clamp and then slid the forks in and bolted on the custom front subframe, after making a new piece for my custom carbon fibre headlight mount, taking note to leave plenty of clearance so the fairing fits on and also to ensure plenty of adjustment in all three axes.

Unfortunately I didn't bring my top fairing to the workshop, which would have been useful as I need to determine the height of the clipons. The standard ones that Muzza sold me are a bit rough so, not least in the name of total customisation, I am going to buy some billet ones. Apex seems to fit the bill so will measure up next time and order some bars.

There was also other minor customising jobs to do, like drill a hole in the later model headstock nut. Pic 2. You can see the special nut tool which another one of Muzzas customers made, sitting on top of my headstock nut in Pic 1.

That may be the last part I need from overseas... Maybe! Still need a carbon 1000DS hugger - Ilmberger in Germany sent me a bogus one, so wont be recommending them - which we may yet make ourselves.
 

Attachments

·
Premium Member
Joined
·
579 Posts
Discussion Starter #55
This weekend I did some big stuff... installed the front wheel, fitted the gear linkage... and lots of little things, I forgot the crush washers that go behind the electrical plug washers (Pic1). Not a bad pic of the engine cover colour and my new braided oil lines which came off an S2800 Monster.

I also mucked around with some carbon fibre, I've got a young guy who works for a carbon fibre specialist seeing if he cant make a better 1000SS DS carbon hugger than the workshop can.

I popped my top fairing on (you can see it sitting on the top shelf at the back of the room in Pic 2) and sorted out my headlight adjustment and clip-on height. Have ordered some Apex clip-ons.

With the bike coming together, it looks like I chose the wrong coloured pressure plate. Rizoma makes one which is the same colour as the disc carriers and re-anodised forks. Should I buy a gold one?? Feel free to chime in with your opinion. :think:
 

Attachments

·
Premium Member
Joined
·
941 Posts
Great Work...

Awesome work- Excited to see the finished product. Gold Pressure plate.... for sure.

There is a gold one on Ebay right now, looks to be in good conditon. You could snag it pretty cheap- right now the bid is at .99 + $5 shipping...

Cheers!
 

·
Premium Member
Joined
·
579 Posts
Discussion Starter #58
Awesome work- Excited to see the finished product. Gold Pressure plate.... for sure.

There is a gold one on Ebay right now, looks to be in good conditon. You could snag it pretty cheap- right now the bid is at .99 + $5 shipping...

Cheers!
Cheers for that! A Rizoma one like my red one? (the Rizoma ones are beautiful) I looked this morning and now just again, cant see it, Would you mind flicking me the link. Thanks for that.
 
41 - 60 of 322 Posts
Top