Ducati 996 engine custom build
Discussion
well I dye pen tested all the welds on the frame today, all OK apart from the obvious ones with cracks... its all TIG welded up now and ready for blast and paint
been stripping the wheels tonight as these need painting, first I had problems getting the front bearings out as the inner spacer tube is a tight fit and I could not get on edge of the bearing to knock it out, ended up grinding a piece of flat with a tang on... this soon had it our. MUCH harder were the cush rubbers... I simply could not get to the back of them to get them out. I made a split collet in the end and pulled them out with a big socket! I did think of leaving them in, but the guy who does my powder coating is meticulous... and he would have only moaned! I use Redditch shot blasting, not the cheapest, and definitely not the closest, but simply the best I have found without question. In the past I have had some shocking jobs back from other companies....
been stripping the wheels tonight as these need painting, first I had problems getting the front bearings out as the inner spacer tube is a tight fit and I could not get on edge of the bearing to knock it out, ended up grinding a piece of flat with a tang on... this soon had it our. MUCH harder were the cush rubbers... I simply could not get to the back of them to get them out. I made a split collet in the end and pulled them out with a big socket! I did think of leaving them in, but the guy who does my powder coating is meticulous... and he would have only moaned! I use Redditch shot blasting, not the cheapest, and definitely not the closest, but simply the best I have found without question. In the past I have had some shocking jobs back from other companies....
Bit of a departure from bike building just for a change... thought I would share a couple of other projects I have done recently... One bike related... a table lamp for my study made from a scrap 1000DS piston and barrel. Not bike related, a fire pit come BBQ that I made Stainless Steel. I had the dish spun out of a 750mm diameter blank of 6mm stainless 316. its an interesting process! Initially it was going to be just one grill, but my wife said she wanted a separate veggie grill... hence the two! Bonus brownie points! its been used a lot over the summer, when the BBQ is done, the grills come off, and we throw a few logs on and it becomes a fire pit!
Mr Dendrite said:
The Chuck Norris of fabrication, 
I did the tappets… pleased to say they were all in tolerance! I also took the cams out to check the rockers, they were pretty near perfect, which was a relief!
Took the frame to the powder coaters… but he called me today to say there were marks on one of the frame and he was not happy to coat over them… they must have been under the original paint with filler in them! I took it back home and just touched them with a sharp drill and TIG welded them up and sanded them down. Really not impressed with Ducati frames...
I have also Etch primed the engine ready for a coat of 2K silver tomorrow. It took a lot of hours to remove the paint. I was lucky to find 5 LTR of old stock paint stripper which should keep me going a long time. the modern stuff is next to useless. I masked the engine off, a tip i picked up when I was an apprentice in a Bentley dealership for making gaskets was to tap around the gasket material with a plastic hammer... I do the same masking off.. put the tape on and go around the edge with a small plastic hammer. you get a perfect edge!
Biker's Nemesis said:
I read every update but don't reply often because I just marvel in what you do and how you go about things.
So.. I am only posting to let you know that I like many others do read your thread.
Thank, glad someone is looking! So.. I am only posting to let you know that I like many others do read your thread.
bit more progress... I see a lot of builds spoilt by detail, and have been guilty of it myself in the past, in particular withe old plated parts... One thing I gave been meaning to do for a long time is have a go at DIY plating. Well I did some today and I have to say I am quite pleased with the results! I have used the blue passivate but there is a yellow gold one in the kit.
Edited by buzzer on Saturday 16th November 17:48
AceOfHearts said:
How difficult was it cleaning up all the parts before plating? It's one of those things I really want to try at some stage.
i did some with the bead blaster, and some with a wire brush on the grinder... both worked well. there is an acid cleaner with the kit, and instructions on how to test if its clean. its not that difficult to be honest and I am pleased with the results!Start of putting the engine back together! I know its a risk but I have decided to go open belts, I just love the look...
If anyone notices the weld on the engine stand, well I am truly ashamed...
I have no excuse other than i was really down on gas, and had the wrong tip in the MIG welder. A poor workman always blames his tools so they say 
If anyone notices the weld on the engine stand, well I am truly ashamed...
I have no excuse other than i was really down on gas, and had the wrong tip in the MIG welder. A poor workman always blames his tools so they say 
poo at Paul's said:
I cant be the only one who was wondering if you have sawn that engine down the middle, hinged it, so your missus can hang her necklaces up on the cam lobes.....?
Finished off the clamps and top yoke... and gave everything a polish... Polishing is a long, dirty, and quite dangerous job! I try to do everything at once as it makes a mess in the workshop!
the cueball said:
Awesome work...
What is the kit? Where is the kit? Can I buy the kit?
I'm looking to have a go myself...
Thanks! i bought the £55 Zinc kit from this company. it came with good instructions!What is the kit? Where is the kit? Can I buy the kit?
I'm looking to have a go myself...
https://www.gaterosplating.co.uk/
I wanted to change the colour of the rear spring from yellow to red, and tidy up the shocker… which meant getting the spring off! its no easy task as its VERY strong. I drew up a couple of plates on CAD and sent the drawing to the laser cutter… few days later these came. made it an easy and safe job!
Biker's Nemesis said:
Nicely made spring compressor. I laughed when I saw the polishing photo. I've been covered head to foot many times in the past.
yes, filthy job... and now I find I forgot to do a couple of parts 
Well its back on its wheels... I am pleased at how the Multistrada footrest conversion has worked out, it brings the foot pegs forward quite a bit and should achieve the riding position I was looking for.
Just about to rebuild the brakes... the fronts are fine and the pistons came out easily, but the rear caliper is seized absolutely solid! I have left it connected to the air line overnight, but the pistons have not moved yet!
Not sure about the gold discs on the front... they may have to be changed... we will see...
Yesterday I rebuilt all the hydraulics. I replaced the seals on the rear caliper as this was seized solid and I had to use some penetrating oil to free the pistons.
The calipers came out nice... My bead blaster now gives a really nice finish, that with a coat of ACF-50 keeps its shine. I was never happy with the finish until I picked up a tip from the guy who blasts my big bits... he said my problem was I was working at too high a pressure, and that was shattering the tiny glass beads! sure enough, I turned the pressure right down and the difference is clear!
I may try an anodising kit in the future after the success of the zinc plating!
Also made a wheel spacer to replace the speedo drive which I am not going to use.
The calipers came out nice... My bead blaster now gives a really nice finish, that with a coat of ACF-50 keeps its shine. I was never happy with the finish until I picked up a tip from the guy who blasts my big bits... he said my problem was I was working at too high a pressure, and that was shattering the tiny glass beads! sure enough, I turned the pressure right down and the difference is clear!
I may try an anodising kit in the future after the success of the zinc plating!
Also made a wheel spacer to replace the speedo drive which I am not going to use.
I know its a bit old school… just like me 😁 but I love the look of a mega on a bike… plan was to make a pair but I had trouble finding anyone here who could roll a cone, so I ended up modifying a couple of cheap stainless silencers I bought off Ebay. the removable baffles will satisfy the MOT man 😂and they are now re-packable
poo at Paul's said:
I am cancelling my order and want my deposit back!
The cheque is in the post....the weather has been crap for a few days, so some garage time
made some ends for the swinging arm as I didn't like the originals and they were marked... also made some new stainless bolts. may wheel it out the garage tomorrow 
Got the bike out today into the daylight for the first time in months... Have to say my Iphone takes great pictures! Next job is to start the wiring... its a job I actually love doing, making a loom from scratch. here is my collection of wire from meany years! there is some new stuff in there as well that I got from some newish cars in the vehicle dismantlers last year. Its just too expensive to buy all the colours you need new, its a great source of wire!
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