Well you asked for another Ducati build

[buzzer]

Two jobs in the last few days… Collect the headlight brackets from the water jet cutter, and make an engine cradle so I can lift the frame off easily. I love going to the water jet place, always an interesting visit! Today they were cutting 100mm titanium plate!

[sirch345]

Those water jet cutters are amazing. So you have fixed the fixed headlamp

Nice being able to lift the frame off the engine (like the Storm) rather than having to lift the engine out instead,

Chris.

[buzzer]

well it didn’t take long to get it all apart! Engine out and on the bench… frame welded and off to the shot blasters… I have to say the frame is exceptionally nice, the welding is superb, and its very light... dare I say a lot better quality than Ducati!... I have always had my frames powder coated at a company I have used for years… Last year they let me down badley, lots of broken promises, and in the end I went and collected an unfinished frame. I decided to have it media blasted and do it myself… That worked out well so I have done the same this time. It was back today from the blasters and it's an excellent job.  I will be etch priming it, undercoat, then 2k Clear over base

One of the common problems with the sportster engine is leaking cylinder base gaskets, this one had sighs of a slight leak so for the cost of a set of gaskets I decided to replace them… Pistons are very big! its all like new in there as you would expect for 5000 miles. While I looked a the bike, one thing was bugging me… that straight case line on the engine… so I modified the casing slightly…I like it… many won't!

[sirch345]

Good to hear what you have been doing in your workshop with this build

Interesting to hear that about the welding on the frame, I'm sure Ducati have broad shoulders

Chris.

[buzzer]

The engine is all back together now… its a BIG old lump! I also finished the frame as the weather looks like it will turn too cold next week to do it under the gazebo.

I etch primed it, a coat of 2K primer, them base silver and 2K clear. I don’t think i will go back to powder coat…

[sirch345]

The engine is all back together now… its a BIG old lump! I also finished the frame as the weather looks like it will turn too cold next week to do it under the gazebo.

I etch primed it, a coat of 2K primer, them base silver and 2K clear. I don’t think i will go back to powder coat…

The frame looks great
Looking at the close-up shot of the frame (bottom right photo) I can see what you mean about the welding

Chris.

[buzzer]

The seat is back from the trimmer, and as usual it’s a superb job! The weather has turned cold which meant I had to resort to drying the smaller painted parts in the oven… Good job she is OK with it these day, although the line had been drawn on the dishwasher!

I debated on taking the parts in to the platers, they did a great job last time BUT they did lose a few items, luckily nothing of importance. Not wanting that to happen this time I decided to do it myself again and got out my plating kit which I have been using for years… still great results! They say the devil is in the detail, I see so many builds spoiled due to dull and rusty plated items…

[sirch345]

The seat is back from the trimmer, and as usual it’s a superb job! The weather has turned cold which meant I had to resort to drying the smaller painted parts in the oven… Good job she is OK with it these day, although the line had been drawn on the dishwasher!

I debated on taking the parts in to the platers, they did a great job last time BUT they did lose a few items, luckily nothing of importance. Not wanting that to happen this time I decided to do it myself again and got out my plating kit which I have been using for years… still great results! They say the devil is in the detail, I see so many builds spoiled due to dull and rusty plated items…

The photo of the oven with the bike parts in it is ACE

Good job with the plating, I like how you did the end fittings on that hydraulic hose

The seat looks great too,

Chris.

[tony.mon]

Using the dishwasher is only permitted when you load the parts correctly, in our house, anyway.
If you try to put discs behind the cutlery tray it's a no-no.

[buzzer]

Going together nicely… I do need to slow down! However I made a big fxxxup the other day when I took the rear shocker apart… I forgot they work opposite to normal so when I undid the adjuster nut, I was actually applying more tension onto the. it came off the threads and I realised I would never be able to get it back on… rookie error. I had to cut the outer shroud off. I hope to rescue it as a new one is mega expensive… will post pictures in a few days! but for now here it is going together.

[sirch345]

It’s quite surprising how different it looks with the silver frame instead of the black
It’s looking good

Chris.

[buzzer]

Well I pondered about the shocker… The reason I took it apart was I wanted to expose the spring, but it just didn’t trigger that it works the exact opposite to normal! I looked around and liked the design of the Ohlins one and decided to copy the idea. Back to the water jet cutter to have some plates cut, and I turned them down in the lathe. I drained the oil out and put some in a small bottle with a funnel type top… I timmed how long it took to drain out… then tried some 10 grade oil… much slower… then tried 5 grade and it was the same time! Looks like its SAE 5 in there! Soon as it's on the road I will take it and get it nitrogen filled… but for now I have put some air in there.

[sirch345]

I like the way you worked out what weight oil you needed for the shock

Chris.

[buzzer]

Break in the weather last few days and I was able to paint the wheels… Etch primed, undercoat, and then clear over silver base. I don’t think I will ever go back to powder coat as the 2K finish is FAR better! One tip I picked up many years ago is if you are creating paint lines, (rims are only partially painted) use proper lining tape, not masking tape as that tends to slightly bleed under. Also, don’t wait until the paint is fully cured before removing the masking or you risk pulling paint off.

I also stripped the brakes down and cleaned and re-assembled them… all good in there, the pistons were perfect

[sirch345]

Those wheels look amazing

Thanks for the tip on using proper lining tape rather than ordinary masking tape for creating paint lines

Chris.