New life to old carbon.

[Pablo Pirate]

On the same wave length Mark was trying to get hold of some 888 air scoops and hoses and direct them to the rear.
As for the airbox Very nice Im sure you could sell them How easy is it to manufacture? Looks an art. Tell us the secrets Good to see one off items like that top job.

Cheers Pablo

[geo7863]

Originally Posted by Pablo Pirate

On the same wave length Mark was trying to get hold of some 888 air scoops and hoses and direct them to the rear.
As for the airbox Very nice Im sure you could sell them How easy is it to manufacture? Looks an art. Tell us the secrets Good to see one off items like that top job.

Cheers Pablo

If you want carbon scoops and dont want to cut and alter too much try this website....costs though: -

ReVerie | Online Shop

I decided to cut and chop and glue...I would mould, but thats a skill I never learned...

The airbox is not too hard to make, as its all cut and glue and seal... however, I have to wait till my engine is back from the shop.. (just waiting for cams from the factory) then mount it into the frame to locate the mounting holes and fit the battery box which I will also make. Obviously the important bit is to make sure the carb inlet nozzles line up. I have measured the original box as carefully as possible and used the plastic base of the box on mine, so the inlet nozzles are right..

But I am the sort of fella that can mentally design and picture something pretty complex without having to draw it down, and the end product is usually 90 percent like my original idea... but I measure 20 times and still cut the barsteward wrong!!

[gillan900]

You are a busy man George... It's all looking very good. Nice web site aswell...

As for air ducting to the rear cylinder, the ie model has two plastic ones mounted to the inside of the fairing, they are available in carbon from Ducati Kaemna and I would imagine it wouldn't take too much to alter them to suit the 'carby' fairing. The position of them is good aswell (Pierre Terblanche did get somethings right) as it doesn't interfere with the air flow to the airbox. Having said all that, I do like the originality of the stuff your doing, it's going to be interesting to see the finished articles.

I haven't got round to cutting down the new hugger yet but i'll put up a few pic's when it's done.

Keep it up the good work matee

[geo7863]

Originally Posted by gillan900

You are a busy man George... It's all looking very good. Nice web site aswell...

As for air ducting to the rear cylinder, the ie model has two plastic ones mounted to the inside of the fairing, they are available in carbon from Ducati Kaemna and I would imagine it wouldn't take too much to alter them to suit the 'carby' fairing. The position of them is good aswell (Pierre Terblanche did get somethings right) as it doesn't interfere with the air flow to the airbox. Having said all that, I do like the originality of the stuff your doing, it's going to be interesting to see the finished articles.

I haven't got round to cutting down the new hugger yet but i'll put up a few pic's when it's done.

Keep it up the good work matee

Cheers Ian... I might be going down the makeyourownhugger route too... e-moto..the company who charged me £165 for a 1000DS hugger...and sent me a 91~97 900SS hugger instead, arent answering my e-mails where I am asking for either the proper hugger or a refund.

There is a company in Oz that do the 'proper' hugger for £230.... or it will be convert a monster hugger that has the chain guard extension sticking out... and then try and convert the forward chain guard to fit the tighter angle

[geo7863]

Originally Posted by gillan900

I've fabricated new top lugs , as you say, the standard holes don't line up. Use the bottom ones and just add some carbon sheet to make up new top ones, drill and cut to shape. You will need to cut down the back section that sits below the sub frame a bit, but after that it's a great fit. As I said it's not finished yet but it's coming along nicely

Attachment 10975

Ian

how did you graft that top bit on so 'seamlessly' I have bought a placcy 1000DS hugger and comparing it with the standard carbon 900SS hugger and all the offcuts and right angled bits of carbon that I have, I reckon I can fabricate a replica of the 1000DS hugger in carbon.

However getting it to blend in without seeing the joins may be a problem....whats your secret?

[gillan900]

Originally Posted by geo7863

Ian

how did you graft that top bit on so 'seamlessly' I have bought a placcy 1000DS hugger and comparing it with the standard carbon 900SS hugger and all the offcuts and right angled bits of carbon that I have, I reckon I can fabricate a replica of the 1000DS hugger in carbon.

However getting it to blend in without seeing the joins may be a problem....whats your secret?

George

If you are using some existing carbon pieces to make up these new lugs, rough the surface where you are fixing them on to, then use the clear resin as an adhesive (there was a small lip on mine where I was fixing these that I used to good effect). Leave this to harden then lay new carbon sheet over the top, this covers the old holes and strengthens the new sections. You will need to overlap these sheets where they cover the joints. Repeat this to the underside and then apply some more resin as a thin filler coat to it all. Now use a fine round file, wet/dry to shape and smooth the whole area. You can then either respray the whole hugger in clear lacquer or continue to rub down with wet/dry paper until you get the joints ultra smooth and you can't see any scratches. Polish up the whole ares with t-cut to get a nice finish. Mark and drill out the new holes.

I hope this makes sense mate, the key is using the resin as a type of filler then rubbing it down to give the shape and surface finish.

Cheers,
Ian.

[geo7863]

well here's the nose fairing air ducts, almost complete. The hose diameter is 75mm a bit bigger than I intended, except that a good old length of hose and some carbon right angled tubing came up dirt cheap on ebay, cheaper than one single carbon duct from reverie ltd.

It should however be hidden by the fairing (the pictures show the cheeky czech chick's half fairings), all I have to do once dimensions are finalised is rivit the short section of hose so it flattens more giving extra clearance for the headlight, make plates and brackets for the right angled ducting tube to fit to the frame just infront of the rear cylinder, and then Bob's yer aunts live in lover!!

ps. its a bit wonky on the LHS because the LH fairing is in the way, obviously the fairing will be altered to fit!!

[Paul the Duc]

Hi guys got ot say this dose look a bit waki sorry ! I dont mean to be rude >
I think the idea is good as to push as much Air in to the engine as possible i have a 4lt Jag and have set up the same kind of thing a waking great air filter with air dams .


the car dose puck up very fast and will go on to 160 but also it only averages 16mpg!! in summer!!

I think with this kind of engine you would need a very big Air ducket But also if you have a Carb engine also a Better SPark .

Any way would love to knowif it give any more go.

regards.

Paul

[geo7863]

Originally Posted by Paul the Duc

Hi guys got ot say this dose look a bit waki sorry ! I dont mean to be rude >
I think the idea is good as to push as much Air in to the engine as possible i have a 4lt Jag and have set up the same kind of thing a waking great air filter with air dams .


the car dose puck up very fast and will go on to 160 but also it only averages 16mpg!! in summer!!

I think with this kind of engine you would need a very big Air ducket But also if you have a Carb engine also a Better SPark .

Any way would love to knowif it give any more go.

regards.

Paul

Hi Paul, no its not rude mate you say what you think, but you have the wrong end of the stick here matey, this isnt about ram air induction, although the idea came to me when I saw a ram-air kit for the airbox, taking air from the nose fairing slots

No what we have here me ol' china is a cooling thing, you see the 904cc aircooled cylinders run a bit on the hot side, even more so when you have a 944cc conversion as mine is, Now this is usually only a problem when you push the engine hard i.e race

But I am not taken any chances especially when it can get to 40degrees in the summer here, I am fitting an extra oil cooler, which helps the cooling, but this is being mounted on the top valve cover position ala 900 monster, which cuts some of the airflow over the top of the engine to the rear cylinder, hence detracting from direct airflow cooling.

I saw this cooling hose arrangement on a piccy of a racing F1 (or could have been the prototype race 851) which had ducting and shrouding to the rear cylinder, I dont race but as I said I am not going to take any chances... plus the missus says it keeps me busy and out of trouble doing all these heath robinson mods!!


Geo

[markm]

Excellent work on the nose-job George! If you ever get bored (fat chance, but hey..) with your current job i think you've got an alternative as a "retro fit 900ss designer". Keep up the good work!

Mark

p.s hate to say this.. but instead of tinkering with the duke this sunday i think i'll go for a ride somewhere near Fairford..Been lots of wicked sounding planes flying over these parts these last few days

[Paul the Duc]

Sorry Geo

I was thinking of the rong thing lol cooling now that a diffent thing altogether.

40C were do you live in the desert!

I would go with a wacking great Oil cooler the more the merryer.

sorry cant be any help.

Paul

[geo7863]

Mark, mmm retrofit SS designer......funny you should mention that, I still have a spare frame, forks, 2 swing arms, wheels and various bits and bobs... dont want to see them go to waste...


so the next project..(HAH! aint even 20 percent through the current two!!)... will be a F1/TT1 lookalike... yes I know I can get an F1/TT2 frame... just look at Dans TT2 thread in the 'Chat' forum, but that is one physically very small bike and I am over 6 foot... Getting the bodywork is a doddle, getting the tank cut down to the proper shape isnt!

So thats whats in the pipeline, for 2009/2010

Paul, okay i'll concede 40 degrees is really quite rare here ( I live just west of Prague) but it does frequently get up into the high 30's in a good summer and that's plenty hot for me and my bike.. (this isnt a good summer we had 28 degrees on thursday but that isnt hot)

[markm]

Originally Posted by geo7863

Mark, mmm retrofit SS designer......funny you should mention that, I still have a spare frame, forks, 2 swing arms, wheels and various bits and bobs... dont want to see them go to waste...


so the next project..(HAH! aint even 20 percent through the current two!!)... will be a F1/TT1 lookalike... yes I know I can get an F1/TT2 frame... just look at Dans TT2 thread in the 'Chat' forum, but that is one physically very small bike and I am over 6 foot... Getting the bodywork is a doddle, getting the tank cut down to the proper shape isnt!

So thats whats in the pipeline, for 2009/2010

well you know that Steve is getting rid of his injected 900ss engine...
I've been keeping my eye on that thread of Dan's..a bloody brilliant looking little bike!

[geo7863]

Ok it's not big and its not clever.... but sometimes it's just got to be blinged!!