Project Super Sport comments thread - Page 4 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #76 of 95 (permalink) Old 6-2-2019, 11:47 AM
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Yeah the pistons have some sort of coating... POS.
I have a couple of spares if you want them. I also have seals and scrapers if you want them. Not available from Brembo... liability issues. Steve at Bevel Heaven makes up kits for these, doesn't supply scrapers. You can get the scrapers from Honda, GL500 IIRC.



I just did a set of Yamaha TZ calipers. Worst I have seen in a long time, and irreplaceable.
I ended up drilling a hole in the caliper, driving the piston out from the back, then welding up the hole. A bit of filing and paint, looks as good as new.
Another trick is to drill a hole in the piston and thread it. Screw something into that hole to use as a puller.


... I once launched a piston out of a caliper with air pressure, went across the shop and hit my washing machine, cracking the door. $640 later for a new door and seals....


What color are you using for RED? I need some touch up paint.
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post #77 of 95 (permalink) Old 6-2-2019, 5:00 PM Thread Starter
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Good ya got 'em. I cringe when they're about to pop...loud mf'ers, and really dangerous if precautions not taken.
Yeah, they were plenty loud!! Got the attention of almost everyone in the shop when each one went.



I wrapped the piston and caliper in a shop rag so when they went, they didn't go flying. It worked. Farthest one of them went was a couple feet down the work bench.



Just got done with chores for the day....gonna head out to the garage and get the second caliper rebuilt. Then it's on to the master cylinders......sean


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post #78 of 95 (permalink) Old 6-2-2019, 5:12 PM Thread Starter
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Originally Posted by bitzz View Post
Yeah the pistons have some sort of coating... POS.
I have a couple of spares if you want them. I also have seals and scrapers if you want them. Not available from Brembo... liability issues. Steve at Bevel Heaven makes up kits for these, doesn't supply scrapers. You can get the scrapers from Honda, GL500 IIRC.
That's good to know. AFAIK, you can get the Brembo kits from Gotham Cycle and an eBay storefront. I can't remember the name of it. Bevel Heaven is pretty close by to where I live.



I appreciate the offer on the seals and spares. I was able to get my pistons out and they, along with the seals and scrapers are actually in quite good shape. Just covered in scale and jello like old brake fluid. All good after a trip through my ultrasonic cleaner.


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Originally Posted by bitzz View Post
I just did a set of Yamaha TZ calipers. Worst I have seen in a long time, and irreplaceable.
I ended up drilling a hole in the caliper, driving the piston out from the back, then welding up the hole. A bit of filing and paint, looks as good as new.
Another trick is to drill a hole in the piston and thread it. Screw something into that hole to use as a puller.
I didn't want to resort to that level of brute force as I wanted to preserve the Gold Line calipers as much as possible.



TZ calipers? Are you building a TZ? If so....pics plz


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... I once launched a piston out of a caliper with air pressure, went across the shop and hit my washing machine, cracking the door. $640 later for a new door and seals....
oooohhh.....that's 'spensive!! I can relate though. I once worked in a body shop. I finished a paint job and wound up with a really bad run that required me to re-shoot a fender at the very least. I took off my paint hood, and hucked it on the nearest work bench.



All I heard was a really loud SNAP. I looked over at the bench....and there, with a nice big star and crack was the windshield from the very truck that just got a run in the paint booth. It wasn't $649 but I still had to pay for it.


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What color are you using for RED? I need some touch up paint.
I'm actually changing the color so I didn't try to get any red. I got my paint matched (for the color I want) by the House of Kolor rep at my local ACE Hardware.



Aside from trying to get the OEM red from Color-Rite and paying too much for it, I'd check around and see if you have a local HOK rep to do the same for you.



My apologies if I'm not much help in the red paint arena.....sean


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post #79 of 95 (permalink) Old 6-10-2019, 9:21 PM Thread Starter
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BIG box of parts arrived today.......Air Tech delivery!!!!
Too bad I will be away this weekend so the bodywork won't get sanded and primed. I'll be ready to paint in a couple of weeks though. Getting REALLY close now folks......really close.....sean










BTW....we really need a dancing banana smiley.


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post #80 of 95 (permalink) Old 6-19-2019, 10:01 PM
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Originally Posted by Apriliarider View Post
BIG box of parts arrived today.......Air Tech delivery!!!!
Too bad I will be away this weekend so the bodywork won't get sanded and primed. I'll be ready to paint in a couple of weeks though. Getting REALLY close now folks......really close.....sean










BTW....we really need a dancing banana smiley.
Oh nice. Take pics some so we can drool.

Lol on the dancing banana.

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post #81 of 95 (permalink) Old 6-21-2019, 10:39 AM Thread Starter
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Oh nice. Take pics some so we can drool.

Lol on the dancing banana.

Didn't really get anywhere with the bodywork that arrived. Just unboxed it so nothing really to show off. The only thing I did do was I drilled and mounted the new tail section last night.



Mostly to test fit, but also to see what support needs to go under the seat unit where the rider sits. It's a fairly big gap from the frame tubes to the bottom of the fiberglass.



There is a kit available to make it work but I'd anticipated there would be a support issue. I ordered some tank mounting rubber for the later 900SSie thinking that would suffice. I was wrong. Not going to work.



Anyway, here's a shot of the tail mounted with the new saddle sitting in place:
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post #82 of 95 (permalink) Old 6-26-2019, 1:24 AM Thread Starter
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Got a few more things done in the last couple days. Last night I mixed up some JB Weld steel reinforced epoxy repair.



This is not the stuff you get at Walmart in the two tubes. This stuff comes in a double/siamesed syringe type affair that expels the correct amount of each part when actuated.




Using this stuff, I repaired a number of small things that I'd been preparing for. First, I'd ground out the crack in my alternator cover from the inside. After spraying out the newly grooved out crack with brake clean several time and letting it all flash off, I waited until it was all really dry. Probably 20 minutes or so. Then I applied the JB Weld to the groove. Hopefully this seals the crack and I can reinstall the alternator cover back on the engine.


At the same time, I repaired a crack in the crank case from the same area where a chain derailed at some point in the life of the bike. Then, I did the same to one of the speedometer studs that secure the speedo head to the binnacle.



I managed to get the speedo head reassembled tonight, and installed back in the binnacle.




Also painted the speedo needle in orange to make it more visible. I don't know what color it was before but it was white like the tach needle when I got the bike home. It was a royal pain to take apart and get it all cleaned up inside. Then reassembling the lens and bezel onto the speedo head.....royal PITA. It is now done though, so one more step in the right direction...........sean
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post #83 of 95 (permalink) Old 6-29-2019, 12:57 AM Thread Starter
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Finished filing down the JB Weld repair on the engine last night. Came out quite good I think. It will definitely seal up now. I'll have pics up on the PSS thread later this weekend.



Also bought a "Super Sprox" rear sprocket from eBay last week. Delivered today. It's a "hybrid" sprocket if you are unfamiliar. Aluminum center with steel teeth.



Lighter than a steel sprocket but longer wearing than an aluminum one. That will get fitted this weekend also, with the new titanium sprocket nuts I also got on eBay.



Like I wrote above, pics to follow later this weekend..........sean


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post #84 of 95 (permalink) Old 6-30-2019, 12:35 PM
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A long road indeed, your dedication, effort and time/labor/$$ investment will pay off in the end. Just looking at your posted tidbits, its obvious the quality of your work will result in a striking looker and a reliable, fun performer.

Every facet of this thing was either neglected or abused in some way, to some degree.....seemingly everywhere conceivable.

A huge undertaking. My hat is off in a salute.

As an aside, previous owners who allow this disrepair and degradation to happen to any late model classic, especially a Ducati... need to be admonished.
I'm going through similar, though not nearly as in depth, on "the Pile" Triumph 675 in my possession. Sad to see such lame prior "ownership".
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post #85 of 95 (permalink) Old 7-6-2019, 10:27 PM Thread Starter
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Haven't done a great deal this weekend. With Independence Day parties and get togethers nothing got done Thursday. Yesterday, while I did get a few things done, was basically what I normally do on Sundays which was get my stuff ready for the coming week. Today, well....I wrote off most of the day doing badly needed yard work. That, and watching qualifying for the German round of MotoGP.



What I did get done was locate some proper steels for the clutch, so I'm almost ready to get that whole thing together. I have springs and keepers and all that but I still need to verify stack height and de-glaze the steels.



The other thing is't so much something I got done, but rather something I got. I got all the OEM parts to mount the solo tail I have properly from Ducati Omaha today. I'll be test fitting those tonight. Otherwise, just disassembled the "choke" control and separated it from the clutch master cylinder. That should allow me to get it cleaned up and ready for installation.



Not sure how much progress I'll be making in the immediate future. I have to get two bikes ready for the annual pilgrimage to Laguna Seca Raceway for World SBK weekend. I'll probably have to start tomorrow too, as I wanna have plenty of time to get stuff done...............sean


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post #86 of 95 (permalink) Old 7-16-2019, 1:18 AM Thread Starter
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Back from Laguna Seca and Monterey today. Got home around 2:00 PM after a nice lunch stop at a little place in San Ramon called Fat Maddie's Grille. Pretty cool place, good eats. Kind of a strip mall atmosphere though so nothing special in that department. At least we could keep an eye on our bikes while we ate.....it was San Ramon though so not much to worry about other than the parking skills of car drivers.



As I was in Monterey, nothing got done. Well....nothing on the bike itself. There are however other developments in the works. Parts have been ordered and I'll reveal all once time and developments present themselves in a manner that I can do so. If that all sounds cryptic, it is. There is a surprise brewing that I will reveal when it is appropriate for me to do so.



As World SBK weekend is over for another year, I now have more time to focus on things and get more jobs done. I have not, as yet set a new time table for completion. Just later this year. No rush at all.



Unfortunately, I have to divert a significant sum of project money to a home project that has needed doing for the better part of 2 decades. Sometime in the near future I'm ordering several yards of concrete and having a patio poured in front of my house. Probably somewhere on the order of 5 or 6 yards at least. Maybe more. Needless to say, that will put a huge damper on the project with regard to buying needed parts......sean


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post #87 of 95 (permalink) Old 7-22-2019, 10:37 PM Thread Starter
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Been little activity in the garage since I got back from Monterey. I did manage to finish sanding down the new to me front sub-frame. That should be dry already but I'm gonna leave it to bake in the summer heat in my garage for another few days.



Also sanded and primered the new to me, OEM Vitaloni Baby Turbo mirrors. They were red when I bought them, now they sit, baking in the summer heat in my garage all primered in white.



Made a template for the upholstery I got for the solo seat. The holes are marked now, just gotta drill them out. Might get to that this weekend....or maybe the next couple of days. Depends on my energy after dinner though. More later.....sean


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post #88 of 95 (permalink) Old 7-28-2019, 1:12 AM Thread Starter
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Got a bit of a late start today in the garage. Decided to finally finish up the front wheel. Got out the wet/dry paper and a small tub of water.



I wet sanded the lip on the right side of the wheel. The left side I'd already polished out. For whatever reason, the right side had been difficult. It just didn't polish out as easily as the left side did.



I wet sanded first with a relatively coarse grit to get the lines from grinding off the powder coat. Then I hit it with a fine grit paper and wet sanded to a satin like sheen. Then I hit it lightly with a cutting compound and a felt drum on my drill.



The end product looked much better than the fully polished side honestly...making me think I should just go ahead and redo the polished side so it looks more satin like than chrome like. That's the look I was after rather than the full polished chrome look.



After I was done with the polish, I went ahead and masked off the polished aluminum and after some self etch primer, I shot some white primer before shooting it in the same gold as the rear wheel.



Here's a pic of the masked wheel with the gold paint:



All for now. More yet to come.....getting to the point where major assemblies are ready to be put back together. Today I also ordered a bundle from RSR Moto in the UK. New carbon hugger on the way as well as titanium brake rotor bolts for the front wheel. THAT was 'SPENSIVE.



As there are only a few more major $$ parts I need, I should be able to start putting up more pics in the PSS thread to share the progress......sean
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post #89 of 95 (permalink) Old 8-3-2019, 3:44 PM Thread Starter
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The parts I ordered from RSR Moto came in yesterday. YESTERDAY, all the way from the UK. They didn't even ship until Tuesday. Amazing service.



I had an awesome buying experience with RSR Moto, and I'll definitely be buying from them again. The quality of the parts is worth the money. They ship promptly and use UPS so you know the level of service you're getting with the shipper.



Anyway, once I opened up the box and test fit the parts I'm more than happy with them. Next time (pay day) I'm going to order the front fender from RSR. I'm sure I'll need some more Ti (doesn't everyone?) by then so I'll have to plan out what needs to be Ti and what can just be stainless or aluminum. More later....I need to get out to the garage and get busy!!.....sean


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post #90 of 95 (permalink) Old 8-7-2019, 11:32 PM Thread Starter
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Closer still

Went through my checklists for parts that need replacing as well as consumables. The list has gotten much shorter. Enough so, I can actually share it, and not take up several pages.


Hard parts left to order or otherwise obtain are:
carbon front fender
fork internals (GSXR)
Nichols' engine mount bolts
Ti hardware for rear brake disc
Ti hardware for calipers (all)
Ti rear axle nuts
Various stainless steel hardware (local hardware store)



Consumables left to order or otherwise obtain are:
battery (Shorai)
brake pads (all)
master cylinder rebuild kits (all)
front sprocket
chain
front tire
valve stem for front tire


That's pretty much it. Reduced from several pages worth of stuff. Not a single bolt will be left from what the pile came with. Seriously, nothing has gone untouched.



Every single thing has been taken apart, cleaned, repaired and reassembled or just replaced outright. If it hasn't been yet, it will be soon.



As there is not so much left to order now, I'll be spending less time on parts research and more on actually putting what I have back together.



Next on the agenda is the carbon front fender, which in all honesty could wait, I have a reasonably good plastic fender now. I could just paint it matte black and be good to go on assembly and just replace it later.



That will be followed by the Nichols' Sportsbikes 10mm Engine Mount kit. Once that is here, major assembling can begin. The swing arm pivots in the engine, while the shock bolts to the frame. No rocker, it is a cantilever affair.



That's huge, because once frame and engine are married up, swing arm installed, I'm just the wheels away from a roller. All I'd need then is a front tire and valve stem. Valve stem set is getting ordered soon so won't be an issue. Tire available at my local Cycle Gear so that isn't a long way off either.



In essence, the engine should be ready to go before the end of the month. So, I should have a roller by my birthday in September. Maybe a bit more than a roller.....just not a rideable motorcycle by then. Stay tuned....project completion is getting closer....sean


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post #91 of 95 (permalink) Old 8-17-2019, 8:26 PM Thread Starter
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Another mini-update.

Not much has gotten done since my last post. Seriously, very, very little.

What has gotten done, is a great deal of research on parts and various other things. In doing so, I attempted to take care of the front rotors as they'd been on my brain of late.



As I'm getting very, very close to a rolling chassis, I wanted to make sure that I had brakes to stop the thing whilst rolling it around in the garage. So, I dug out the rotors and gave them a once over.


Now, I'd taken them off when I disassembled the bike and run them through a parts washer to get all the suspension fluid off them. I only partially succeeded in that endeavor.



What I'd wanted to do, was to use the stock rotors and turn them into full floating rotors by drilling out the rivets and installing a button kit.


In order to do that, I needed to know the diameter of the button so I could order the correct kit. I had to drill out at least one of the rivets so I could find the diameter.



I wanted to keep the stock carrier and rotor band to both keep the cost down. Also, I happen to both like the look of the OEM carrier with its round holes and gold 'anodizing' and I wanted to keep it looking as stock as I could.



I was both disappointed and surprised at what I discovered during this little operation. 1st off, the stock OEM center carrier is not anodized, it's painted. (shoulda been my first clue)



2nd the paint on mine is a mess. It peeled badly when I ran it through the parts washer.



3rd is the defining thing....the carrier is not aluminum but steel. When I reached this stunning conclusion, I had to double check it with a magnet to make sure.



Finally, as I drilled out the rivet head, the parts heated up and the un-mistakeable scent of burning suspension fluid filled the air. So much for getting them clean...though that point is pretty moot now.



More research as I find a set of "snow flake" rotors from a 916-996. The "snow flake" carrier is already verified alloy construction as there is set on my 996.



The only other progress is I got two things for the project this past week. A set of Ariete angled valve stems for the front wheel. Already installed too.


I also got a new "idiot light" plastic film for the idiot light pod on my OEM binnacle. The original one had a hole in it and it was not in good shape at all.



That's all for now. I did try to order a new carbon front fender from RSR Moto, but they were out of stock for the matte finish one I want. Had to leave a request for an email when they're back in stock.



More some time later. Considering a break from the forum until I can offer real progress to the PSS..........sean


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post #92 of 95 (permalink) Old 8-25-2019, 5:07 PM Thread Starter
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Last update for a bit...

Two developments since my last visit here to update progress on my 900 SS rebuild/resto-mod.



As previously recorded, the rotor carriers on the OEM set of rotors I had are steel, painted to resemble alloy. Nice looking but HEAVY. I ordered a set of rotors on eBay around the time I wrote that last post. Well, they came in and exceeded my expectation. Turns out, they are not alloy carriers with stainless steel rotors but rather alloy carriers with full floating carbon steel rotors. Both together weigh less than a single OEM rotor with the steel carrier.



After a close examination, I determined they must be EBC Pro-lite rotors. Mostly because there are but 9 floater buttons. OEM Ducati/Brembo have 10. Also, as there is some rust on the rotors, it is evident they are not stainless steel. Possibly ductile iron or cast iron but not likely. Pro-lites fit the description to a tee.



The second development is of much greater significance. I got a new to me engine. It is in much better external shape than the original. It hasn't been subject to a chain derailment...or at least, bears no signs of damage from one. (might have had a case saver installed?) Came with a nice anodized billet crank cover from Nichols MFG, as well as a billet clutch basket from them.



All for now....gonna have to locate a set of alloy backed friction discs to go with the billet basket should I use it. Otherwise, I'll be taking a short break while I get stuff done. Be back when I have progress and pics to share.........sean


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post #93 of 95 (permalink) Old 9-2-2019, 9:51 PM Thread Starter
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Put the clutch together today...at least up to the pressure plate install. That is when I realized I didn't have the push rod "hat" handy and couldn't find it right then either. Oh well. Tomorrow is another day.



Didn't get much else done. On the plus side, I did finally get the transmission back in my kids truck this weekend so that is a soon to be moving project. At least I'll be able to get all the bikes out of the garage instead of just the ones lined up with the gap between his daily and his project truck.



Nothing else to tell.....gonna go back to taking a forum break for a little while....sean
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post #94 of 95 (permalink) Old 9-5-2019, 7:37 PM Thread Starter
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Oil pressure switch arrived today. That'll be installed after dinner tonight. Then back to the clutch...maybe. Still trying to work out the stack height issues.....sean


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My garage: 2000.5 Aprilia Mille R, 2000 Ducati 996, 1994 EX500 basket case, 1993 Ducati 900 SS, 2004 Suzuki GSXR600, 1992 GSXR750 oil boiler, 1983 Suzuki XN-85 Turbo
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post #95 of 95 (permalink) Old 9-8-2019, 7:26 PM Thread Starter
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Garage
Addendum to the "sorta update" on the PSS thread

A couple of boxes in parts arrived since my last update. Also, more parts ordered and some clean up done.



1st, as previously posted, the new oil pressure switch arrived. I installed that, and the next night a new Ducabike breather and Corse Design fill plug arrived from MotoWheels in Sacramento. Those are installed also.



Second, still dealing with the stack height on the clutch. According the Ian Falloon book on restoration, Ducati Belt Drive Two Valve Twins Restoration Guide the 900SS requires a total of 16 plates with a stack height of 38.5mm. Pretty sure mine is somewhere in that neighborhood. Just gotta figure out the plate thicknesses to achieve that (I have 3mm frictions and stock is 2.5mm but I also have 2mm and 1.5mm steels) and still have the vented cover fit. Might end up spacing the cover out to make sure there sufficient clearance.



Third, onward to the newer developments. I ordered a new engine bolt that I'm awaiting to begin mounting the frame on the engine. Also awaiting new plug wires from NGK (thanks for the tip @ducatiman!!). Also waiting on the new spring retainers and stainlesss steel case saver I ordered from MotoWheels too.



While waiting, I got busy cleaning up the airbox for its return to the engine and carbs. What a mess. Like everything else on this bike has been from day 1.



I detailed the wire and spring keeper stuff in my last post to the PSS thread. This is more of an addendum. As I cleaned up the airbox, I kept looking at the shitty pins that were used to anchor the hold down baling wire for the filter retainer. I got more and more annoyed as my OCD kept kicking in.



I finally finished with the clean up and decided that I had to do something about the pins. Yes, they worked. They also looked like someone took a pair of diagonal cutters to a coat hanger to make them. Unacceptable on a Ducati, particularly one being restored.



I ended up fabricating new pins out of commercially available round stock typically used in construction. If you just read that and are slightly confused, that's a euphemism for nails. Yep, nails. Now before you think Apriliarider sure has a double standard, I didn't just cut off a nail and use it......well, I did but not exactly.



I just took the time to not only measure and make sure that the particular nail I used was going to fit, but also dressed the ends to give them the professional look of manufactured dowels.




The pin that came with the bike above, my fabricated pin below. Up close view below:



The end result, after cleaning up the grime inside and outside the airbox, as well as scraping off a bunch of shitty paint that was either peeling or faded, cleaning the filter and the retainer:



More in the near future...but likely in the PSS thread....sean


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My garage: 2000.5 Aprilia Mille R, 2000 Ducati 996, 1994 EX500 basket case, 1993 Ducati 900 SS, 2004 Suzuki GSXR600, 1992 GSXR750 oil boiler, 1983 Suzuki XN-85 Turbo
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