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Of the two items, I'm more intrigued by the clutch cover. That looks superb. I'm guessing he made the insert? If so he's got a great artistic eye.
 

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Discussion Starter #142
I couldn't find where he wrote about that in his posts on Ducati MS. I know he had the insert water jet cut somewhere local to him. IIRC, it was supposed to mimic the wheel design. The clutch cover he used hydrographic dip on too. I think it was the stock cover and used his mill to cut out the face of it and machine a lip into it for the insert he had made. That's all from memory though. If you pop on to Ducati MS just search for posts by buzzer. That's his forum name there.......sean
 

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Discussion Starter #143
Got a few things done on the PSS today. Removed and disassembled the instrument binnacle so I can clean it up and get it ready to reinstall. Once done, I'll start on installing the wiring harness. I ordered a new "film" cover for the idiot light pod. The old one was in bad shape and had a hole in it.

The intrusion of water into the pod resulted in some green corrosion forming on the copper trails of the circuit board inside. Would not be that big a deal but the sockets for the wedge bulbs contact the trails for power.

This past week I fabricated the brackets that have to be glassed into the solo tail section to support the rear of it. Once I fabbed them up, I bolted the brackets that hold the pads to the brackets and set them on the frame tubes. With the tail section installed, I was able to trace the bracket outline onto the fiberglass so I had a good indication where to glass the brackets in.
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Today I made some minor modifications to the brackets, drilling small holes for the purpose of allowing the epoxy resin through. This is to aid in adhesion to keep the brackets in place under weight. Once completed, I placed them one at a time on the marks, and started with application of epoxy.
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After a coat of epoxy, I applied fiberglass in strips to anchor the brackets.
 

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Discussion Starter #144
Assembled the tail end today. Here's what it looks like underneath so you get an idea of what those brackets were actually for:
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It really stiffens up the fiberglass tail. With all the bolts installed and those supports in place, you wouldn't think it possible but you can literally push the bike from the tail it's that much more rigid. That's not even all the bracket/support structure. There's more that bolts to the seat and supports the front where the rider's weight is centered..

More later on. But first I wanna share this:
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That's the back of my Surface computer. We got a Cricut machine a little while back and I've been experimenting with the old Cagiva era Ducati script. My nostaligic favorite of all the Ducati logos and scripts. Came out pretty good in gold carbon vinyl. I've since made some in black carbon and in red. Seems the smaller 6" ones are not nearly as easy to work with as the larger 12" ones like the one above.

Next I'm going to try the old Ducati "elefant" logo to go with the script above. I'll post more on that here when I get it done in some manner of presentability. Also, I ordered a heat press that is capable of doing t-shirts as well as hats, mugs and pint glasses. That's still a month out from delivery but once I get that, I'm thinking EX-500 dot com t-shirts. If there is any interest in that I'm sure we can work out the details with admin. Not looking to make money off them, but not looking to lose it either.

Already got a sublimation kit for making transfers too. Just waiting on the "pens" to be able to make iron on type transfers that last essentially forever. Think bicycle jersey permanence and you'd have the right idea. More on all of that later, once I get the press and figure out how to work things to a level I am happy with......sean
 

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Discussion Starter #145
Got busy yesterday with cleaning up the binnacle and getting it ready for reassembly. However, I found that like everything else on this project bike, it was not as straight forward as all that.

Turns out, the binnacle had been painted at some point (rather poorly at that) and what looked like just needing a cleaning up, actually had to be scraped off. That added an extra couple of hours to the task.
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Once I did manage to get it all cleaned up, I discovered some cracks in a tube where the idiot light pod screws into. Seen above as the upper of the two holes in the waffle like grid on the right.

I wound up filling that with some JB Weld. Probably should have gone with the marine grade epoxy I've been using to repair and/or reinforce fiberglass. It sets up in just a few minutes where the JB Weld takes hours.

The pod itself had some minor corrosion issues. The wedge bulb holders twist lock onto the circuit board which has soldered copper trails where the twist lock makes electrical contact.

These had turned green with corrosion. I sanded that off and applied some "No-Krode" which is an aviation grade corrosion preventative.
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Once I got all that cleaned up, I swapped out the majority of the bulbs for LED bulbs. All but the fuel level warning light and the turn signal indicator light. Just due to the way the system works, neither should be replaced with an LED due to how the incandescent bulb functions as part of each of those circuits.

A long while back I ordered a new "film" to replace the old nasty original. The new film is more like a proper lens than the thin plastic film it replaces. I'll be installing that on the pod later today.

I'm planning on using epoxy (the same marine grade stuff) to secure it. It comes with an adhesive backing but I don't feel like that will be substantial enough to hold it permanently. Not given how much surface area there is to bond to.

More later..........sean
 

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Discussion Starter #146
More on the binnacle. Here's a close up of the cracked tube:
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The side opposite of this one, has a crack also, and it's worse. Hence the need for the epoxy.
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Here is the "film" I wrote about in my last post:
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That's it for now.....Once all the epoxies cure, I'll drill the tube out so it can accept the proper size screw, in stainless of course.
 

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Discussion Starter #147
Spent a bit of time in the garage today. Got a bit done. Also got a few parts in from Ducati Omaha so I was able to finish up the seat/solo tail assembly. Now, I gotta take it all apart and get it ready to paint.

Got the left side fairing drilled today. I also sprayed some high build primer on the upper and spent a great deal of my day wet sanding the upper. Still needs another coat or two of primer and several more hours wet sanding. I mocked it all up so I could show what it will sort of look like:
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Starting to look like complete motorcycle again.


I also took apart the tach and painted the needle, as well as sanding and painting the old weathered. bezel. I managed to completely wreck the paint upon crimping the bezel back on. I'd already done the speedo some months ago, and as my last posts showed, I'd already replaced the idiot light "film". Other than drilling out the epoxied cracked tube, it is ready for installation:
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Spent some time working on the old OEM fairings today. I've got a plan to paint them black and make it so I can swap out body work....or use it to build another SS at some point. To that end, I finished stripping off the remaining old nasty paint. In doing so, I discovered that at some point body work was done over the old finish, clear coat and all. More on that in my next post.
 

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Discussion Starter #148
I worked primarily on the right side fairing as it is the most damaged and will take the longest to repair. It already had some pretty shoddy repairs made to it that I will have to remove prior to making any further repairs. There is a protrusion above the turn signal that was filled with uncured plastic filler. I was able to scoop some of it out with a razor blade.
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The OEM paint was professionally painted over at some point. The body work was done over this second paint job. Shoddily at that. All the work I've uncovered that appears to be done after that is all complete crap. Nothing was prepped correctly, custom candy apple paint was laid on over the clear coat of the previous paint job, and then another coat of red, and finally a 1 mm thick coat of polyurethane.
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At the top of this pic, you can see a sample of the different layers of paint as well as the clear coat that was left on and painted over.
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Discussion Starter #149
More pics. Some of the poorly repaired damage:
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Discussion Starter #150
Spent a little time in the garage today. Got the fairing put together for fitment check. I have some adjustments to make yet. Got more primer on the tank. Assembled my instrument binnacle and installed it on the bike.

On the binnacle, I'd attempted to assemble it yesterday but the Tach studs were spinning when I tried to install the lock nuts. To repair this, I drilled divots in both the stud base and the back of the tach housing.

I mixed up some JB weld and filled the gap and the divots. Today, the JB weld was cured and set, and the lock nuts went on easily. I installed the Tach into the binnacle and tightened the lock nuts down to just snug.

Tomorrow, I plan to pedal in the AM before it gets stupid hot out.(forecast is 100. it was like 50 a week and a half ago) After my pedal, it's time to get started on installing the wiring harness. Not something I've looked forward to. I'll update again once I make more progress.........sean
 

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Discussion Starter #151 (Edited)
Got started on the wiring harness. I’ve not been excited about getting started on this phase of the project.

A previous owner hacked up the harness to install a HID set up. Poorly executed is not descriptive enough.

First I had to un-f*ck that mess so I could splice in a proper head lamp connector for an H4 bulb.

Got that done today, and it came out pretty Pro if I may critique my own work.

Also, the ignition connector looked like this:
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Rather than try to replace this mess with the proper OEM style connector I decided to go a different route. I bought a Deutsch connector kit and used one to replace both sides of the connector.

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I used Deutsh connectors professionally on the heavy equipment I spent so many years working on. They're sealed and as weather tite as can be found.

I've literally got decades of experience using these so I'm really comfortable using them for critical wiring connectors.

I find them more robust than GM's weather pak and "Metri-pak" connectors.

More later....made little other progress on the PSS as I spent most of yesterday and quite a bit today working on the 996...sean
 

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Discussion Starter #152
Approaching the 2 year point on this project. Sometimes I think, this is taking FOREVER, but that's because well....it IS.

Not much is gonna get done for a little bit. Off to the Ducati MS West Coast Meet here in a week. Meaning this weekend is all gonna be getting ready to go.

More a bit later on in June.........sean
 

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Discussion Starter #153 (Edited)
Unfortunately, I've been neglecting this project due to so much other routine maintenance on other things. I've simply put them off for too long a time due to this project. One thing I managed to get done shortly after returning from the dot MS West Coast Meet was to finally replace the leaking water pump in my old 2003 Suburban. That wound up taking an entire afternoon.

After that, I had to replace my side yard gate...well, at least one anchor post and the gate side that swung on it. That took most of a morning on a day off.

Then came all the required work on my Aprilia. I'd neglected the old girl for some time due to both this project and the 996. It was seriously time to show it some love. I detailed that in another thread, elsewhere in the forum, but that wound up being almost an entire day.

Then the 996 love, also detailed in another thread, took over my time. It is far from being done too, and it needs other stuff, like new tires and an oil change. Tires will have to wait as the little GSXR is now lined up for a significant amount of work too.

It also needs tires, as well as an oil change, plus coolant change and installation of the new hoses I bought for it a year ago.

The work on the GSXR will get done first as I already have everything to do it save the oil and tires. Tires will get ordered on payday (next Friday) and I'll get those knocked out as soon as they arrive. Barring any surprises anyway.

Like the surprise of my oldest son's wedding. That took up today. Found out about it last night. Yes, it was sudden, but not like that. It wasn't supposed to go down until October.

996 will get an oil change soon, before I continue on with the diagnostics on the EFI system. All of the above happens BEFORE I get back to working on the PSS. This does not mean nothing is being done in the mean time.

I've ordered parts and gotten to a few bits here and there. New head light bulbs arrived (nice new LEDs) and when I went to install them on the OEM head lamp shell, the wire retainer was missing.

I remembered right around then that it wasn't present when I got the bike because some numpty failed miserably at installing an HID set up. It did not work when I got the bike and was one of the first things to go.

I looked up and in fact, ordered some wire retainers for the H4 bulb. None were correct, and there were 6 in the box. I'm on the fence about modifying one so that I can use that. Mean while, it's held in with safety wire while it sits in the protective box I stored the shell in.

Rewired the head light wiring also, as it was hacked to bits in the fiasco described above.

The side fairings have been removed to reinforce the mount holes. I did one side already by laminating some carbon fiber cloth onto the back of the AirTech glass.

Difficult stuff to work when you have to cut it into strips for the job. Probably should have just ordered the Carbon Kevlar cloth and gone with that.

About the same time that I ordered a few parts for the 996, I ordered a billet front sprocket cover from eBay for the PSS. I think it's on the slow boat from China despite being listed as located in SoCal.

According the ad, it's located less than an 8 hour drive away. Still waiting on it after a month. Think that about covers it for now. More, after I finish up all the other stuff on my plate.
 

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Discussion Starter #154
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Wouldn't you know it? As soon as I posted here about my cover being on the slow Chinese boat, it arrived in the mail.

Went out to the garage with every intention of installing this cover, and starting the oil change on the 996. Never is that simple though. As soon as I tried to fit the cover, it was evident that the cover was not an exact fit compared to the OEM.

Wound up having to take my dremmel and a carbide burr to reshape the "leading edge" where it meets the slave cylinder. Took a while but I was able to get the correct shape for it to bolt up.

When I checked it against the OEM cover, the new profile I reshaped was nearly an exact match. Imagine that. Billet aluminum is better in my view than the OEM plastic cover. Doesn't look as cheesy.

Not certain about the red though. I mean, it matches the timing cover and the slave cylinder but kinda seems like too much red.

That and if I swap the slave cylinder out, I have a black Oberon I'm considering swapping in. If the cover were black it might be a better visual. Gold would match the rest of the billet parts I've installed.

Maybe leave it red for a while and see if it grows on me. If not, I'll just refinish it in black. Or paint it gold. It's just an eBay cheapy. $35 is all I spent on it. More later.
 
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