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Steve-o's Projects Thread

Postby Steve-o » Thu Jan 10, 2013 8:22 pm

J, here you go. I figure I can just keep this one going as a catch all for all of the various things I get into. I am a bit short on pictures now, but I promise I will get more up soon.

So, in somewhat chronological order, here are the things that have kept me from working on my bike until this past week.

Last fall I decided to finally look into what was wrong with my MGB so I could either sell it or start driving it. That led to lots of carb tuning and a complete rebuild of the brake system. Everything in the brakes is new or rebuilt except the steel lines. It turns out both wheel cylinders were shot, one caliper was frozen, and the power booster was leaking... needless to say the difference in stopping power is amazing. Oh, and the rotors bolt to the inside of the front hubs, so I went head and replaced the front wheel bearings while I was at it. I also rebuilt the whole clutch hydraulic system. I finally drove it sometime in late October for the first time in over 2 years. I am ashamed to say it sat that long because of a bad intake gasket that cost $5. Anyway, here is a picture of the fun.

Image


So, this summer the mower started using coolant and blowing lots of oil smoke out of the crankcase breather (for those that don't know, we mow approx 5 acres and have a 72" diesel commercial mower). I was looking into rebuilding the engine, and was about to start ordering parts when I found a used engine with 300 hours for sale, so at the beginning of December the MG went to the mower garage and the mower took the MG's spot in the attached garage and the teardown commenced. It took about 4 hours to get the engine out and then I spent about 8 more cleaning everything. I am slowly getting externals and new parts put on the new engine and hopefully will get it back together soon. Sorry, no pictures right now but I will get some. Its hard to tell it is even a mower at this point.

That whole project got slowed down a bit when I finally decided on an old Bolens garden tractor for snow clearing and garden tilling duties. I picked up a 38" snow blower and 33" tiller just north of Beaverun at thanksgiving, then a couple weeks later I picked up a tractor in Indy. It needed some TLC, so I started working it instead of the mower. I had to make a battery hold down, and I pulled the carb off to rebuild it. I quickly decided to just buy a new one, and that proved to be a good plan. It runs great now. Unfortunately my tach didn't come in before the snow came so I couldn't adjust the governor, which meant I couldn't even use it to clear the driveway.

So, in the middle of all that my friend Chris told me he found a project bike that had spun a rod bearing and needed a new engine, but it had some VERY tasty bits on it and it was super clean. So, the Friday after Christmas, we drove down to Commonwealth Cycles in Louisville in the Sprinter and picked up his pile of parts. There was one large box, the front half of a bike, a swing arm, and four plastic tubs filled with engine parts. We did some investigating and we think it needs new rods and pistons, the crank needs to be repaired, the cylinders need to be re-plated, it needs all new intake valves, and two exhaust valves. Right now the plan is to buy a used engine so he can at least ride it while we find aftermarket companies to make as many of these parts as possible. It should be a fun project to help out with. So, who can guess what kind of bike this is?

Image


Now, on to my bike. I don't know what got into me, but this past weekend I had a whole day to work on my bikes, so I decided to get started working on getting my extra cases cut and mounted in my 93 RS chassis so I can run that Tommy Crawford pipe next year. So, I split the cases and then used a secret high tech method to cut the kickstart housing off.

Image


I made a crude red oak aft mount just to mock everything up. With only a hand drill it didn't work out so well. It worked for a first try, but I needed something better. So Monday after work I picked up this:
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I also ordered some materials to complete the conversion:
Image


Another thing I ordered was a compound table for the drill press so I could do some light milling. That arrived yesterday and after looking at it I decided it wasn't really going to do what I wanted it to do, so I sent it back and ordered another tool that should be here in a week or two. Once I get that I should be able to whip up some mounts pretty quickly. I will post pictures when it arrives. For now I am pretty much stalled, so my extra cylinder will go out for a re-plate and I will see if I can at least get the new engine in the mower and I should have more time to post up pictures of everything.
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Re: Steve-o's Projects Thread

Postby Luckystar64 » Fri Jan 11, 2013 3:02 am

Looks like an older 900SS or 750SS. Around '93-'95? Old 750F1-- '86 maybe? I LOVE the old Superlights, but that would have a white frame. --L*64
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Re: Steve-o's Projects Thread

Postby Steve-o » Fri Jan 11, 2013 6:57 am

Those are some good guesses Tony, but not quite right. He does have a pristine superlight in his shop right now. That is one nice bike. There are a few pretty obvious clues in the pictues. I am sure somebody on here will pick up on them right away.
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Re: Steve-o's Projects Thread

Postby fireman_343 » Fri Jan 11, 2013 8:29 am

Duc frame... Not a monster... Ummm.. 749, 848, 998?? It has a wide front wind screen like a 916, but a newer gauge.. Hard to tell from the pic
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Re: Steve-o's Projects Thread

Postby Steve-o » Fri Jan 11, 2013 8:52 am

You are getting closer Brian. Good catch on the dash. That is one of the clues. There are several other clues visible that are pretty obvious to someone that knows this particular model. Like the stock front brake adjuster... I have a feeling J will get it. Matt Rhem would definitely get it, and Hatten would probably get it.
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Re: Steve-o's Projects Thread

Postby JReid » Fri Jan 11, 2013 9:19 am

Excellent! Love the thread, Steve-o. After hearing about the MGB for a while it's nice to see it and good on 'ya for getting road worthy again. Looking forward to seeing your progress on those CR cases. I'm jealous of that new drill press of yours. My guess on the Duc? 1098. Sounds like a fun project. Hatten would be proud.
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Re: Steve-o's Projects Thread

Postby Steve-o » Fri Jan 11, 2013 9:44 am

Thanks J. I have some better pictures of the MG somewhere. I will have to look for them. It was really tough bring myself to start hacking up a set of cases, but it does look pretty cool know that the housing is off. Tomorrow I may get a picture of the engine in there with that tommy crawford pipe mounted up. That is providing a lot of motivation for me. I can't wait to hear that pipe. If you like that drill press you are really going to like the next tool I have coming. You are getting closer on the Duc. I wish Photobucket hadn't resized the picture. If you could zoom in you could see all of the carbon fiber and the number plate on the top triple clamp, that would make it pretty easy. Also if you could see the forks that would be a dead givaway.
Last edited by Steve-o on Fri Jan 11, 2013 9:52 am, edited 1 time in total.
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Re: Steve-o's Projects Thread

Postby Luckystar64 » Fri Jan 11, 2013 3:54 pm

Late '90's 916 maybe?? COULDN"T be a Raymond Roche style 851 now? Could it be? As far as Ducs go-- I don't favor the racers. I dig the obscure SS line for some reason. --L*64
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Re: Steve-o's Projects Thread

Postby Steve-o » Fri Jan 11, 2013 4:18 pm

You are really putting some thought into this aren't you Tony. You are thinking too old though. J and Brian had the right era with the 848 and 1098, just not quite the right model. I am pretty sure everything you can see in the pictures is stock. Including those sweet fork caps.
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Re: Steve-o's Projects Thread

Postby latency » Fri Jan 11, 2013 5:24 pm

errrrr...... I am jealous. 1098R

Dude, mo pics, mo pics!!! Definitely need to see some mower porn.
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Re: Steve-o's Projects Thread

Postby fireman_343 » Fri Jan 11, 2013 7:19 pm

I've got it.. 1198 Superbike Spiecal Edition
Once u said number plate, and forks... Now I see it!
Last edited by fireman_343 on Fri Jan 11, 2013 7:24 pm, edited 2 times in total.
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Re: Steve-o's Projects Thread

Postby Steve-o » Fri Jan 11, 2013 8:54 pm

Man, you guys are coming up with some good bikes, but still not quite right. He already has an 1198 S Corse edition, so it isn't in the 1098/1198 family. It is definitely a street bike, no race edition, but it is covered in carbon fiber. Even carbon fiber bodywork stock. Brian, think of another limited edition Duc. This one is #567 of 1500. Somebody has to get it now!
Last edited by Steve-o on Fri Jan 11, 2013 8:56 pm, edited 1 time in total.
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Re: Steve-o's Projects Thread

Postby JReid » Sat Jan 12, 2013 6:49 am

No way, not a D16RR?!
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Re: Steve-o's Projects Thread

Postby Steve-o » Sat Jan 12, 2013 9:01 am

Yep, there is a D16RR in my Sprinter in that picture. The previous owner blew the engine twice and the second time Ducati wouldn't warranty it and the estimate from the dealer was almost $20k to fix it so he sold it as a parts bike. It is in mint condition and came with BST carbon wheels, Brembo T drive rotors, the full GP exhaust system, The GP lower and tail section, brand new paint from peach pit, Microtec and Ducati Performance ECUs, an aftermarket slipper clutch and cover, plus all of the stock parts that were removed including the stock exhaust that has been ceramic coated and a new set of tires in the plastic, and both sets of wheels have virtually new tires. When the GP exhaust was installed some well known Ducati tuner spent 8 hours on the dyno with it. This thing is SWEET. He makes me carry a towel with me to wipe the drool off as I go. :lol:

Over the last couple weeks we have had a good look at the engine internals (yes, I have had every part of a D16RR engine in my hands), and we have determined that one crank journal needs to be repaired, two con rods need to be repaired or replaced, two pistons need to be repaired or replaced, the cylinders need to be re-plated, all of the intake valves need to be replaced, and two of the exhaust valves may need to be replaced. With the price and long lead times for OEM parts, the plan is to get aftermarket companies to make some of the parts cheaper than the OEM parts. Until then, he may get a used engine just so he (and I) can ride the bike and take our time getting the other engine put back together. I promise there will be more pictures soon, and I will see if I can get him to ride it up to CRP sometime this season.

Well, now that someone has guessed it, I can leave the computer and go rearrange the garage to make room for the shipment I am expecting Thursday.
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Re: Steve-o's Projects Thread

Postby fireman_343 » Sat Jan 12, 2013 9:31 am

Oh man, I've never seen a D16RR in person... That's one bad ass bike man!! Wow!!!
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Re: Steve-o's Projects Thread

Postby Steve-o » Sat Jan 12, 2013 4:29 pm

Yeah, and from what I hear, this is one of the most bad ass ones in the country. Its only the third one I have ever seen in person. I can't wait to get to ride it! :mrgreen:
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Re: Steve-o's Projects Thread

Postby Steve-o » Sat Jan 12, 2013 10:04 pm

Ok, so I have a new piece of shop equipment coming this week and I needed to make room for it, plus I hated the work benches the previous owner built, so I spent the day working on the garage. Here is what I started with:
Image

Image

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It took a while to get the benches cleared off:
Image


The guy that built these things was not thinking about taking them apart. Everything but the tops was put together with nails, and then nailed to the studs. I ended up taking the tops off and cutting them apart to get them out. It was a serious pain in the ass.
Image

Image


I replaced some insulation and put up a little drywall, then put my workbench that I built 7 years ago for our last house back together. I missed that workbench.
Image


And here is what it looks like now:
Image

Image

Image


I am going to take out the cabinet to the left of the drill press and install a permanent bench there for the drill press and my new equipment. I really need a bigger garage. 24X24 is just too small for everything. And now, the next couple are just for you Kyle.

Old engine on left, new engine on right
Image

Image


Here is about 60% of the mower. I got a little carried away disassembling it. It is a rear engine front deck mower, so the big hole is where the engine goes.
Image


Action shot:
Image


Moving from the old house to the new house:
Image

Image



And something random I just figured out, if you happen to have a 50X80X16mm bearing sitting around, it makes a great coaster. The bottom of the can fits perfectly.
Image


Thats all I have for now. See you guys tomorrow.
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Re: Steve-o's Projects Thread

Postby slickwill » Sun Jan 13, 2013 8:45 pm

D16RR. Very cool. Been high on my want list since the day it came out. I've never ridden one but I've sat on a few of them around the country at various places. Can't wait to hear more about it.
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Re: Steve-o's Projects Thread

Postby Steve-o » Wed Jan 16, 2013 6:53 am

The mill should be here Thursday, so I spent last evening working the aforementioned bench for the mill and drill press. Tonight I will sand it down and put the first coat of stain/poly on it. I won't be able to do the second coat until Thursday, so I may hvae to wait until Friday to get everything set up.

Front (sorry it is blurry)
Image


Back
Image


Now that it is all put together, I am beginning to rethink my choice of leg material. Those 4X4s seem awfully spindly... maybe I should have used 6X6s.
Last edited by Steve-o on Fri Mar 08, 2013 9:05 am, edited 1 time in total.
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Re: Steve-o's Projects Thread

Postby Steve-o » Thu Jan 17, 2013 6:34 pm

Ok, time for some updates. Today when I got home from work these two packages were waiting for me.
Image


Inside were some fun tools. A standard drill set from 1/16 to 1/2 in 64th increments, a metric set from 1 to 13 mm in .5 mm increments, some end mills, a spot drill, a center drill, a vise, a square, and some layout dye.
Image


So after I unpacked that stuff I put coat number 2 of the stain/poly on the new bench.
Image


I wasn't too sure about this stuff after the first coat, but the second coat looks much better.

So after sharpening a couple knives and eating dinner, the Fedex guy finally showed up with this!
Image


And I proceeded to open the crate... it was so easy it was scary. Once I got the top off with the pry bar I just pulled on the sides and they came off.
Image

Image

Image


And finally, I got to the mill! :mrgreen:
Image


Unfortunately the mill got here too late to do anything with it today since I have to leave to go to a concert in a few minutes. Tomorrow after work I will get it up on the bench and hopefully get it all set up and get the spindle broken in. I should be making chips this weekend.
Last edited by Steve-o on Fri Mar 08, 2013 9:11 am, edited 1 time in total.
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