DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: maxBetteridge on Jan 21, 2016, 04:12:27

Title: Ducati Mobster
Post by: maxBetteridge on Jan 21, 2016, 04:12:27
Not much of a forum user if I'm honest.. This is my first post on this site, pretty much my first post on any forum.

I'm 24, live in Auckland, New Zealand, and work as a product development engineer.
So I got my first bike just over a year ago, a suzuki GSX400. Here's the finished product:

http://www.returnofthecaferacers.com/2016/01/first-timer-gsx400-cafe-racer.html

(https://static.wixstatic.com/media/4ae3bf_702eb7659cfe4f7aa0b38ca67cffc54c.jpg/v1/fit/w_975,h_650,q_90,usm_0.66_1.00_0.01/4ae3bf_702eb7659cfe4f7aa0b38ca67cffc54c.jpg)

I might share some of the build later on in another post but for now you can see some build photos on my website:
http://www.maxbetteridgedesign.com/#!building-the-gsx400-cafe-racer/jm2qa

I bought the GSX as a project and planned to keep it. I had never ridden a bike when I bought it so I had to learn and get my licence before I could really get into the build. After I finished it I enjoyed riding it for a few weeks but realised I enjoyed the building much more than the riding so I sold it to start the next project.

In NZ we are limited to 650cc for learners licence and below a power to weight ratio. The GSX was a good compromise toward the upper end of the power to weight limit. We are also limited on the types of modifications we are allowed before it becomes a non-learner bike, hence the mods on the GSX were pretty conservative.

The new bike is a 2005 Ducati Monster:
(https://static.wixstatic.com/media/4ae3bf_a9dff42474fc4f0ead14333957615328.jpg/v1/fit/w_800,h_531,q_90/4ae3bf_a9dff42474fc4f0ead14333957615328.jpg)

And here's the first concept sketch:
(https://static.wixstatic.com/media/4ae3bf_bfaa1d1da3ff49a6a6de7e9bcec8a21b.jpg/v1/fit/w_800,h_531,q_90/4ae3bf_bfaa1d1da3ff49a6a6de7e9bcec8a21b.jpg)

It's a 400cc so it's still a learner bike. This time I want to do something which is a bit less edgy with more subtle styling. I had my first experience with fibreglassing on the GSX and was surprised at how easy it was so this time I have been talked into doing a full composite belly pan, tail, and tank. I want to use exposed basalt fiber for it's amazing colour and texture, and because it seems like nobody has really done it before. I want to make features of the frame, the engine, and the basalt and most importantly get rid of the  bubbly curves and get rid of the red!

I got the bike in December, about a month ago, and I've been doing a lot of designing and planning. I finally got some good 'before' photos last weekend so I've got stuck into pulling it apart, ordering bits, and building parts. More updates on what I've already done will come soon.

Follow me on instagram for build pics @max_betteridge_design
www.instagram.com/max_betteridge_design/
Title: Re: Ducati Mobster
Post by: Tune-A-Fish© on Jan 21, 2016, 09:20:56
Nice work, digin the concept bike for sure.

You must be a lightweight, that katana has a small saddle
Title: Re: Ducati Mobster
Post by: twerth on Jan 21, 2016, 09:43:29
Did you say your Monster is 400cc? I thought the smallest monster that year was a 620cc.
Title: Re: Ducati Mobster
Post by: treitz on Jan 21, 2016, 12:14:10
Welcome! I really like how that Zuki came out. Look forward to watching the Duc come around too.
Title: Re: Ducati Mobster
Post by: coyote13 on Jan 21, 2016, 12:15:51
Did you say your Monster is 400cc? I thought the smallest monster that year was a 620cc.

It was.....in the US  8)
Title: Re: Ducati Mobster
Post by: canyoncarver on Jan 21, 2016, 18:00:24
Concept sketch is a beauty.
Title: Re: Ducati Mobster
Post by: Hurco550 on Jan 21, 2016, 18:17:33
Concept sketch is a beauty.
Agreed!
Title: Re: Ducati Mobster
Post by: kiwiguy on Jan 22, 2016, 03:46:24
In Newmarket then fella. Do you visit the Carbon Cafe? Some niicce scooters there mate! I try to get down once a month or so for lunch with a mate just to have a squizz
http://www.carbon-garage.com/ worth a coffee
following along, always liked the Dukes
Title: Re: Ducati Mobster
Post by: NoRiders on Jan 22, 2016, 08:06:00
The GSX looks sweet.

Concept bike could do with the tank/seat being much lower as it looks top heavy and the seat is higher than stock and looks perched. I'm sure the tank/side fairing could be made to hug the trellis frame much more. Lose the horrendous end can, for a tucked under silencer maybe?

Looking forward to your updates fella.
Title: Re: Ducati Mobster
Post by: Tune-A-Fish© on Jan 22, 2016, 09:16:49
The GSX looks sweet.

Concept bike could do with the tank/seat being much lower as it looks top heavy and the seat is higher than stock and looks perched. I'm sure the tank/side fairing could be made to hug the trellis frame much more. Lose the horrendous end can, for a tucked under silencer maybe?

Looking forward to your updates fella.

I was thinking same... look closer, the seat is in the same sweet spot and only if any slightly elevated .5" maybe. Look from frame to top of ride position, it's super close.
Title: Re: Ducati Mobster
Post by: maxBetteridge on Jan 22, 2016, 18:15:23
In Newmarket then fella. Do you visit the Carbon Cafe?
Hey Kiwiguy, just started looking through your build, haven't get very far through it yet but I'm seriously impressed!
Yeah those pics are in Newmarket. I'm out in Mt Wellington though. I'm a big fan of Carbon Garage! I try to get there every second Saturday if I can too. Might see you there sometime.
Title: Re: Ducati Mobster
Post by: maxBetteridge on Jan 22, 2016, 18:53:18
The first thing I started on was CADing up some of the bodywork too see if I could make it look nice from other angles, not just the side. I will make all of my mould plugs either from a laser-cut waffle skeleton or CNC it from foam or MDF. Either way I will eventually use these CAD models to create the parts.
I was able to find a model of the bike on Grabcad which got me started but I didn't trust it much. I know it is based on an older frame than what I've got and I know there are at least a few inaccuracies, but it was enough to make a start.
Here's a bit of the progression:
(https://static.wixstatic.com/media/4ae3bf_7f1f0cef1a56413e947e79c262be752c.jpg/v1/fit/w_1200,h_518,q_90,usm_0.66_1.00_0.01/4ae3bf_7f1f0cef1a56413e947e79c262be752c.jpg)

I worked out pretty quickly that having the tank drop down below the level of the frame it would need to be REALLY wide. It would be a huge part to make a mould for (too wide for any of the CNCs I have access to I think) and the top and bottom halves of the tank would be much harder to make and to make them fit together seamlessly. So reluctantly I re-caded it to follow the top of the frame and I think I have come to qiute like the new look it gives

(https://static.wixstatic.com/media/4ae3bf_639c10ecf08447f3a2522ad46839f470.jpg/v1/fit/w_1200,h_547,q_90,usm_0.66_1.00_0.01/4ae3bf_639c10ecf08447f3a2522ad46839f470.jpg)

(https://static.wixstatic.com/media/4ae3bf_907212e0c0c0436b980df66766c42f53.jpg/v1/fit/w_1200,h_542,q_90,usm_0.66_1.00_0.01/4ae3bf_907212e0c0c0436b980df66766c42f53.jpg)

(https://static.wixstatic.com/media/4ae3bf_8daea92aea6e4d3999fc1b134ce894d9.jpg/v1/fit/w_1200,h_608,q_90,usm_0.66_1.00_0.01/4ae3bf_8daea92aea6e4d3999fc1b134ce894d9.jpg)

(https://static.wixstatic.com/media/4ae3bf_1b60fc18771a4a1d83e650a0dc24374e.jpg/v1/fit/w_867,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_1b60fc18771a4a1d83e650a0dc24374e.jpg)
Title: Re: Ducati Mobster
Post by: maxBetteridge on Jan 22, 2016, 19:21:07
I bought a 3d scanner to help me build the GSX last year so I was glad to be able to make use of it again for the mobster. When I bought it it seemed like a bit of a waste of money and time but it was awesome to have it ready to go for this project :)

The scanner is just an xbox kinect camera connected to a pc with some free software. It works pretty well but lacks a bit of fine resolution. I have found that if you scan the entire bike it will come out quite well and fairly accurate, but the definition really suffers. To get good detail you need to focus on small areas of the bike at a time and stitch them together in cad later. At the moment I am interested in the details under the tank (battery, air box etc.) so I know how big to design my new tank.

Here's the setup:
(https://static.wixstatic.com/media/4ae3bf_786812f7b30a4ff0acdde6b4a203215e.jpg/v1/fit/w_817,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_786812f7b30a4ff0acdde6b4a203215e.jpg)

And here's a scan of just the details under the tank:
(https://static.wixstatic.com/media/4ae3bf_7a7505fbf5654592a4fc4cb55c7af9f2.jpg/v1/fit/w_600,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_7a7505fbf5654592a4fc4cb55c7af9f2.jpg)

And finally some more CAD with the new scan:
(https://static.wixstatic.com/media/4ae3bf_c6452b83872847a985249d3ddef83c58.jpg/v1/fit/w_1192,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_c6452b83872847a985249d3ddef83c58.jpg)

(https://static.wixstatic.com/media/4ae3bf_94b8ed39b02b445aa930ecc467799a92.jpg/v1/fit/w_1186,h_596,q_90,usm_0.66_1.00_0.01/4ae3bf_94b8ed39b02b445aa930ecc467799a92.jpg)
You can see the air box is going to have to go, and the ecu and bits around the battery will need shuffling around.

(https://static.wixstatic.com/media/4ae3bf_ee37d9d5e83d4e6e8691f21086afd62e.jpg/v1/fit/w_1200,h_565,q_90,usm_0.66_1.00_0.01/4ae3bf_ee37d9d5e83d4e6e8691f21086afd62e.jpg)

(https://static.wixstatic.com/media/4ae3bf_a6a17f019933435fb17f13ba07b9f78c.jpg/v1/fit/w_1200,h_584,q_90,usm_0.66_1.00_0.01/4ae3bf_a6a17f019933435fb17f13ba07b9f78c.jpg)

BTW if any builders around Auckland want to give the scanner a go just flick me a message and we should be able to sort something out :) The more use it gets the better.
Title: Re: Ducati Mobster
Post by: treitz on Jan 22, 2016, 19:31:16
Love the new tank placement and lines. This is going to turn out great.
Title: Re: Ducati Mobster
Post by: Weasel on Jan 22, 2016, 20:13:28
Impressive first effort. Looks like you started with a pretty complete machine. Smart move.
Title: Re: Ducati Mobster
Post by: canyoncarver on Jan 22, 2016, 21:57:24
Your use of the open source Kinect stuff is pretty cool.  I've got one I've been playing with.  Nice work.
Title: Re: Ducati Mobster
Post by: kiwiguy on Jan 23, 2016, 17:19:36
Hey Kiwiguy, just started looking through your build, haven't get very far through it yet but I'm seriously impressed!
Yeah those pics are in Newmarket. I'm out in Mt Wellington though. I'm a big fan of Carbon Garage! I try to get there every second Saturday if I can too. Might see you there sometime.
Thanks mate, taken some time to get to where I am at with mine, but more about the build at the moment.
your tank and seat design is the ducks nuts, love the lines and the short kick up seat, very close to what I have floating in my head for my build. You have some cool skills with the CAD mate! Are you going to run the exhaust cans like that, have you thought about something different? Perhaps make up a 1 piece muffler to run up between the rear of the engine and rear wheel?? I made a new stainless muffler for a mates 1050 Sprint that would be about that size. Just a thought. Looking forward to this build fella
Title: Re: Ducati Mobster
Post by: maxBetteridge on Jan 23, 2016, 20:46:29
I have been planning to keep the termi cans but almost everyone I speak to about it thinks I should get rid of them! I am planning on building everything on this in such a way that I can sell this one and easily duplicate it and build a second one almost identical. So thinking about it that way I would probably be better off designing it around a new set of cans or something custom because chances are the next one won't have the same termis on it.

Here's my problem; these exhausts sound awesome, I'm addicted to the sound and I think if someone takes it for a test ride the sound will really sell it to them. These termis are nice and deep and probably fool people into thinking it's bigger than a 400 (and considering the type of person who might buy this will be a learner who's not allowed a bike much bigger than this, I think that they'd like to fool people into thinking it is a bigger bike)

So if anyone can give me some advise on some exhaust options which will sound equally awesome and look better then I'm keen to hear them. I'm also very open to the idea of welding op my own segmented pipes in ss or something but again I'm just worried that they'll sound awful.. Am I right?


Sent from my iPhone using Tapatalk
Title: Re: Ducati Mobster
Post by: maxBetteridge on Jan 23, 2016, 20:52:28
I like what this guy did, they look like they're just the cheap GP pipes you find on ebay. Would you guys think these would sound any good compared to the Termigninis I've got?
(http://kickstart.bikeexif.com/wp-content/uploads/2013/11/ducati-monster-900-5.jpg)
(http://kickstart.bikeexif.com/wp-content/uploads/2013/11/ducati-monster-900-3.jpg)
Title: Re: Ducati Mobster
Post by: Tune-A-Fish© on Jan 23, 2016, 21:02:46
looks like a hand made tuned exhaust to me, If it performs then the noise is Ducati Music. The classic color is spot on badass.
Title: Re: Ducati Mobster
Post by: maxBetteridge on Jan 23, 2016, 21:14:33
These are the tips I thought he might've used. The rest of the pipes are custom I'm guessing.

http://www.ebay.com/ulk/itm/181965363975


Sent from my iPhone using Tapatalk
Title: Re: Ducati Mobster
Post by: Tune-A-Fish© on Jan 23, 2016, 21:21:36
Nah... look inside the cans, you can see they have way bigger baffle ports around the corner and those eBay cans are small and close to the end.

This is a 100% bike no way anything but the best was used.
Title: Re: Ducati Mobster
Post by: kiwiguy on Jan 23, 2016, 22:19:37
I was more thinking of the lines of something like this. (pls excuse the drawing, I can bearly spell CAD let alone use one)
then you could still utalise the OE front pipes of the Duke, and make new secondary's and up pipe into your muffler
Title: Re: Ducati Mobster
Post by: maxBetteridge on Jan 25, 2016, 03:29:32
Before I began modifying the bike I got a few 'before' shots at a carpark I think I might use for the 'after' shots. Here's a couple:

(https://static.wixstatic.com/media/4ae3bf_688ba11b7f0d4bffb52fcd1df7f9d360.jpg/v1/fit/w_817,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_688ba11b7f0d4bffb52fcd1df7f9d360.jpg)

(https://static.wixstatic.com/media/4ae3bf_59f6c2ace3ae44f6ade2425550728aa3.jpg/v1/fit/w_817,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_59f6c2ace3ae44f6ade2425550728aa3.jpg)

(https://static.wixstatic.com/media/4ae3bf_811fdfaf394d4feda31fa392b29387bb.jpg/v1/fit/w_1092,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_811fdfaf394d4feda31fa392b29387bb.jpg)



And I couldn't resist photoshopping on my CAD to check it looks like I imagined..
(https://static.wixstatic.com/media/4ae3bf_f2a375cdb82443b484718b3ec611b0db.jpg/v1/fit/w_1092,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_f2a375cdb82443b484718b3ec611b0db.jpg)

Thought I'd throw this in too. I'll admit this shot is a bit staged.. but I have gone through probably close to 100 prints, sketches, and overlays to get to a design I'm happy with:) This is just a few
(https://static.wixstatic.com/media/4ae3bf_38d7c1cbcc2e4afe8d8ab95c479f66f5.jpg/v1/fit/w_613,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_38d7c1cbcc2e4afe8d8ab95c479f66f5.jpg)

Title: Re: Ducati Mobster
Post by: maxBetteridge on Jan 25, 2016, 03:57:31
The first thing I want to do is clean up the front end. I'm going to do most of the same things that I did to the GSX so there's not too many unknowns, just a bunch of work to get out of the way.I'm hoping that once I've got the front done I'll be able to get back on the road with it and get used to the new riding position and make a few more decisions about the seat position, rearsets, and things like that.

I stripped the headlight and the mess of confusing Italian designed brackets and mounts behind it. I then got into the new triple clamp. I am planning to redesign the existing speedo enclosure soon, so the mounting of this is not too critical at this stage.

I used 20mm plate to make these triple clamps. The design is a little unconventional but easier to make on the machines I've got available compared to a standard triple clamp design. When I made the triple clamp for the GSX I cleared it with a local motorcycle certifier who liked the design so I'm pretty sure this one will be sweet too.


Designing and programming (and checking it will fit around the existing holes in the scrap piece of plate):
(https://static.wixstatic.com/media/4ae3bf_ec4c5a7f31a149fb92458180dbeed1d1.jpg/v1/fit/w_817,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_ec4c5a7f31a149fb92458180dbeed1d1.jpg)


Machining
(https://static.wixstatic.com/media/4ae3bf_1780a4c31c9d4945ac7e3d200d031247.jpg/v1/fit/w_817,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_1780a4c31c9d4945ac7e3d200d031247.jpg)

Top side finished
(https://static.wixstatic.com/media/4ae3bf_6995c187765943d0aec2c819cf6c066b.jpg/v1/fit/w_613,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_6995c187765943d0aec2c819cf6c066b.jpg)
(Not the best surface finish.. There's some rubbing from the face mill because the plate is so large and not clamped/supported very well. But I think I will bead blast and anodise all of these parts eventually so I'm happy enough)

(https://static.wixstatic.com/media/4ae3bf_59421941a68d463bba08858b1440afd4.jpg/v1/fit/w_817,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_59421941a68d463bba08858b1440afd4.jpg)

Bottom side finished and chopped out
(https://static.wixstatic.com/media/4ae3bf_80e897d8603a40c28f8c29dec8f53028.jpg/v1/fit/w_613,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_80e897d8603a40c28f8c29dec8f53028.jpg)

Milled off the tabs, drilled, counterbored, and tapped the clamp screws. And it fits.
(https://static.wixstatic.com/media/4ae3bf_61318f2cce2b4c5d839f849f5e242843.jpg/v1/fit/w_817,h_613,q_90,usm_0.66_1.00_0.01/4ae3bf_61318f2cce2b4c5d839f849f5e242843.jpg)


My workmate later pointed out, after looking at my CAD that the rounds on the front aren't symmetrical.. So I had to make another set! Not quite finished yet, but they're sitting under my desk waiting for some more attention. Probably nobody would ever notice the asymmetry, I mean even I didn't until he pointed it out. But the difference between a 50mm rad and a 100mm rad is pretty significant when you know it's there!
Title: Re: Ducati Mobster
Post by: NoRiders on Jan 25, 2016, 06:36:09
Awesome final design, hope it works out in reality? Looking forward to the result.

I can now see the radius on each stanchion differs, I'd say the left is out and the right looks...well, right.
Title: Re: Ducati Mobster
Post by: Tune-A-Fish© on Jan 25, 2016, 09:04:04
Nice job, I like the tool marks and would likely anodize just the way they are... natural color as well.

P.S. Can I have the screw ups, I have a Ducatai Monster complete front end they would go nicely on.
Title: Re: Ducati Mobster
Post by: maxBetteridge on Jan 29, 2016, 23:02:39
Almost up to date on the build now :)

I got some clipons and bar-ends from aliexpress and, as with the last set I bought out of asia, was really impressed with the build quality for the price! Had to bore out the bars a little in the lathe to get the mirrors to fit but apart from that these came together well.

(https://static.wixstatic.com/media/4ae3bf_0791143989b74ca5af6d76a41558619d.jpg/v1/fill/w_460,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_0791143989b74ca5af6d76a41558619d.jpg)

Don't have a photo but the clutch and brake MCs fouled on the clipon mounts and caused me issues assembling everything. Basically I couldn't fit the levers far enough up the bars to give enough space for the controls and grips. To get around this I machined some crescent shaped spacers to space the levers/master cylinders out 5mm from the bars. Got some SS cap screws which were 5mm longer and put it all together and I think it is all sweet now.

Took it for a quick ride up and down the driveway with the new bars on and I was amazed at the difference they made! The original riding position on these monsters is awful imo. Being that much lower is probably not great for comfort but is definitely a big improvement in the feel of the bike.



The next big thing I am working on at the moment is repackaging the gauges. I would love to put on a new speedo and trash the existing ones but because the immobiliser is built into the gauges on this bike I think I have to stick with the originals. I want to slim them down as much as possible and simplify the look of them. I have decided to try a composite (basalt fiber) enclosure with an anodised aluminium face with laser engraved markings. (Laser engraving anodised aluminium is a great way to get a professional touch which is actually really cheap and easy to do).

First thing I did was strip down the gauges to figure out what approach to take on remaking this component and measure things up.

I gave it a scan on another 3D scanner:
(https://static.wixstatic.com/media/4ae3bf_adce61f212e74c679bd1c010bba3e046.jpg/v1/fill/w_772,h_579,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_adce61f212e74c679bd1c010bba3e046.jpg)

And started CADing
(https://static.wixstatic.com/media/4ae3bf_d536589659504e1ba96140e6201bc5c4.jpg/v1/fill/w_817,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_d536589659504e1ba96140e6201bc5c4.jpg)

Laser cut a mockup of the faceplate to check everything lined up (it didn't first time around..) and tested the position on the bike
(https://static.wixstatic.com/media/4ae3bf_3e01d8a6f72947408b7d019791051bfc.jpg/v1/fill/w_596,h_596,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_3e01d8a6f72947408b7d019791051bfc.jpg)

I can't shrink down the gauges as much as I had hoped but I will simplify the enclosure and get rid of some of the unnecessary complex shapes. I'm also changing their position quite a lot, lowering them and flattening them. I want them to tuck in behind the triple clamp as much as possible and line up with the top line of the frame. I want to design this component in such a way that I could sell it as a kit in the future so I might take my time making sure it's designed well. But not sure if this will eventuate, just an idea at this stage:)

Pulling the needles / hands off the gauges was the scariest thing I've had to do on this bike so far. I think they must be glued on and you really have to put some serious force into it to get them off! They made a terrifying crack when they finally gave out too! but nothing broke so all good.
Title: Re: Ducati Mobster
Post by: maxBetteridge on Jan 29, 2016, 23:11:09
If anyone can suggest a cheap and easy way I can work around the factory immobiliser and install some different gauges I'd love to hear it!
From what I can tell it's impossible to get around the immobiliser unless I go for an aftermarket ecu which I'd rather not deal with. Does anyone have any experience with this or have any other suggestions for me to look into? 
Title: Re: Ducati Mobster
Post by: Ryan Stecken on Jan 30, 2016, 04:07:31
Great work man.
Title: Re: Ducati Mobster
Post by: coyote13 on Feb 01, 2016, 11:55:46
If anyone can suggest a cheap and easy way I can work around the factory immobiliser and install some different gauges I'd love to hear it!
From what I can tell it's impossible to get around the immobiliser unless I go for an aftermarket ecu which I'd rather not deal with. Does anyone have any experience with this or have any other suggestions for me to look into?

The guys over on www.ducatimonster.org forums might be able to help with your immobilizer.  Think you'd have better luck with that kind of technical question on a more make/model specific forum.
Title: Re: Ducati Mobster
Post by: maxBetteridge on Mar 19, 2016, 18:00:02
Lots of progress in this post.

Right now all my parts are waiting for me to pick up from the anodiser so nothing is assembled just yet.

I am going to wrap my grips in leather the same way I did my GSX. It will be about 20mm wide strip wound around the bars and needs a 'clamp' at each end to stop them from unwinding. I found that on the last one the clamps didn't really do much, they were loose enough to be able to rotate around quite freely but that was enough to hold the ends of the leather where they needed to be. These parts are a bit over-engineered but if I made them much smaller the cap screws I used wouldn't fit. (I made 3 sets of these)

Half way done:
(https://static.wixstatic.com/media/4ae3bf_3dcc41ebff87401ba795bc0fd34cade0.jpg/v1/fill/w_817,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_3dcc41ebff87401ba795bc0fd34cade0.jpg)

Ready for anodising:
(https://static.wixstatic.com/media/4ae3bf_7553ad7636da46568ebbc3902bdd20e1.jpg/v1/fill/w_613,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_7553ad7636da46568ebbc3902bdd20e1.jpg)

I also managed to score 3 full hides of the soft greeny-brown leather in the first pic. Was originally from a closing down handbag factory so it's a LOT nicer than the leather I used on the GSX.

I received my basalt fibre from China:
(https://static.wixstatic.com/media/4ae3bf_4a672617fa0847a9bb63f8af22a8d6bc.jpg/v1/fill/w_460,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_4a672617fa0847a9bb63f8af22a8d6bc.jpg)

And made the mould for my speedo enclosure out of a big block of scrap billet:
(https://static.wixstatic.com/media/4ae3bf_4281720c9da04a87830fa1e3d26cee4d.jpg/v1/fill/w_460,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_4281720c9da04a87830fa1e3d26cee4d.jpg)

(https://static.wixstatic.com/media/4ae3bf_2ce980f6ccc94e508a532e03b2fffa30.jpg/v1/fill/w_613,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_2ce980f6ccc94e508a532e03b2fffa30.jpg)

Prepped the mould with mould release wax then PVA. Laid two layers of basalt and then 3 layers of glass then peel ply.
(https://static.wixstatic.com/media/4ae3bf_c35b13aac7594faebae285312814ab45.jpg/v1/fill/w_460,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_c35b13aac7594faebae285312814ab45.jpg)

(https://static.wixstatic.com/media/4ae3bf_86e490c5da1848bd888b0b628053c9ca.jpg/v1/fill/w_460,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_86e490c5da1848bd888b0b628053c9ca.jpg)

(https://static.wixstatic.com/media/4ae3bf_40c3c12c122a4dcab4b189cd7db02731.jpg/v1/fill/w_460,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_40c3c12c122a4dcab4b189cd7db02731.jpg)
The Basalt darkened up a lot which I was a bit disappointed about but when you get it in the sunlight you still get a distinct gold glow so I'm happy enough.

For the second and third parts I practiced a few tricks with the layup, the two layers of basalt were glued together with spray glue before I did the layup. This helped a lot to keep the fibres nice and square and made it a lot stiffer when putting it in the mould. I also heated up my mould to about 60C and wet the surface out with a thick coat of epoxy and left it for about an hour (upside down so the excess dripped out) so it was tacky before I laid the basalt in and added the rest of the resin. These came out a lot shinier:
(https://static.wixstatic.com/media/4ae3bf_cea0a63605db40cc99fbbc1aec4192d6.jpg/v1/fill/w_345,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_cea0a63605db40cc99fbbc1aec4192d6.jpg)
Title: Re: Ducati Mobster
Post by: maxBetteridge on Mar 19, 2016, 19:25:50
Also made brackets to hold the new speedo and mounted it with some rubber grommets (this is the practice part, haven't cut the nice parts yet)

(http://[instagram]https://static.wixstatic.com/media/4ae3bf_b4b024a5dfa840b888f768a8ca7dd203.jpg/v1/fill/w_460,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_b4b024a5dfa840b888f768a8ca7dd203.jpg)

Made a new faceplate for the speedo from ali plate. This has holes which the backlight shines through to show the markings, the text will be laser cut onto the anodising (but won't light up with the backlight obviously). This part I've asked to be anodised black so the laser cutting will show up well I hope.

(https://static.wixstatic.com/media/4ae3bf_1963265ce3ca4fb49f3f3510cf9bbc23.jpg/v1/fill/w_460,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_1963265ce3ca4fb49f3f3510cf9bbc23.jpg)

This whole speedo project has been developed as I go along. When I started I wasn't planning to have any sort of bezel but my friends talked me into it so.. the back of the bezel:
(https://static.wixstatic.com/media/4ae3bf_0fa9768cc3944940be771fd657e879df.jpg/v1/fill/w_460,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_0fa9768cc3944940be771fd657e879df.jpg)

And the front:
(https://static.wixstatic.com/media/4ae3bf_5087f4ed19d34682a6d107e10cf40c76.jpg/v1/fill/w_460,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_5087f4ed19d34682a6d107e10cf40c76.jpg)
The partially assembled thing:
(https://static.wixstatic.com/media/4ae3bf_072eff68268b495d8e9667f08b879059.jpg/v1/fill/w_613,h_613,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_072eff68268b495d8e9667f08b879059.jpg)

And a quick video of it:
https://www.instagram.com/p/BBwdojeAM9[/instagram]R/


Made some new headlight brackets next.

The clamps to attach to the forks:
(https://static.wixstatic.com/media/4ae3bf_7604f631aa9c491787029c6e00d06408.jpg/v1/fill/w_569,h_569,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_7604f631aa9c491787029c6e00d06408.jpg)

I made some ears out of stainless plate
(https://static.wixstatic.com/media/4ae3bf_b8b828d6f2e548af8142fc20dc12d2db.jpg/v1/fill/w_567,h_569,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_b8b828d6f2e548af8142fc20dc12d2db.jpg)

But after thinking on it for a few days I wasn't quite happy so designed some new ones which played on the shapes and angles of the frame

(https://static.wixstatic.com/media/4ae3bf_9665dd3603b749ac8fcf73fa6933dd4d.jpg/v1/fill/w_569,h_569,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_9665dd3603b749ac8fcf73fa6933dd4d.jpg)

(https://static.wixstatic.com/media/4ae3bf_2f9d13931f8f4c6796c76d5d683fbd93.jpg/v1/fill/w_759,h_569,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_2f9d13931f8f4c6796c76d5d683fbd93.jpg)

(https://static.wixstatic.com/media/4ae3bf_d9ad49995acf4980856614ea2f614dbc.jpg/v1/fill/w_759,h_569,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_d9ad49995acf4980856614ea2f614dbc.jpg)


And finally disassembled everything and spent a few hours sanding to get it ready for anodising
(https://static.wixstatic.com/media/4ae3bf_0cb9ee48e68b4740af473ecb8eeef582.jpg/v1/fill/w_569,h_569,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_0cb9ee48e68b4740af473ecb8eeef582.jpg)

(https://static.wixstatic.com/media/4ae3bf_3f80396ee8b34254a2588953de244179.jpg/v1/fill/w_427,h_569,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_3f80396ee8b34254a2588953de244179.jpg)
Title: Re: Ducati Mobster
Post by: Tune-A-Fish© on Mar 19, 2016, 19:35:12
Sweet headlight brackets... I bought some just like em from China for $19
Title: Re: Ducati Mobster
Post by: Kanticoy on Mar 19, 2016, 20:33:41
Sweet headlight brackets... I bought some just like em from China for $19

Cool story bro. . However this guy just proved that he had the fortitude to forego the Chinese made crap and bucked up, chucked up a chunk of metal, and made his own from scratch just the way he wanted them. You attempted to place the label of fool on the guy but I don't think it reached its intended target in this case.
Title: Re: Ducati Mobster
Post by: Tune-A-Fish© on Mar 19, 2016, 20:38:09
Cool story bro. . However this guy just proved that he had the fortitude to forego the Chinese made crap and bucked up, chucked up a chunk of metal, and made his own from scratch just the way he wanted them. You attempted to place the label of fool on the guy but I don't think it reached its intended target in this case.

No shit. I can read and see that this is some high grade shit... He likely see's the humor.

Crap? it's the same in the end with slightly lower quality... my headlight wont know unless i tell it SHHHH!
Title: Re: Ducati Mobster
Post by: trek97 on Mar 19, 2016, 20:38:19
Dude!  The stuff you are doing is freakin cool.
Title: Re: Ducati Mobster
Post by: Kanticoy on Mar 19, 2016, 20:43:20

No shit. I can read and see that this is some high grade shit... He likely see's the humor.

Crap? it's the same in the end with slightly lower quality... my headlight wont know unless i tell it SHHHH!

Point is let's not assume that everybody gets this fucked up sense of humor where we insult them and hope that they get the "joke" while the rest of the world looks in and sees somebody acting like a tool. I've used Chinese parts. But I sure as hell appreciate epic work like is doing. As far as being mostly the same? That's debatable. This is pro grade quality. Dude knows his way around a machine shop, obviously, and there will be nothing quite like it when he's done because he put in the effort. But in the end, the fact that he made it from a raw chunk of metal into what he wanted....that sets it apart.

MaxB, friggin killer dude.


Sent from my iPhone using Tapatalk
Title: Re: Ducati Mobster
Post by: maxBetteridge on Mar 19, 2016, 22:04:40
Cheers guys, you're both totally right (except the part where you imply I know what I'm doing). I am a big fan of cheap Chinese crap but at the moment I'm just playing to my strengths and CNCing some eye catching bits.
The way I see it I just saved myself $19 ;)
Title: Re: Ducati Mobster
Post by: Tune-A-Fish© on Mar 19, 2016, 22:07:52
Rock on, Next time make two of each and sell it here, I have the same chassis and would love some of those parts for the front end.

Oh wait! :)
Title: Re: Ducati Mobster
Post by: 2digit-2t on Mar 19, 2016, 22:09:45
jeebus.  wish i had access to the stuff you do.  jelly
Title: Re: Ducati Mobster
Post by: brad black on Mar 19, 2016, 23:40:02
If anyone can suggest a cheap and easy way I can work around the factory immobiliser and install some different gauges I'd love to hear it!
From what I can tell it's impossible to get around the immobiliser unless I go for an aftermarket ecu which I'd rather not deal with. Does anyone have any experience with this or have any other suggestions for me to look into?

just reflash the ecu to remove the immo function.  simple.  no need for dash or coded key.
Title: Re: Ducati Mobster
Post by: brad black on Mar 19, 2016, 23:46:02
headlight brackets are very cool.

ime, mufflers are mufflers.  they all sound the same pretty much.  without mufflers, or with the really short boom tube style crap, it'll just be blub blub loud like a harley.

one of my customers has a 400 with the carbon round danmotos and they sound much like anything else to me.  maybe a bit louder.
Title: Re: Ducati Mobster
Post by: brad black on Mar 20, 2016, 00:18:22
Sweet headlight brackets... I bought some just like em from China for $19

link?
Title: Re: Ducati Mobster
Post by: Sonreir on Mar 20, 2016, 01:21:21
As a fellow Monster rider, I can't not follow this one.
Title: Re: Ducati Mobster
Post by: jag767 on Mar 20, 2016, 08:58:49
Threads like these remind me how little I know.
Title: Re: Ducati Mobster
Post by: Tune-A-Fish© on Mar 20, 2016, 09:38:20
Threads like these remind me how little I know.

About tool making or life in general  ;D The man is very good at his craft.

Maybe some basic lesson in cad is in order here... As i see it today, the art is in the design and the parts are the result of a 3D design drawing executed in automation by the machines. What we have here is a skilled cad operator and a very fine offering of machines and materials, but not rocket science.

Don't sell yourself short, this very competent tool maker, but may not be as good at baking a cake as my wife and I think that is equally important... especially if it's my sons birthday  ;D
Title: Re: Ducati Mobster
Post by: jag767 on Mar 20, 2016, 12:10:41
About tool making or life in general  ;D The man is very good at his craft.

Maybe some basic lesson in cad is in order here... As i see it today, the art is in the design and the parts are the result of a 3D design drawing executed in automation by the machines. What we have here is a skilled cad operator and a very fine offering of machines and materials, but not rocket science.

Don't sell yourself short, this very competent tool maker, but may not be as good at baking a cake as my wife and I think that is equally important... especially if it's my sons birthday  ;D

Thats deep man  :o
Title: Re: Ducati Mobster
Post by: maxBetteridge on Apr 04, 2016, 21:19:50
Got my anodised parts back and was stoked wit the results:

(https://static.wixstatic.com/media/4ae3bf_39767d537ae24e00b2cd2648e32740a3.jpg/v1/fill/w_943,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_39767d537ae24e00b2cd2648e32740a3.jpg)



While I was waiting to get the anodising done I designed the speedo backplate engraving. Once I got the parts back I did a few practice passes and then did the final pieces and again, stoked with the results:

(https://static.wixstatic.com/media/4ae3bf_ea6a6882bc1b49b98a2855e2b27b772c.jpg/v1/fill/w_707,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_ea6a6882bc1b49b98a2855e2b27b772c.jpg)

(https://static.wixstatic.com/media/4ae3bf_bf2491bc54664e02be32da92b7ae9200.jpg/v1/fill/w_943,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_bf2491bc54664e02be32da92b7ae9200.jpg)

Laser cut some 2mm acrylic for the lens and used a Woodruff cutter to cut some recesses in the bezel so the acrylic snapped into place. Was planning to use some UV cure superglue to help hold the acrylic in the bezel but the fit was so tight (and the snap so satisfying!) that I don't think it even needs it:

(https://static.wixstatic.com/media/4ae3bf_96b71ab829684cd398aff19b025b5c05.jpg/v1/fill/w_707,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_96b71ab829684cd398aff19b025b5c05.jpg)

I proudly showed the photos of my progress to my girlfriend and the first thing she said was 'you're going to change the green lights right'. I laughed and immediately said no way that's too hard... But after thinking about it for a few days I realised she was right..

Half way done replacing the green leds with white ones:
(https://static.wixstatic.com/media/4ae3bf_d43efe2084cb43d49948e9f51cc03b68.jpg/v1/fill/w_707,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_d43efe2084cb43d49948e9f51cc03b68.jpg)

(https://static.wixstatic.com/media/4ae3bf_0aafe34bd82249f79b27724e6a323745.jpg/v1/fill/w_1289,h_967,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_0aafe34bd82249f79b27724e6a323745.jpg)

(https://static.wixstatic.com/media/4ae3bf_601a6f2df01b4f0ebb95fff44bd8ffeb.jpg/v1/fill/w_725,h_967,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_601a6f2df01b4f0ebb95fff44bd8ffeb.jpg)
I don't really want the white lights to be a feature but hopefully they will just complement the rest of the build and not stand out like the green ones.

Fitted the laser-cut leather grips last night too with the CNC'd clamps. I used double-sided tape on the bars to help hold the leather steady. I soaked the leather overnight to stretch it and fitted them while it was still wet so that it will shrink as it dries. The double-sided tape didn't hold onto the wet leather very well but I'm hoping that as it dries the adhesive on the tape will eventually stick and still do its job. As of this morning the leather feels quite dry and seems to have tightened up around the bars quite nicely.

(https://static.wixstatic.com/media/4ae3bf_11130d5961ec4e2991f9a4a0eb60707d.jpg/v1/fill/w_725,h_967,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_11130d5961ec4e2991f9a4a0eb60707d.jpg)

(https://static.wixstatic.com/media/4ae3bf_17544181e77141588ab996dda4bee7df.jpg/v1/fill/w_725,h_967,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_17544181e77141588ab996dda4bee7df.jpg)

And finally, turned up some acetal adapters for the new uni filters.
(https://static.wixstatic.com/media/4ae3bf_d8f4becea44b49bfb2fd64284aed7eeb.jpg/v1/fill/w_725,h_967,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_d8f4becea44b49bfb2fd64284aed7eeb.jpg)
Fitting these and remounting all the components that attach to the stock airbox and crankcase breather etc will be the next big task.
Title: Re: Ducati Mobster
Post by: DesmoBro on Apr 04, 2016, 21:42:21
Mmmmmmmmmmmm
Title: Re: Ducati Mobster
Post by: farmer92 on Apr 04, 2016, 21:55:46

Mmmmmmmmmmmm
+20
Title: Re: Ducati Mobster
Post by: JustinLonghorn on Apr 05, 2016, 08:34:03
I am in.
Title: Re: Ducati Mobster
Post by: Ryan Stecken on Apr 05, 2016, 12:39:43
Those parts are the popes slippers.
Title: Re: Ducati Mobster
Post by: maxBetteridge on May 04, 2016, 02:12:43
Just a few updates:

Fitted my pod filters (and I'm happy with the clearance for the new tank):
(https://static.wixstatic.com/media/4ae3bf_45e4b2ebcf404d7d91b1821446a832f2.jpg/v1/fill/w_943,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_45e4b2ebcf404d7d91b1821446a832f2.jpg)



Since the front coil was attached to the air box I had to make a new bracket for that, I also wanted to relocate the ECU to in front of the battery rather than beside it and same with the relays. The ambient air pressure sensor was also tucked in behind the headlight so I shifted that onto the new bracket too:
(https://static.wixstatic.com/media/4ae3bf_3c92b7252efa42f1a5d3333617a43ee1.jpg/v1/fill/w_695,h_926,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_3c92b7252efa42f1a5d3333617a43ee1.jpg)

(https://static.wixstatic.com/media/4ae3bf_bcbe75de68964c678ac9f222b6174d01.jpg/v1/fill/w_707,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_bcbe75de68964c678ac9f222b6174d01.jpg)



I made another bracket at the back for the rear coil and reg/rec and got rid of the oil breather catch-can:
(https://static.wixstatic.com/media/4ae3bf_f280f803bf0e422f99110dc19f47ee51.jpg/v1/fill/w_695,h_926,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_f280f803bf0e422f99110dc19f47ee51.jpg)

(https://static.wixstatic.com/media/4ae3bf_0619acd9ca2e41148e3b108de21e5262.jpg/v1/fill/w_707,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_0619acd9ca2e41148e3b108de21e5262.jpg)



Been a lot of loom rerouting to achieve all of this and I've tried to hide the loom as much as possible. There's still a lot more rerouting required but will get to that eventually..


Got some new front indicators and wired them up. Still got to tweak this wiring a bit because it's a bit weak for my liking at the moment.
(https://static.wixstatic.com/media/4ae3bf_b94b63086770480ba8451cf446664b6b.jpg/v1/fill/w_707,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_b94b63086770480ba8451cf446664b6b.jpg)

(https://static.wixstatic.com/media/4ae3bf_e83c460f5ec94c2db2e0104230f7578a.jpg/v1/fill/w_707,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_e83c460f5ec94c2db2e0104230f7578a.jpg)



I have been planning how to make the mould for the belly pan next and thinking about the approach I will use for the seat and tank too. I had the belly pan tool planned and ready to build before I realised I wanted to add a roll-over on the top edge to try and make it look a bit nicer. Adding the roll-over means I can't just cut the edge of the part until it fits (which was my initial plan), I have to actually design it to fit perfectly before I mould it. To do this I needed a better 3d scan of that part of the bike. And while I had my scanner out I took the opportunity to get a better scan of the top of the bike with the tank off and with the new pods. This is the new scan with the roll-over edge on the belly pan (the seat and tank still need some work):
(https://static.wixstatic.com/media/4ae3bf_2e512b5a18334285af0ddacb4c8aafa4.jpg/v1/fill/w_992,h_624,al_c,q_90/4ae3bf_2e512b5a18334285af0ddacb4c8aafa4.jpg)


This was the initial plan for the belly pan mould. 16 layers of 9mm MDF (per side), covered in a layer of polyester bog and CNC machined back to a smooth A-surface. This needs to be redesigned now for the roll-over but once it is done I will use this as a test/experiment for making the seat and tank moulds using the same process
(https://static.wixstatic.com/media/4ae3bf_e4f7c66b53dc4a66a65937be0bfc74f4.png/v1/fill/w_920,h_798,al_c/4ae3bf_e4f7c66b53dc4a66a65937be0bfc74f4.png)


If you'd like to see more photos and some of the other projects I'm working on follow me on instagram https://www.instagram.com/max_betteridge_design/
or check out my website www.maxbetteridgedesign.com
Title: Re: Ducati Mobster
Post by: tenshots1 on May 04, 2016, 11:30:54
Coolest thread ive looked through in a long time.  Parts look awesome!  I have to go buy a CNC now.
Title: Re: Ducati Mobster
Post by: Tune-A-Fish© on May 04, 2016, 11:36:13
Coolest thread ive looked through in a long time.  Parts look awesome!  I have to go buy a CNC now.

I wish it were that simple  ::)
Title: Re: Ducati Mobster
Post by: tenshots1 on May 04, 2016, 11:38:28
I wish it were that simple  ::)

Haha agreed! It'd probably take me a year to figure out how to make a CNC cut a triangle.
Title: Re: Ducati Mobster
Post by: cosworth on May 04, 2016, 15:55:59
As a fellow Monster rider, I can't not follow this one.

Love my 620ie Dark. Subscribed as well.
Title: Re: Ducati Mobster
Post by: cosworth on May 04, 2016, 16:00:10
If the tank, seat, and gunt pan were a kit...
Title: Re: Ducati Mobster
Post by: advCo on May 04, 2016, 17:48:24
Making some awesome stuff here man. I havent had access to a CNC or laser rig in a few years now, its killing me  ;D. Just a waterjet but pretty limited to what you can do on that.

Not that I don't love making things the old fashioned way, but when I work most of the day in CAD/3D its nice to just be able to hit send and have a perfect part at the end of the day.

Will definitely be checking in on this. Keep it up mate.
Title: Re: Ducati Mobster
Post by: JPM on May 07, 2016, 01:17:21
Loving all the custom work on this.  That's what really sets some bikes apart in my opinion.
Title: Re: Ducati Mobster
Post by: 45exmayor on May 07, 2016, 09:04:13
looking at the plate you made for the coil regulator i notced you left the regulator on top under the seat.  do you have room to put it under the plate so it gets better air flow and stays cooler.  when i had my monster i did that and never had a problem with it.
Title: Re: Ducati Mobster
Post by: maxBetteridge on May 08, 2016, 06:31:16
looking at the plate you made for the coil regulator i notced you left the regulator on top under the seat.  do you have room to put it under the plate so it gets better air flow and stays cooler.  when i had my monster i did that and never had a problem with it.

Thanks for the tip. Is overheating a problem with monster regulators? It was originally on the top side like this and I think the changes I'm planning to make to the seat will only improve the air flow so I'm inclined to leave it as is and see how It goes.
I'll have another think about it though.
Title: Re: Ducati Mobster
Post by: maxBetteridge on Jun 20, 2016, 04:52:34
Been quite a busy month on the Ducati

I spent a bit of time redesigning the belly pan mould to include the rollover on the top edge and also finished up the tail mould design. This is what they look like laid out for lasercutting
(https://static.wixstatic.com/media/4ae3bf_9c2e662046924233a47f5f98cef47b27~mv2.jpg/v1/fill/w_759,h_742,al_c,q_90/4ae3bf_9c2e662046924233a47f5f98cef47b27~mv2.jpg)

They took two entire sheets of 9mm MDF but here's the result:
(https://static.wixstatic.com/media/4ae3bf_d6bea35c1e7c4d42ae204d861d169dc2~mv2.jpg/v1/fill/w_595,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_d6bea35c1e7c4d42ae204d861d169dc2~mv2.jpg)

I can't figure out how to embed an instagram video on this forum but I made a quick timelapse of the laser cutting :)
http://www.pikore.com/m/1248459941728014067_43020050 (http://www.pikore.com/m/1248459941728014067_43020050)

All the layers were stacked and glued and then given a brush with polyester to keep moisture out. They were then given a thick covering in bog and machined in the CNC. I designed the MDF to be at least 2mm below the A-surface but eventually changed my mind and did my finishing cut 1mm deeper than intended because I didn't build up enough bog at the outset. I also allowed 9.3mm between each layer of MDF to allow for a bit of glue thickness but in the end I realised 0.3mm excess was way too much.. Hence why you can see stripes of MDF showing through near the deepest parts on the mould. 

(https://static.wixstatic.com/media/4ae3bf_4f761af183ea40c09dd19377f32b3561~mv2.jpg/v1/fill/w_595,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_4f761af183ea40c09dd19377f32b3561~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_b3ad61cafa154a3880e23294fb34ef4b~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_b3ad61cafa154a3880e23294fb34ef4b~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_03bf26c7d34940e68894e40aeb86e76d~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_03bf26c7d34940e68894e40aeb86e76d~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_cb494c8efaea40cd93e2e8cc614c1e02~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_cb494c8efaea40cd93e2e8cc614c1e02~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_9464e8baa436458186343848e8927237~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_9464e8baa436458186343848e8927237~mv2.jpg)

After I got the belly pan halfway done I decided it made more sense to start with the tail mould because being a smaller part and only a single part tool (not split down the center) it'd be easier to start with that one. Same story with this mould except on top of allowing too much thickness for glue I also failed to clamp the mould squarely in the CNC so the MDF shows through quite a lot more on this mould.
(https://static.wixstatic.com/media/4ae3bf_4664c1cdf1414d999d114c87355d3154~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_4664c1cdf1414d999d114c87355d3154~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_63ddbfcaa4d94f8781732d3c7e587a4d~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_63ddbfcaa4d94f8781732d3c7e587a4d~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_3cb0c4b73c2b4591820d194818b2bedb~mv2_d_1200_1200_s_2.jpg/v1/fill/w_793,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_3cb0c4b73c2b4591820d194818b2bedb~mv2_d_1200_1200_s_2.jpg)

You wouldn't believe the hours of filling and sanding to get to this point:
(https://static.wixstatic.com/media/4ae3bf_6967552e7e5f4fadbfe8c5f24007dfcd~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_6967552e7e5f4fadbfe8c5f24007dfcd~mv2.jpg)

And then the extra hours to sand the gel coat:
(https://static.wixstatic.com/media/4ae3bf_330fda8ff8264a8a8c6fe7678cde7dc9~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_330fda8ff8264a8a8c6fe7678cde7dc9~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_ea7f6d6dc223418e998c4cfab23066d3~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_ea7f6d6dc223418e998c4cfab23066d3~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_60903fc62a62482cbbc0278767e01baf~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_60903fc62a62482cbbc0278767e01baf~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_fb1ddb00554f473db6a9a1d3a4f37eac~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_fb1ddb00554f473db6a9a1d3a4f37eac~mv2.jpg)
Came out all good in the end though. There's still a lot of imperfections in the mould but considering I'm only going to be pulling a few parts from this mould I figure it'll take less time to just sand the imperfections out of the parts rather than get the tool perfect.

Having the tool CADed was great because I could flatten out my A-surfaces and create patterns to cut the basalt and glass fibre with to fit the mould perfectly:

(https://static.wixstatic.com/media/4ae3bf_bf61a4a2cd734d7185bf137a131c6e43~mv2.jpg/v1/fill/w_1200,h_618,al_c,q_90/4ae3bf_bf61a4a2cd734d7185bf137a131c6e43~mv2.jpg)

I had read that the laser cutter could cut basalt fibre but until now I hadn't tried it. It works mint! Basalt is quite similar to carbon fibre to cut and you can make a mess of it with scissors. Laser cutting gives you a perfect cut edge and even has the added benefit that it melts and fuses the fibres at the edges so they hold their shape beautifully and don't fray or unravel easily. I just did a small test with basalt, these pics are just cutting and test fitting glass mat:

(https://static.wixstatic.com/media/4ae3bf_c1b3523615f9456fb0ba48ef80dfb3b9~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_c1b3523615f9456fb0ba48ef80dfb3b9~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_52c6f06dfa964cf882eaf8eb1da8ee70~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_52c6f06dfa964cf882eaf8eb1da8ee70~mv2.jpg)

I did the same thing to cut my core mat which will give the tail a bit of structure (why not put some go-faster-holes in there when you've got a laser cutter)

(https://static.wixstatic.com/media/4ae3bf_f49cb6ea1d7e471091d4b7408e67e0ea~mv2.jpg/v1/fill/w_1057,h_793,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_f49cb6ea1d7e471091d4b7408e67e0ea~mv2.jpg)



And another timelapse showing the CNC and some of the prep work :D
http://www.pikore.com/m/1252743608285581288_43020050 (http://www.pikore.com/m/1252743608285581288_43020050)



Right now I'm waiting to borrow a vacuum pump from my workmate to finish the tail. In the meantime I finished working on the tank CAD and started on the tank upper. I have modified the tank CAD to bring the front of the tank forward and wrap around the key/ignition barrel. This makes the parts trickier and bigger but I think I would've regretted it if I'd have left it the way it was because it would've just looked lazy!
I decided to try a more traditional method for this part. It's almost too big to fit in the CNC and I think this way will work out cheaper and will hopefully be a bit less prep work (at the cost of some accuracy). I am going to laser cut a honeycomb structure and fill the gaps with expanding foam, sand it, bog it, and sand it to make the plugs (one for the LHS and one for the RHS, I will build and prep them together but they will be two separate plugs to make the mould making easy).

(https://static.wixstatic.com/media/4ae3bf_bcc4dc5fa5fd45779f8748b7d34de7d0~mv2.jpg/v1/fill/w_1200,h_574,al_c,q_90/4ae3bf_bcc4dc5fa5fd45779f8748b7d34de7d0~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_9c6dcaddda6e4bc4a4eb1ea7db6e1576~mv2.jpg/v1/fill/w_1200,h_683,al_c,q_90/4ae3bf_9c6dcaddda6e4bc4a4eb1ea7db6e1576~mv2.jpg)



Lastly I had some trouble finding a crankcase breather which would fit so I bought a smaller one and machined the coupling out to make it fit
(https://static.wixstatic.com/media/4ae3bf_934aec6c291844b9a1ab03fd5ff4b624~mv2.jpg/v1/fill/w_1097,h_776,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_934aec6c291844b9a1ab03fd5ff4b624~mv2.jpg)


I'm ambitiously aiming to get this bike ride-able for the Distinguished Gentleman's Ride 2016 which is just over 3 months away.. Let's see how we go....   




If anyone's still reading don't forget to follow along on instagram @max_betteridge_design
 https://www.instagram.com/max_betteridge_design/ (https://www.instagram.com/max_betteridge_design/)
Title: Re: Ducati Mobster
Post by: BigNickel on Jun 20, 2016, 07:53:14
Wow, some truly great custom work here. Can't wait to see more!
Title: Re: Ducati Mobster
Post by: maxBetteridge on Jun 28, 2016, 01:56:38
I've just made a few tail parts in the last few days.

Here's another quick timelapse of the prep and layup:
http://www.pikore.com/m/1279994575313705878_43020050

The prep:
(https://static.wixstatic.com/media/4ae3bf_af3a671928ea412889bdade71418ccf4~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_af3a671928ea412889bdade71418ccf4~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_16bf7919f526435daaaab2b652b3cfc9~mv2_d_1200_1200_s_2.jpg/v1/fill/w_943,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_16bf7919f526435daaaab2b652b3cfc9~mv2_d_1200_1200_s_2.jpg)

The first part:
(https://static.wixstatic.com/media/4ae3bf_de19dd405e1142bbb99a0d60581e3020~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_de19dd405e1142bbb99a0d60581e3020~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_7ec85b9b4db74df7a18b9303bc065c4f~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_7ec85b9b4db74df7a18b9303bc065c4f~mv2.jpg)

This part has two layers of basalt, 4 layers of glass (plus scraps) and a 3mm foam core mat. It came out really well except was a bitch to demould; took me about an hour and a half and all of my strength just to pull it out of the mould haha. I used about 8 coats of release wax and a coat of release PVA. I realised that the PVA layer was too thin which was probably one of my biggest issues. I also struggled because I could wedge in pieces of plastic sheet around the edges and release it bit by bit around the edge, but I had no way to wedge any plastic in to release any of the surfaces around the bulge in the centre. Also the bleeder sheet I used was not porous enough and I used too much resin so the part was very resin-rich making it heavier than necessary and the weave didn't show through as well as it should.

So I made a second part. I put on three more coats of wax and then two coats of PVA and put the PVA on much thicker. I put much larger holes in my bleeder and used 15% less resin. Here is the part fresh out of the mould:

(https://static.wixstatic.com/media/4ae3bf_627701f4ddfc4bf3b1d2dd7f75792387~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_627701f4ddfc4bf3b1d2dd7f75792387~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_4ecec1b4220d4ad9bcf3d54600b007a0~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_4ecec1b4220d4ad9bcf3d54600b007a0~mv2.jpg)

And the underside showing the core mat:
(https://static.wixstatic.com/media/4ae3bf_3a46ea7a890c4b5bb42a27da7518661a~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_3a46ea7a890c4b5bb42a27da7518661a~mv2.jpg)

Looks mean in the sunlight so I'm happy :D
(https://static.wixstatic.com/media/4ae3bf_2c2219024f704eef876c6463a03c31d5~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_2c2219024f704eef876c6463a03c31d5~mv2.jpg)


Currently still working on my belly pan mould and the plug for the tank upper. I can also start thinking about the seat cushion and stitching something up.
Falling behind schedule a bit... But I'll keep pushing on.
Title: Re: Ducati Mobster
Post by: mazza on Jun 29, 2016, 04:22:43
Bloody hell......amazing stuff. Got the same time frame as you. Missed last year's gentleman's bike ride, not going to miss this year's!!!
Title: Re: Ducati Mobster
Post by: coyote13 on Jun 29, 2016, 11:42:47
This is brilliant man, really impressive attention to detail.


Think I said that a few pages back but it bears repeating!
Title: Re: Ducati Mobster
Post by: 1fasgsxr on Jun 29, 2016, 13:24:04
Nice !!
Title: Re: Ducati Mobster
Post by: maxBetteridge on Aug 03, 2016, 21:42:28
Ok, just over a month since my last post. Looking less and less likely that I'm going to hit my September deadline.. but here's where we're at:

I've been building my tank plug (/form/pattern. Most people think I'm talking about the filler cap when I talk about the 'tank plug'). It's laser cut mdf, filled with expanding foam, one layer of glass, and body filler.

(https://static.wixstatic.com/media/4ae3bf_62b035f602e941079428a85cc09aade2~mv2_d_1200_1200_s_2.jpg/v1/fill/w_943,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_62b035f602e941079428a85cc09aade2~mv2_d_1200_1200_s_2.jpg)


Mocked up with the tail:
(https://static.wixstatic.com/media/4ae3bf_2e35f9a6768444f7b4d24b7080759918~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_2e35f9a6768444f7b4d24b7080759918~mv2.jpg)


(https://static.wixstatic.com/media/4ae3bf_9743ec8709a5479c878eb8fc06233f30~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_9743ec8709a5479c878eb8fc06233f30~mv2.jpg)


I deliberately made the mdf stick out from the serface of the part in CAD so that I could sand it back like this to get to its true shape. This was probably not a great idea in retrospect; should've made the edge of the MDF sit on and below the surface because sanding it back introduced a bit of guesswork:

(https://static.wixstatic.com/media/4ae3bf_8c30f0959fe24b068ee12ccfc697fa74~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_8c30f0959fe24b068ee12ccfc697fa74~mv2.jpg)


Next step was filling the skeleton with expanding foam and cutting it back to shape. Messy but satisfying:
(https://static.wixstatic.com/media/4ae3bf_3359144f5f524cac802edda968727c03~mv2_d_1200_1200_s_2.jpg/v1/fill/w_943,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_3359144f5f524cac802edda968727c03~mv2_d_1200_1200_s_2.jpg)


Because I was planning to use bog as the top layer and sand it back to the final shape I needed to add a layer of fibreglass on top of the foam. The idea of this was to create a hard protective layer for sanding. I didn't want to sand the bog and sand through to the foam because the foam is so much softer than the bog it would sand away much faster. The glass was intended to prevent that. I used one layer of 200gsm glass which wasn't really enough, two layers would've been much better. I also used polyester resin; because bog is polyester based this made a strong base for the bog to bond to:

(https://static.wixstatic.com/media/4ae3bf_a2b118a9393f42b48db8142bd9769d28~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_a2b118a9393f42b48db8142bd9769d28~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_6fc4efc6f6ee4baf914fa76c00b2e810~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_6fc4efc6f6ee4baf914fa76c00b2e810~mv2.jpg)

Adding the bog:
(https://static.wixstatic.com/media/4ae3bf_7dc6833a09ac4574a2cabb5237d586e4~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_7dc6833a09ac4574a2cabb5237d586e4~mv2.jpg)

And sanding it back:
(https://static.wixstatic.com/media/4ae3bf_e94b218e79bf4e1fb5e30cbe19ece0ee~mv2_d_1200_1200_s_2.jpg/v1/fill/w_943,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_e94b218e79bf4e1fb5e30cbe19ece0ee~mv2_d_1200_1200_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_f6a6196487d24dfa8ab423431c75ce04~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_f6a6196487d24dfa8ab423431c75ce04~mv2.jpg)

Many many hours summarised in two photographs^^
There's still more work to do on this plug. I think this will be the next thing I work on.



Next is the seat cushion. First I started the fibreglass seat cushion base. This is to attach the foam and upholstery to and will locate into and bolt through the tail part. I used the same mould that I made the tail part with. This was always the plan but actually worked out a whole lot better than I imagined :)

Laying up the cushion base (no vacuum bag for this layup):
(https://static.wixstatic.com/media/4ae3bf_7cdf5265c9b845a1a82b3d7cb3b1d892~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_7cdf5265c9b845a1a82b3d7cb3b1d892~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_a3e7e3a6c49d4159bb28a6f11e3077c5~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_a3e7e3a6c49d4159bb28a6f11e3077c5~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_f275714069794c8ab15e1edc457c1f48~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_f275714069794c8ab15e1edc457c1f48~mv2.jpg)


I needed a stud to stick out through the bottom of the seat cushion to bolt the cushion to the tail part:
(https://static.wixstatic.com/media/4ae3bf_b888ac27eca04f648674756da7c1c34e~mv2.jpg/v1/fill/w_1181,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_b888ac27eca04f648674756da7c1c34e~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_22a2b5586cfe4f1e8affb5312622d0f4~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_22a2b5586cfe4f1e8affb5312622d0f4~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_b6fca07fe0b141fa91da3bfe35fc0676~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_b6fca07fe0b141fa91da3bfe35fc0676~mv2.jpg)

For the foam I hot glued layers of an old yoga mat to the fibreglass and linished it back to make the final shape:
(https://static.wixstatic.com/media/4ae3bf_4433eba13f16421db0c5260a50c49cf3~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_4433eba13f16421db0c5260a50c49cf3~mv2.jpg)

I added a lip around the perimeter of the seat base so that the leather will stretch around this and the fasteners will sit below the level of the lip. This is something I copied from the DeBolex ducati build. I didn't do this on my last build and it made a HUGE difference! The lip itself is just two layers of core mat soaked with resin.

(https://static.wixstatic.com/media/4ae3bf_ad5410212a3741f582b3c995c7244818~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_ad5410212a3741f582b3c995c7244818~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_8fff5b4f0df04d5888859318d3928ab7~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_8fff5b4f0df04d5888859318d3928ab7~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_4796b4898651483bb3ccf887b5d17421~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_4796b4898651483bb3ccf887b5d17421~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_dcfc85a0635348bb860b64c07ec2545f~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_dcfc85a0635348bb860b64c07ec2545f~mv2.jpg)


On to the upholstery. I started out with paper patterns to get the rough shape. Then I scanned it and CADed over the template to get the shape for the leather. I made one test cover with fabric, then a test one from leather, then a final one in leather.

Laser cutting the leather:
(https://static.wixstatic.com/media/4ae3bf_520338064f714c03b29ace2d7db01f22~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_520338064f714c03b29ace2d7db01f22~mv2.jpg)

Stitching the first leather test:
(https://static.wixstatic.com/media/4ae3bf_03f146c8001f46648c785bad287fb7a6~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_03f146c8001f46648c785bad287fb7a6~mv2.jpg)

Test fitting:
(https://static.wixstatic.com/media/4ae3bf_4064a99bc3f04537b0f258bee99250ab~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_4064a99bc3f04537b0f258bee99250ab~mv2.jpg)

There were a few things wrong with the test piece so made a few changes before stitching up the final seat cover:
(https://static.wixstatic.com/media/4ae3bf_794b22542862406fb4bf00e314a71ec2~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_794b22542862406fb4bf00e314a71ec2~mv2.jpg)

We got a waterjet cutter at work so I decided to make some custom washers for attaching the upholstery. Don't ask me why... Again copying the DeBolex bike:
(https://static.wixstatic.com/media/4ae3bf_40528f3d910c4f028b48a32f014af1f4~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_40528f3d910c4f028b48a32f014af1f4~mv2.jpg)

Note the fasteners sitting sub-flush:
(https://static.wixstatic.com/media/4ae3bf_7c197571176f4335a9710bc0e24c8580~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_7c197571176f4335a9710bc0e24c8580~mv2.jpg)

Fitted and finished:
(https://static.wixstatic.com/media/4ae3bf_1704c76ae8ee4d348370432fcd5ea7f5~mv2.jpg/v1/fill/w_1200,h_899,al_c,q_90/4ae3bf_1704c76ae8ee4d348370432fcd5ea7f5~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_e825d2e9b62d46b7a94dee0db3103628~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_e825d2e9b62d46b7a94dee0db3103628~mv2.jpg)


Also made a captive nut ring to screw my fuel filler cap into when I fit it to the tank. These were cut on the waterjet cutter and I'll tap the holes soon:
(https://static.wixstatic.com/media/4ae3bf_241c0ae387154463a2f4a25dc5af1c48~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_241c0ae387154463a2f4a25dc5af1c48~mv2.jpg)


Next is the belly pan. 2 layers of basalt fibre and three layer of glass with a foam core. Took almost an entire day just to prep the materials and mould this part >.< Not to mention prepping the mould which took days and days...:
(https://static.wixstatic.com/media/4ae3bf_9ca2a321dc284f6a88276968fd0795e9~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_9ca2a321dc284f6a88276968fd0795e9~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_2295b2491a0b43b88156114a247190bb~mv2.jpg/v1/fill/w_707,h_943,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_2295b2491a0b43b88156114a247190bb~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_df1947472b724d55ac5c89a5658ec438~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_df1947472b724d55ac5c89a5658ec438~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_c377b6adf079470ca8e9127bcdc77319~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_c377b6adf079470ca8e9127bcdc77319~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_7d1279b7826f4a90a51943291fe0ef33~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_7d1279b7826f4a90a51943291fe0ef33~mv2.jpg)


Lastly a few mockups with the parts on the bike (all the parts still need trimming and finishing):
(https://static.wixstatic.com/media/4ae3bf_b238134e0a7e4d6db020f6941768c94c~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_b238134e0a7e4d6db020f6941768c94c~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_ff6742d76eee4f179bd4db7e6f57d3c6~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_ff6742d76eee4f179bd4db7e6f57d3c6~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_49caa66ab2744a35972350b2123582ac~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_49caa66ab2744a35972350b2123582ac~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_a44da3fcd8ff4611831c1b726a6ea529~mv2.jpg/v1/fill/w_1200,h_900,al_c,q_90/4ae3bf_a44da3fcd8ff4611831c1b726a6ea529~mv2.jpg)


Pretty stoked with how all the components are coming together so far :D

If anyone's still reading find me on instagram @max_betteridge_design
https://www.instagram.com/max_betteridge_design/

And check out the build on my website:
http://www.maxbetteridgedesign.com/building-the-ducati-cafe-racer

Title: Re: Ducati Mobster
Post by: Rustyhama on Aug 04, 2016, 08:37:05
Yowsers Max! What sort of custom moto work shop have you got there fella? Most of us kiwis on these forums do it out in the garage with whatever's lying around like Munro and Britten. I've never seen anything like that sort of tech going into a custom build before. Very cool stuff! It must be awesome having access to all that sweet kit and you have some talent and skill to put it all together too. Looks like I'll miss the gentleman's ride this year too. I get my license back in October after too much twisty wristy on my Z750. Keen to follow this through.

Sent from my SM-G935F using Tapatalk
Title: Re: Ducati Mobster
Post by: 3DogNate on Aug 05, 2016, 17:32:42
Amazing looking build... Two thumbs up!!!
Title: Re: Ducati Mobster
Post by: johnu on Aug 05, 2016, 21:53:59
Wow awesome work, love your attention to detail and the fact that you are using all the modern tech that you have available.  Not my style but I will be watching this thread because I can learn and me amazed at modern tech.  I'm an old skool fabricator with modern ideas but admire I your skills for sure :)
Title: Re: Ducati Mobster
Post by: Pan1cReaper on Aug 10, 2016, 16:29:02
Ive always admired something about the combo of nerd tech and gear head. Pretty awesome what you can do with this stuff. Coming together nicely and I second the attention to detail.
Title: Re: Ducati Mobster
Post by: maxBetteridge on Oct 14, 2016, 07:00:03
This tank mould has been WAY more work than I expected but it's finally pretty much done! I have been working on it a lot and you'd never know just by looking at it.. Let's just say I have a new appreciation for custom made composite parts.

So in last post I had pretty much constructed the plug(/form) and it just needed finishing. As it turned out the 'finishing' was probably the majority of the work. Every time I sanded it I thought it'd be the last time and then I sanded through into the fibreglass underneath and had to chop out a chunk and fill it back in with bog and sand again, or else I would find a bubble where the fibreglass was not bonded to the foam underneath it so I would have to cut the whole region out and fill it with bog and sand it again.

Anyway..
After a lot of sanding and filling I was getting pretty close. I threw down a guide coat with cheap rattle can paint:
(https://static.wixstatic.com/media/4ae3bf_a754ddc7d37548a79bd684db94a3a6e5~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_a754ddc7d37548a79bd684db94a3a6e5~mv2_d_1600_1200_s_2.jpg)

And sanded it down with a sanding block to get rid of the high points:
(https://static.wixstatic.com/media/4ae3bf_97bb8e5c11a140e89b02dc646102f670~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_97bb8e5c11a140e89b02dc646102f670~mv2_d_1600_1200_s_2.jpg)

You can see there were still some low areas (where the black paint is still on the part) so it got more filling and sanding until I was happy enough with it and hit it with an epoxy primer I had left over from my last cafe racer project. I used this paint because I thought it would be a nice high build which would help me fill in a few smaller holes and hollows:
(https://static.wixstatic.com/media/4ae3bf_45d191c7beb8444a8acdf2bd8c385f0c~mv2_d_1600_1600_s_2.jpg/v1/fill/w_608,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_45d191c7beb8444a8acdf2bd8c385f0c~mv2_d_1600_1600_s_2.jpg)

I blocked this down again got it even flatter and smoother.

Next I had to extend the bottom edge of the plug to allow me to build the mould out beyond the edge of the part. I made this flange by gluing strips of EVA foam onto the base of the plug using Ados F2. This then got covered with polyester resin so that the clearcoat would stick to it (not really sure if this was necessary)
(https://static.wixstatic.com/media/4ae3bf_b0d283aaa2e34f87994dc7f28ae55755~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_b0d283aaa2e34f87994dc7f28ae55755~mv2_d_1600_1200_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_82ce29e7497c405c966762f7fc534874~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_82ce29e7497c405c966762f7fc534874~mv2_d_1600_1200_s_2.jpg)

Then a couple thick layers clearcoat:
(https://static.wixstatic.com/media/4ae3bf_2f409585516d4eeea565246d8e5bb243~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_2f409585516d4eeea565246d8e5bb243~mv2_d_1600_1200_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_68539f48027b42daacfda72370e58968~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_68539f48027b42daacfda72370e58968~mv2_d_1600_1200_s_2.jpg)

The clearcoat had my signature look - orange peel, fish eyes, and runs - so it needed some scraping with a razor blade (after leaving it for a day rugged up with an oil heater in the garage) and then more sanding and polishing. I went a bit overboard with the polishing, sanding up to 2000 grit then a cutting compound and then a finishing polish. This made for a great result but it didn't really transfer that well to the mould (I think because of the PVA mould release)

(https://static.wixstatic.com/media/4ae3bf_50c4efc38e494f81a709245572ec0539~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_50c4efc38e494f81a709245572ec0539~mv2_d_1600_1200_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_e9004d1693394d7e8023aa8853962413~mv2_d_1200_1600_s_2.jpg/v1/fill/w_456,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_e9004d1693394d7e8023aa8853962413~mv2_d_1200_1600_s_2.jpg)


Here's a short video I made for my instagram of the final polish:
https://youtu.be/xdq7ZuSPdyQ


The fish eyes and gaps around the foam flange were filled with plasticine and modelling clay and shaved down with a razor blade:
(https://static.wixstatic.com/media/4ae3bf_e52c5ee8d9b8455b8e4bc4b1f984ab89~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_e52c5ee8d9b8455b8e4bc4b1f984ab89~mv2_d_1600_1200_s_2.jpg)

Finally it got 6 coats of mould release wax and PVA before starting the mould.

Here's a timelapse I made of me making the mould. About 12 hours work condensed into a nice three minute video, I hope you enjoy :)
https://youtu.be/c7sliT8tXnk

Getting the PVA to have a glassy smooth finish without any runs was a nightmare. I have done it before but never with a part this big. I tried spraying on the PVA with my paint gun and thinned it down with alcohol - both bad ideas.
Eventually after many redos I got something good enough.

After the PVA I painted on the tooling gelcoat:
(https://static.wixstatic.com/media/4ae3bf_8acf7ca1f223493197fd853bb762689e~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_8acf7ca1f223493197fd853bb762689e~mv2_d_1600_1200_s_2.jpg)

Then laid about 2 layers of 100gsm woven glass:
(https://static.wixstatic.com/media/4ae3bf_8ad216c3f9ec4eafafa9207df50598cd~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_8ad216c3f9ec4eafafa9207df50598cd~mv2_d_1600_1200_s_2.jpg)

The next day I filleted the central flange with bog (using polyester resin means the bog should stick good) and laid more glass over it.
(https://static.wixstatic.com/media/4ae3bf_4be5a7e6519b43cebca843e569c813d6~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_4be5a7e6519b43cebca843e569c813d6~mv2_d_1600_1200_s_2.jpg)

I started with some 200gsm offcuts, then about 1.5sqm of chop strand which was about one and a half layers, and then a full layer of 200gsm as a top layer to cover up the nasty chop strand.
(https://static.wixstatic.com/media/4ae3bf_8d4e0bdb5132404ebb8caa2b65888ddc~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_8d4e0bdb5132404ebb8caa2b65888ddc~mv2_d_1600_1200_s_2.jpg)

It came out pretty good
(https://static.wixstatic.com/media/4ae3bf_4e6db3aff0254b9fbb8682b2024b52a4~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_4e6db3aff0254b9fbb8682b2024b52a4~mv2_d_1600_1200_s_2.jpg)

bolted together and trimmed:
(https://static.wixstatic.com/media/4ae3bf_b8c32cb8f07448159c3f0ba6a5dfa80e~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_b8c32cb8f07448159c3f0ba6a5dfa80e~mv2_d_1600_1200_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_3d0467cb9c3f45699558a202d2244420~mv2_d_1600_1200_s_2.jpg/v1/fill/w_811,h_608,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_3d0467cb9c3f45699558a202d2244420~mv2_d_1600_1200_s_2.jpg)


I missed my original deadline - DGR 2016 - so I guess my new deadline is DGR 2017. Still a ton more to do and I have been inspired to put in a lot more effort into the details after I get this bodywork done. I am thinking I will strip the frame and do something special with it and get the engine casings polished up and a few things like that. Probably won't be finishing this any time soon...

And one more thing, I got contacted about a month ago by photographer Johny Cook ( https://www.facebook.com/JohnyCookPhotography/ ) who asked if I wanted to take the bike out for a photoshoot in the ranges out west of Auckland. I was stoked with the shots he got, this is how the bike is looking right now. Totally excited to get this thing finished now and shoot it again properly with that awful red tank gone!!

(http://scontent.cdninstagram.com/t51.2885-15/s750x750/sh0.08/e35/14288189_310398749340562_374210546_n.jpg?ig_cache_key=MTM0MzAwNDQxODUxODExNDg3OA%3D%3D.2)

(http://scontent.cdninstagram.com/t51.2885-15/s750x750/sh0.08/e35/14474275_1897817670446555_4651674199767646208_n.jpg?ig_cache_key=MTM1NzA2NTkxMjAzMzU2Mzk0MQ%3D%3D.2)

(http://scontent.cdninstagram.com/t51.2885-15/s750x750/sh0.08/e35/14487450_1140207122728581_5163613775802138624_n.jpg?ig_cache_key=MTM1MDU2MTUyNDIyOTQwMzkxMA%3D%3D.2)


If you're still reading find me on instagram @max_betteridge_design
https://www.instagram.com/max_betteridge_design/

And check out the build on my website:
http://www.maxbetteridgedesign.com/building-the-ducati-cafe-racer
Title: Re: Ducati Mobster
Post by: The Limey on Oct 14, 2016, 08:08:41
Stunning workmanship, pantie moistening equipment, but most of all a fantastic eye for design, style and detail.  Just amazing.
Title: Re: Ducati Mobster
Post by: mothgils on Oct 14, 2016, 08:28:00
Amazing work!  A true craftsman!  Not sure how I have missed this build but count me in!
Title: Re: Ducati Mobster
Post by: Tune-A-Fish© on Oct 14, 2016, 08:54:06
Cool plastics, but I'm waiting for the mechanics end, the performance bits, rotating massiveness that swims in oily goodness ness  :o
Title: Re: Ducati Mobster
Post by: Ichiban Moto on Oct 14, 2016, 10:05:48
      most excellent badass awesomeness  :D

      i need to make one of those water jet thingies
Title: Re: Ducati Mobster
Post by: focusinprogress on Oct 14, 2016, 15:55:57
extremely impressive composite work.
Title: Re: Ducati Mobster
Post by: xb33bsa on Oct 14, 2016, 16:18:39
thats really awesome crasftsmanship you got my vote not that that means anything
i was wondering if you did any rough prototyping of the seat so that you could ride and see how the rider position is,
because it looks to me like you cannot move at all,it looks like you are stuck in one position
Title: Re: Ducati Mobster
Post by: maxBetteridge on Feb 24, 2017, 04:16:35
Long time.. Little progress...

I have made the upper part of the tank and it looks pretty mean! But sadly that's about it for this update.

Here are a few timelapse videos of the process
https://youtu.be/2_lYc6ZfxpE


I vacuum bagged the part into the mould. It has 2x layers of basalt, 1x layer of kevlar, and I think 4x layers of glass.

Here's the part in the mould with the peel ply removed:
(https://static.wixstatic.com/media/4ae3bf_d441b50d6c4144319d9a6fdb11bb2e67~mv2.jpeg/v1/fill/w_1038,h_778,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_d441b50d6c4144319d9a6fdb11bb2e67~mv2.jpg)

And fresh out of the mould:
(https://static.wixstatic.com/media/4ae3bf_9123b17aa504453a867872095be2813a~mv2.jpeg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_9123b17aa504453a867872095be2813a~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_b5937e50535441dab9ad894a5c2cb81a~mv2.jpeg/v1/fill/w_1038,h_775,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_b5937e50535441dab9ad894a5c2cb81a~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_d3b03a59e1cd4489812c64b330459077~mv2.jpeg/v1/fill/w_1038,h_778,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_d3b03a59e1cd4489812c64b330459077~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_f87399a4c16e4c82a4842b4c86ebbbb5~mv2.jpeg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_f87399a4c16e4c82a4842b4c86ebbbb5~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_89513aea7c53484eabfac832c474f0dd~mv2.jpeg/v1/fill/w_844,h_1125,al_c,q_90/4ae3bf_89513aea7c53484eabfac832c474f0dd~mv2.jpg)

There are a bunch of bubbles and a few big voids which will need patching with epoxy and polishing back. Luckily though most of these imperfections are on the upper half of the tank which will be painted over so I think I'll get away with it. I think one of my big mistakes with this part was mixing up 500ml of epoxy at once which started to heat up and gel really quickly meaning that the first batch of epoxy in the mould was nearly set by the time I applied the vacuum. I should've mixed much smaller batches and possibly done the part in a few separate layups. Still planning to make a second one of these parts so hopefully I can do a better job on the next one.

Finally, I gave the tank a trim (damn hard to cut through kevlar btw. took two nights and a few hacksaw blades) and mocked it up on the frame. It's just temporary and not sitting in the correct spot but pretty happy with how it transforms the look!

(https://static.wixstatic.com/media/4ae3bf_20eea717a68147aabcb907443303731d~mv2.jpeg/v1/fill/w_1038,h_778,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_20eea717a68147aabcb907443303731d~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_342f1f23156441468bd52014b288afe9~mv2.jpeg/v1/fill/w_1038,h_780,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_342f1f23156441468bd52014b288afe9~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_7176e890193f44b79f038fe2b542a367~mv2.jpeg/v1/fill/w_1038,h_778,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_7176e890193f44b79f038fe2b542a367~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_294bcdb3584d42639c7db10c04a39f7c~mv2.jpeg/v1/fill/w_844,h_1127,al_c,q_90/4ae3bf_294bcdb3584d42639c7db10c04a39f7c~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_256e2c0d1aa3484c9751fab49a15d5ab~mv2.jpeg/v1/fill/w_1037,h_777,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_256e2c0d1aa3484c9751fab49a15d5ab~mv2.jpg)

Did a quick photoshop which shows what I'm aiming for. Added some paint, shifted the tail and tank to their correct position, removed the cans (not sure exactly what I'll do with the exhaust), shortened the subframe, shrunk the front fender, and raised the rear sus.
(https://static.wixstatic.com/media/4ae3bf_d7ece4b486fe49b6a7a0fbe0ab5adc11~mv2.jpeg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_d7ece4b486fe49b6a7a0fbe0ab5adc11~mv2.jpg)


Next step is to make the mould for the base of the tank, line the inside faces with Caswell tank liner and glue the halves together to finish off the part. Once I've got it together and checked it fits the bike then I'll go back and lay up the second tank.




If anyone's still reading find me on instagram @max_betteridge_design
https://www.instagram.com/max_betteridge_design/

And check out the build on my website:
http://www.maxbetteridgedesign.com/building-the-ducati-cafe-racer





P.S. to anyone who is out there wanting info on making a composite fibreglass / carbon fibre fuel tank. I have had a quick email conversation with Fantino from over on SOHC4 forum. He is building a sweet CB500 and he is a bit of a composites guru. He's doing a carbon tank and tail for his bike:

http://forums.sohc4.net/index.php/topic,159637.50.html
(http://i1293.photobucket.com/albums/b593/fantinno/Tank20and20Seat20Concept_zpsyiyecowt.jpg)

Here is our email convo:





Hi Evan,

My name's Max, I'm half way through a Ducati Monster cafe racer build and I've got a few questions about composite fuel tanks.

Here's a link to my build thread on Do The Ton: http://www.dotheton.com/forum/index.php?topic=68876.60

I am building a new tail, belly pan, and fuel tank from basalt fibre. I've just moulded the upper half of my tank but I haven't finished the lower half yet and haven't assembled it yet (and haven't put up the latest pics yet either).


My workmate put me onto your thread because you're also building a composite tank and you obviously know your stuff about resins and fuels. I live in New Zealand where we don't have ethanol in most of our fuels. I have made the tank with basalt, glass, and a layer of kevlar and I have laid it up with standard marine grade epoxy. My intention was to then coat the inside of the tank with a fuel tank liner like the POR15 product or something similar. Before I go any further with this part I just wanted to get your opinion on it and check if it's wise to keep going with this method or if I need to redo it with a better resin?
You mention on your thread that the tank liner delaminating from the tank could be an issue, is this something I need to worry about? Do you know if there are particular liners which are compatible with epoxy?
I have also had a quick search for the resin you said you used but I can't find a supplier in New Zealand and I'm not sure how difficult it would be to import.

This is the resin I have used: http://www.nzfibreglass.co.nz/2015/shopexd.asp?id=87
And I was going to buy something like this to line it: http://www.ebay.com.au/itm/POR15-STANDARD-FUEL-TANK-SEALER-1-LITRE-/191990282149?hash=item2cb38337a5:g:t14AAOSwXeJYGA5w

Thanks a lot for your help,
Max.








Hi Max,

Very impressive work, you've been very thorough with your mold design and fabrication. I'm jealous of your access to NC machines, definitely what I miss most from my days working in aerospace! The laser cut coremat is super slick! Basalt fiber is also pretty uncommon in these parts, is this an easy to find product in NZ?

My own mold making progress has been significantly slowed down due to work obligations and indecision on locking down my CAD, but I've taken to 3D printing my molds as I don't really have the patience for more traditional fabrication. This is actually how we've started making low run production molds at my current work, it's really been a huge boon for productivity.

Anyways, onto your specific questions :)

Not knowing what additives go into your local fuels (and how that may change over the next 1,5,10 years) I can't offer much insight about how everything will hold up other than to say you should make a test coupon and do a submersion test for peace of mind. You may find your lam epoxy holds up fine without any coatings. To be frank, most general laminating epoxies (Bis-A/Amide) are already gasoline resistant. They may degrade over time, especially in elevated temperatures, but you're unlikely to see the epoxy dissolve into the fuel and clog up lines, even aggressive modern fuels. Failure is more likely to manifest in the deterioration of mechanical properties, so it will become more of an issue of tank longevity. I'll emphasize again that you should test your resin as there are literally hundreds of resin and hardener formulations and thousands of combinations thereof.

The poor reputation of composite tanks "melting" and gumming up the works is largely due to the majority of commercially available composite tanks being made from polyester resins which do not fare well with modern US gas. These tanks are primarily intended for racing, so the fuel blends are different and the tanks get emptied and dried out between races. It is their use on street bikes where folks start to see issues with the fuel system getting clogged.

In general I also would say with any composite fuel tank it's probably good advice to drain and store your fuel when you're not frequently riding the bike.

POR-15 will probably *work* but it's not my favorite coating for epoxy. It's a polyurethane based coating that cures via a humidity activated catalyst. Most coating failures are typically a result of improper surface prep or poor application conditions, as this coating relies entirely on mechanical bonding to its substrate. When it fails it tends to flake off or come off in sheets and block fuel lines. You have access to the inside of the tank before you join it together so you'll be able to prep the surface better than just shaking some screws around and rinsing it out with acetone.

Generally speaking, urethane is less chemically resistant than epoxies, so I'm doubtful it will gain you much and does add some risk due to the possibility of delam. POR-15 as a tank sealer is better suited as a lower cost option for polyester tanks which have very poor chemical resistance and where it's best suited as a sealer and rust inhibitor on steel tanks.

Unfortunately even on my side of the pond access to more exotic epoxy formulations are pretty limited if you are a small volume consumer. MAX GRE and the Caswell tank liner are about the only options I've found for Bis-F/Novolac (Phenol) based epoxies. They have improved chemical resistance across the board and are well suited to fuel tank applications.

You'll notice that most folks who complain about failure of the Caswell kit and other liners complain that it breaks off in pieces, and it's usually a steel tank. I can almost guarantee this is due to a combination of bad surface prep and differing rates of thermal expansion between the tank and liner. If you can get your hands on a Caswell kit you can avoid this with good surface prep, but also your liner and matrix will be more or less the same material and will expand at the same rate which will help some. If your matrix resin is still a bit green, you may also get some cross linking at the boundary layer which will improve adhesion between the coating and your substrate.

It's probably overkill to build an entire tank from a Novolac epoxy, but I like the peace of mind.

You can improve the properties of any epoxy product by post-curing. In fuel tank applications, your biggest enemy is heat. Elevated temperatures reduce the mechanical and chemical properties of your resin. When you cure epoxy at room temperature it cross-links polymer chains until they chains become long and tangled and lose enough mobility to make any additional links (vitrification). Post curing the resin at a higher temp increases the mobility of the chains and allows more complete cross-linking and thus a higher glass transition temperature, improved chemical resistance and improved mechanical properties. General amine/amide based laminating resins typically have a fairly narrow range for improvement before the resin will begin to degrade, but you can probably get away with baking the part at 55-65C for 2-4 hours and will see some improvement in your resin properties.

I don't know if any of this was really helpful or provided any additional clarity for your project, but if you have any other questions I'm happy to offer what advice I can.

Keep up the good work Max, your project looks awesome!


-Evan









Thanks a lot for your reply Evan. it's given me a lot more confidence.

I'm definitely spoilt with my access to machines and equipment. At least I make the most of it unlike most of my other workmates ;)
I like your approach, especially what you've done with the 3d printed plug. The tank upper is the first composite part I've made the traditional way shaping the plug by hand and making a fibreglass mould and I don't think I'll do it again! Something like an FDM form to get you 90% of the way there is not a bad option at all.

I couldn't find basalt anywhere in NZ, I even struggled to find it overseas. I bought all of my basalt and kevlar from china through Alibaba. Overall a good experience and the seller was helpful, however the mat did get slightly bent and damaged in transit. Thankfully this is less of an issue with basalt than it is with carbon as the weave is much less prominent and more forgiving in the final part.

I have had a look through the Caswell site and I really like the sound of their product. I will do a bit more research and see if I can get my hands on a kit. I'm kicking myself for throwing away the offcuts from my tank upper now. I actually saved them and left them on the floor of my garage thinking I might want them but after a few weeks I chucked them all out! I'll have to do the submersion test with some offcuts of the next part. I had also considered baking the parts but wasn't sure if that was necessary and as I don't have an oven big enough at my disposal I thought I might forget about it. After what you've said though I will make sure I bake everything once the halves are glued together.

I did have one other question, I read in your thread that you were planning to keep the kevlar away from the outer edge of the part to make trimming easier. Is this common practice? Will this not compromise the strength of the seam which is most likely already a weak area of the part? This is the first time I've ever worked with kevlar and I couldn't believe how hard it was to trim. If you think it's ok to end the kevlar layer slightly before the edge then I think I will give that a go for the next part.

If there's one piece of advise I've got to offer which I don't think many composites guys know is that a laser cutter makes light work of cutting peelply, glass, basalt, and even kevlar (not laminated, just the mat). I haven't tried carbon but I imagine it'd be similar to basalt. It makes a beautiful neat edge and actually fuses the fibres so they won't fray and makes them very easy to handle. Especially useful for someone like you who is already designing in CAD. I cut mine on a 90 Watt laser which is very low power, practically any laser cutting shop would be capable of doing it and their prices are pretty reasonable. But then again you probably have all the fancy tools and tricks which I don't have for working with carbon and kevlar..

As long as you don't object I might put this email chain up on my build thread for others to read. Seems hard to find much helpful info on this topic online, this might help someone else later on.

All the best with your progress. I've got no doubt you're getting there faster than I am at the moment!

Thanks,

Max.





Yes, feel free to post our correspondence. You're right, it can be very hard to find more in-depth information on composites for DIYers.

I ended up deciding the first plug was a little too big, so I'm reprinting it scaled down. I'm trying out saving a step by printing the mold surfaces directly. Will take about 50% longer to print and use about twice as much material, but it should save time and money over the traditional method in the end.

See if you can find a datasheet for your resin system, just to be sure what temperature your resin can handle. Most general purpose lam resins should post-cure fine in the 55-70C range, 80C will probably be pushing it. Make sure you heat up and cool the part while it's in the mold to prevent it warping and setting into a new shape.

I'm not sure what type of business your shop is, but I often have good luck getting resin "samples" from industrial suppliers by expressing interest in a product from my business email. I'm always surprised when European chemical suppliers send products across the pond and even cover the shipping! Drop in the bucket for them I guess.

With the Caswell kit, I think they deliver it in bags now instead of cans, but I would pour the two halves into a resealable container. Since you have the luxury of having both halves of the tank split apart, you can brush on the epoxy and get much more even coverage with less material waste compared to slosh coating. I bet you would have enough left over to use the Caswell resin as your adhesive to join the two tank halves together, might need to thicken it up a bit with some fumed silica though.

Laser cutting kevlar actually sounds like a really good idea I might have to bring up at our next continuous improvement meeting, it's a real nightmare to cut dry fabric. We use an ultrasonic shear for the most part at my current work, but we're not usually cutting out very precise shapes. From what I've heard carbon needs a significantly higher powered laser, but I've never tested it. At my old job everything was prepreg so it wasn't compatible with lasers, they cut everything on big NC plotters with ultrasonic knife blades.

Regarding kevlar setback... It depends on your application and what you're trying to achieve. Apologies in advance if I am repeating information you already know, but the thing about composite fuel tanks is they're not really "engineered" structural parts. The properties of the composite we are taking advantage of are low weight, relative ease of fabrication and cosmetics. From a mechanical perspective, we're taking the "black aluminum" approach by constructing the part entirely out of woven fabrics and thus having *relatively* uniform properties in all directions (as opposed to say a structural carbon part which would have unidirectional fibers oriented to account for a tensile load along a specific axis of the part). This is fine because a gas tank isn't a part that sees high loads in any specific direction. The most likely high-load scenario for a tank is (unfortunately) a crash.

Keep in mind that strength and stiffness are not the same, carbon is stiff and strong but likely to fail in high energy impact loads (the fibers kink and break under compression and propagate cracks). Kevlar is strong  and abrasion resistant, but not stiff. It won't add much stiffness to our composite part (it's about as stiff as glass), however, If it is used to reinforce areas that may see an impact load or drag on the ground, we can expect a better chance of the tank not cracking at the location of impact or being quickly worn through by the asphalt. This is good when we are trying to avoid spilling flammable liquids on the pavement, haha.

Kevlar will be most effective on the sides of your tank or wherever a part is likely to hit the ground if the bike is dropped, you may even consider adding a little extra kevlar locally where the tank will contact the ground if dropper. It will add some toughness to your overall laminate, but shouldn't significantly change the strength of your part near the seams. The adhesive joint is likely to fail first anyways (adhesive joints can be stronger than their adherends, but typically only when bond lines are very thin, uniform with controlled surface preparation). You can always setback the kevlar around cutouts like the filler cap and petcock and keep it at one or both seams if you are concerned. A tip for finishing fuzzy edges on trimmed kevlar parts is to wet them out with CA adhesive (superglue) and sand the edge down. The fuzzy edges will break off and as long as you don't sand too deep, you will avoid fuzzing out more material.

Sorry for the long-winded answer to a simple question!


-Evan
Title: Re: Ducati Mobster
Post by: doc_rot on Feb 24, 2017, 12:59:02
Nice work. Thanks for posting that's conversation. Very interesting. I think a part that large and with so many layers would be a perfect candidate for resin infusion rather than a wet layup. 
Title: Re: Ducati Mobster
Post by: maxBetteridge on Feb 24, 2017, 22:56:20
I think a part that large and with so many layers would be a perfect candidate for resin infusion rather than a wet layup.

You're not the first person to say that @doc_rot. I've just never tried it and don't know anyone who has and I'm scared I'll screw it up!If I did mess it up it'd be a pretty expensive screw up.. But I am going to look into it next time I make this part. I think it might be time I learnt
Title: Re: Ducati Mobster
Post by: maxBetteridge on Sep 02, 2017, 20:23:27
Sorry to say that I have almost run out of enthusiasm to keep updating this thread :S
Here is the progress from the last six (!) months

I have been taking it quite easy on this project but I visited Deus Ex in LA a few months ago and returned with renewed enthusiasm, and with the Distinguished Gentleman's Ride coming up later this month I was determined to get the bike rideable, if not completely finished by then. It's not quite finished yet, but it's close now!

(https://static.wixstatic.com/media/4ae3bf_782455ed50ad4fc78d0cd5cfb376cc49~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_782455ed50ad4fc78d0cd5cfb376cc49~mv2.jpg)

Last time I had just made my first tank upper. I have since made a new one of these with much better results. I was a lot more careful to get the vacuum onto the part before the resin started curing; I split the job up into two separate layups and also kept my mixed resin cool by tipping it into a shallow tray. I was able to get a much better surface with much smaller bubbles and also the weave of the basalt showed much more prominently.

The next step was the base of the fuel tank. This mould was made with laser cut 10mm MDF and designed to be disassembled during demoulding.

(https://static.wixstatic.com/media/4ae3bf_0b1832d4257d43c4afccbcdefbfa0f6f~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_0b1832d4257d43c4afccbcdefbfa0f6f~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_800e06dfada34bb88f47865a63f81896~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_800e06dfada34bb88f47865a63f81896~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_bb88c44e617e4e0c9e4b4d28043efe7d~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_bb88c44e617e4e0c9e4b4d28043efe7d~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_4c3e684b99c44bedb63da0c41a2a3515~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_4c3e684b99c44bedb63da0c41a2a3515~mv2.jpg)


The part fit the frame well and I also checked that it would fit snug inside the upper before moving on
(https://static.wixstatic.com/media/4ae3bf_2e2439f5826841de8e33080557f0a187~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_2e2439f5826841de8e33080557f0a187~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_3828d8067f4c432aa39f55bc1d725c48~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_3828d8067f4c432aa39f55bc1d725c48~mv2.jpg)

I made a custom flange to mount the fuelpump and level sensor and feed/return lines.
(https://static.wixstatic.com/media/4ae3bf_cc5504a4a5954c628ba6969fbdd09515~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_cc5504a4a5954c628ba6969fbdd09515~mv2.jpg)

I copied the design of the California Cycleworks MTT flange thinking that it would fit my tank but it did not... By the time I realised this it was almost too late. The fuel level sensor was directly on top of the cross member on the frame where the old tank hinge mounted and I didn't want to cut this member for certification reasons. I ended up salvaging the M30x1.5 thread from the centre of my part and relocating it off to the side of the tank base and remaking a new flat flange plate which actually made the whole thing a lot simpler to assemble.
I glued a ring of 10mm aluminium with tapped holes onto the inside of the tank and a 2mm stainless ring on the outside of the tank for both the fuel pump flange and the fuel filler cap to screw into and seal up against.
(https://static.wixstatic.com/media/4ae3bf_c1a4e5d245094a40a192eab449c0ee7b~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_c1a4e5d245094a40a192eab449c0ee7b~mv2.jpg)

I glued the upper and lower halves of the tank using epoxy with adhesive filler. Before gluing the halves together I coated the inside faces of both components with Caswell fuel tank liner which is an epoxy based system. After the halves were glued together I put more Caswell into the tank and tried to 'slosh' it around to cover the newly made seams. This product was far too thick to be sloshed around. It slowly dripped around the inside like honey. I should have thinned it down as they suggested in the instructions but the instructions were slightly ambiguous as to what thinner I needed to use and I was affraid to use an incompatible thinner and ruin the result.
(https://static.wixstatic.com/media/4ae3bf_860090a4dba54a8daf5774536c8e18a9~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_860090a4dba54a8daf5774536c8e18a9~mv2.jpg)

I collected some nitrile gasket material and cut my own gasket for the fuel pump flange, I used fibre washers and loctite 567 to try and seal the screws which secure the plate. I haven't pressure tested this but I'm fairly confident it'll hold. And on a side note I did a submersion test with an offcut of my tank upper in petrol and it showed no signs of deteriorating so I don't think the Caswell was even necessary.

I couldn't use the original rubber tank feet at the front of the tank because they just didn't fit. I also wanted to avoid any point loads on the fibreglass, so I made up this support which wedges between the frame tubes. This has a few patches of thin EVA foam on top to take out any vibrations and further spread the load on the glass.
(https://static.wixstatic.com/media/4ae3bf_e24675eeab764cbd9dca0b18bcffa270~mv2.jpg/v1/fill/w_1038,h_1038,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_e24675eeab764cbd9dca0b18bcffa270~mv2.jpg)

On the rear of the tank I have reused the original rubber mount which rests directly on the fuel pump flange plate (I'm still not sure if this is a good thing or a bad thing but it'll do for now).
The original tank was secured to the frame with a hinge at the rear and an over-centre latch at the front. I had no way of attaching a hinge to the base of my tank and I had no space to adapt a latch for the front either so I had to do something a bit different. A common solution is the fuel tank strap which I wasn't very excited about but it has a lot of merits mechanically, so I gave it a go.
I waterjet cut some 2mm stainless for the straps
(https://static.wixstatic.com/media/4ae3bf_378d74913b7748b4ab9f49b47596d29a~mv2_d_1280_1280_s_2.jpg/v1/fill/w_1038,h_1038,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_378d74913b7748b4ab9f49b47596d29a~mv2_d_1280_1280_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_e656042d83e348568aaed1faa7fcf218~mv2.jpg/v1/fill/w_1038,h_1038,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_e656042d83e348568aaed1faa7fcf218~mv2.jpg)

I opted to have the straps attach directly to the fuel filler cap and they had to go on top of the cap flange which left a large gap between the strap and the actual surface of the tank. To fix this I had to jog the strap down about 3mm. Because this is such an obvious part of the bike I didn't want to use straight jogs because they would look terrible, so I was left with only one (extravagant) option:
(https://static.wixstatic.com/media/4ae3bf_81ed3b4632f24c4e8ec0e715edb619c8~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_81ed3b4632f24c4e8ec0e715edb619c8~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_b8d55a813ca64d4298d8804bee48f11f~mv2.jpg/v1/fill/w_1038,h_1038,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_b8d55a813ca64d4298d8804bee48f11f~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_69dba3fd0edb40bca4f198bc77d08a6e~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_69dba3fd0edb40bca4f198bc77d08a6e~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_b376789fa4734d13a24a39cfbcfd6003~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_b376789fa4734d13a24a39cfbcfd6003~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_46a029a4c5a3424e84ef2a8bb440b208~mv2.jpg/v1/fill/w_1038,h_1038,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_46a029a4c5a3424e84ef2a8bb440b208~mv2.jpg)

I think the result is pretty slick and it's probably better than not having a strap at all, so I'm happy :)
To finish it off I backed it with the same leather I used on the seat and grips and laser engraved a retro Ducati logo onto it
(https://static.wixstatic.com/media/4ae3bf_6617eb85294840aab5d1852939d7f0e0~mv2.jpg/v1/fill/w_1038,h_1178,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_6617eb85294840aab5d1852939d7f0e0~mv2.jpg)


For the seat pan I used waterjet stainless. I didn't want to weld on a hoop because of possible certification complications and also I don't think it really needs that much strength out the back for only a single passenger. I designed the seat pan to slide into the ends of the frame and bolt onto the original front sear mount. These photos don't show it but there are two aluminium plugs turned down to the ID of the frame and bolted onto the vertical part of the tray which slide about 50mm down the tube to secure it.
(https://static.wixstatic.com/media/4ae3bf_58bd3f8e17074f8ea9e233b822716bf3~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_58bd3f8e17074f8ea9e233b822716bf3~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_3a1dd8b3ee9e49d0a3b8d5f03a22eb84~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_3a1dd8b3ee9e49d0a3b8d5f03a22eb84~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_a2ab0821f7b44f1e9ff40f55a63bc475~mv2.jpg/v1/fill/w_1038,h_1038,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_a2ab0821f7b44f1e9ff40f55a63bc475~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_bf4fc268559e41d98d929ed3f8673056~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_bf4fc268559e41d98d929ed3f8673056~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_94771eb2216a471180e16dd8e7f9fef3~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_94771eb2216a471180e16dd8e7f9fef3~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_81ca24d8b100436f984392d185f6170d~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_81ca24d8b100436f984392d185f6170d~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_af1749c02fa743a2b7efed79176224e8~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_af1749c02fa743a2b7efed79176224e8~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_edc63f53447c409a98a9265f36d76262~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_edc63f53447c409a98a9265f36d76262~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_0871030889e44ee4b4c4d916ef36ab82~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_0871030889e44ee4b4c4d916ef36ab82~mv2.jpg)


I also made (/stole) a numberplate bracket on the end of the swingarm. I made this with 2mm stainless but it's a bit flimsy so I will remake this with something a bit thicker when I get time.
(https://static.wixstatic.com/media/4ae3bf_cd582e65d427441f884af233927ba656~mv2.jpg/v1/fill/w_1038,h_779,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_cd582e65d427441f884af233927ba656~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_f7562ec578b4456eb21e5b941b5474b2~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_f7562ec578b4456eb21e5b941b5474b2~mv2.jpg)

Lastly I stripped the frame, detabbed it, had it sandblasted, and had it powdercoated in Dulux Matt Champagne Kinetic colour. The rearsets also had some surgery and a lot of polishing.
(https://static.wixstatic.com/media/4ae3bf_a189db94c19e480f9fd9fe27e6d1b33a~mv2.jpg/v1/fill/w_1038,h_1038,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_a189db94c19e480f9fd9fe27e6d1b33a~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_5e8fe3e386be42bd9e4295d44c3dd0bf~mv2.jpg/v1/fill/w_967,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_5e8fe3e386be42bd9e4295d44c3dd0bf~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_bcce4aecfa2e4d479ba668ef955fe36c~mv2.jpg/v1/fill/w_1038,h_1038,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_bcce4aecfa2e4d479ba668ef955fe36c~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_43ad11159c6f41da8fda6dfbf69a6909~mv2.jpg/v1/fill/w_1038,h_1038,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_43ad11159c6f41da8fda6dfbf69a6909~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_69823f8bd1b846f89dc5bc214af231e0~mv2.jpg/v1/fill/w_906,h_1208,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_69823f8bd1b846f89dc5bc214af231e0~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_c09e943574f3479085b75d2005832e05~mv2.jpg/v1/fill/w_1038,h_1038,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_c09e943574f3479085b75d2005832e05~mv2.jpg)


The frame is now reassembled, all the wiring done, and just waiting on a few brackets to mount the belly pan, some eshaust mid-pipes, and paint. I think that's it!

Next post will be the photoshoot ;)



If you're still reading find me on instagram @max_betteridge_design
https://www.instagram.com/max_betteridge_design/

And check out the build on my website:
http://www.maxbetteridgedesign.com/building-the-ducati-cafe-racer
Title: Re: Ducati Mobster
Post by: hooligan998 on Sep 03, 2017, 00:52:17
Amazing work.  In for the finish!
Title: Re: Ducati Mobster
Post by: stroker crazy on Sep 03, 2017, 03:09:41
Next post will be the photoshoot ;)

Can't wait!

Crazy
Title: Re: Ducati Mobster
Post by: johnu on Sep 03, 2017, 20:26:18
Really liking this build!  Love the use of technology!  Imho I would do a modern gp style exhaust or a reverse mega.  Looking forward to more updates :)
Title: Re: Ducati Mobster
Post by: Ryan Stecken on Sep 04, 2017, 03:55:17
This is just amazing!Youre fab skills are the popes slippers!
Title: Re: Ducati Mobster
Post by: JadusMotorcycleParts on Sep 10, 2017, 06:26:47
Keep it up man, this is a stunning build.  Love your combo of skills from cad work, to machining to the glass work.  Amazing.  Bike has brutal stance.  Thanks for sharing.
Title: Re: Ducati Mobster
Post by: focusinprogress on Sep 11, 2017, 16:02:58
killer stuff going on here. Keep the pics coming.
Title: Re: Ducati Mobster
Post by: 1fasgsxr on Sep 11, 2017, 16:06:39
I hope those exhaust cans don't drag.. this thing is looking amazing!
Title: Re: Ducati Mobster
Post by: maxBetteridge on Nov 18, 2017, 20:35:09
It's finished!

Here are the final things that needed doing.
One of the cans was quite damaged on the outside so I flipped the sleeve to hide the damage.
(https://static.wixstatic.com/media/4ae3bf_73cee6a26ebe47f5a280b67a3129091a~mv2.jpg/v1/fill/w_974,h_691,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_73cee6a26ebe47f5a280b67a3129091a~mv2.jpg)

I had to waterjet some stainless straps which hung the cans at the right height and offset from the stock hanger.
(https://static.wixstatic.com/media/4ae3bf_1797cfd8e9cb4adcb258afb3442f2d82~mv2.jpg/v1/fill/w_478,h_598,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_1797cfd8e9cb4adcb258afb3442f2d82~mv2.jpg)

Then just had to make the intermediate pipes to connect them up. I could've gone to an exhaust shop and hot some bends or at least some straight pipe to segment cut.. But I thought I'd try something different with the material I already had.
(https://static.wixstatic.com/media/4ae3bf_96476d07bd0549e1880bb9f4267b7257~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_96476d07bd0549e1880bb9f4267b7257~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_8360d8275cc14dddaf1b2c186f90015e~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_8360d8275cc14dddaf1b2c186f90015e~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_229911a63aea431fb5b20ff62ec0ca4f~mv2.jpg/v1/fill/w_478,h_478,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_229911a63aea431fb5b20ff62ec0ca4f~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_104714f08f694fb9828512892065dce6~mv2.jpg/v1/fill/w_478,h_478,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_104714f08f694fb9828512892065dce6~mv2.jpg)
(BTW they're not supposed to be symmetrical!)
Since I couldn't transport the bike and I don't have a welder at home I had to use the 3D scan and CAD the pipes in Rhino and unroll the segments and waterjet them all connected so that when I rolled and bent them they should all align and match the angles in CAD. This meant I was able to tack them up at work without test fitting on the bike, then only test fitting them once they were welded up. It worked an absolute treat!

The paint was basically the only thing which I outsourced and I'm glad I did! The parts took I think 4x coats of clear just to get a flat surface to lay the basecoat on and then more clear.

(https://static.wixstatic.com/media/4ae3bf_cb8d9f71aa4448dd91da9a89bc4b473a~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_cb8d9f71aa4448dd91da9a89bc4b473a~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_8313f1f1e72242fead6628c9932c741c~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_8313f1f1e72242fead6628c9932c741c~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_6b49bc1263af43969ab4b22f706b8a24~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_6b49bc1263af43969ab4b22f706b8a24~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_03b83d92c7ea45488de10c718d0313ac~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_03b83d92c7ea45488de10c718d0313ac~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_beebac480756495b98f3b4cf7ec9601b~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_beebac480756495b98f3b4cf7ec9601b~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_84d38837e79645aaa3349554c51e3c65~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_84d38837e79645aaa3349554c51e3c65~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_fedad20d941d4c2394e7a028bbe29af2~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_fedad20d941d4c2394e7a028bbe29af2~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_114f99ae7cf542bbabba9750436b7cff~mv2_d_1280_1280_s_2.jpg/v1/fill/w_478,h_478,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_114f99ae7cf542bbabba9750436b7cff~mv2_d_1280_1280_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_d202f8adaf25425a84e97d3e54ca431c~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_d202f8adaf25425a84e97d3e54ca431c~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_a337d92d86d54b71996c7fe8f2e4d550~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_a337d92d86d54b71996c7fe8f2e4d550~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_5c6958b64b5f4f0f80ae42165c49b92f~mv2.jpg/v1/fill/w_478,h_637,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_5c6958b64b5f4f0f80ae42165c49b92f~mv2.jpg)


A few weeks before I finished the bike I came across another custom Monster named the Mobster; I had always been treating Mobster as a bit of a working name for the bike but seeing another one come out with that name made the decision easy for me, the bike definitely needed a new name..

So here it finally is - the 'Flat White'

(https://static.wixstatic.com/media/4ae3bf_97f2bc089c6b4c98b411069a6c9ed132~mv2_d_2048_1365_s_2.jpg/v1/fill/w_479,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_97f2bc089c6b4c98b411069a6c9ed132~mv2_d_2048_1365_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_8aae79e5c4f243e4a339084e5b73adf3~mv2_d_2048_1365_s_2.jpg/v1/fill/w_479,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_8aae79e5c4f243e4a339084e5b73adf3~mv2_d_2048_1365_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_9b5505d6055240b0a22234ab2ccfda0b~mv2_d_2048_1365_s_2.jpg/v1/fill/w_479,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_9b5505d6055240b0a22234ab2ccfda0b~mv2_d_2048_1365_s_2.webp)

(https://static.wixstatic.com/media/4ae3bf_3f8cc4c0db8c4a3c924b03a843224b0d~mv2_d_2048_1365_s_2.jpg/v1/fill/w_479,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_3f8cc4c0db8c4a3c924b03a843224b0d~mv2_d_2048_1365_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_f9166a194f0b48af8975db44e0147759~mv2_d_2048_1366_s_2.jpg/v1/fill/w_478,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_f9166a194f0b48af8975db44e0147759~mv2_d_2048_1366_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_d3e3eed0ccc847d79143440a1dde01e4~mv2_d_2048_1365_s_2.jpg/v1/fill/w_479,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_d3e3eed0ccc847d79143440a1dde01e4~mv2_d_2048_1365_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_18ed30ddb36b4a4a93d6fcc677989b84~mv2_d_2048_1365_s_2.jpg/v1/fill/w_479,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_18ed30ddb36b4a4a93d6fcc677989b84~mv2_d_2048_1365_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_4be601e5e2b9470d911a75ce81d31de5~mv2_d_2048_1366_s_2.jpg/v1/fill/w_478,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_4be601e5e2b9470d911a75ce81d31de5~mv2_d_2048_1366_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_69ec95dbeaca4d6bbd6deb3154d107de~mv2_d_2048_1365_s_2.jpg/v1/fill/w_479,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_69ec95dbeaca4d6bbd6deb3154d107de~mv2_d_2048_1365_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_9297ab850e4f41b5b4f50bd36f5af084~mv2_d_2048_1365_s_2.jpg/v1/fill/w_479,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_9297ab850e4f41b5b4f50bd36f5af084~mv2_d_2048_1365_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_a9f07cfb4f6c46c79186dd6fc14fa389~mv2_d_2048_1365_s_2.jpg/v1/fill/w_479,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_a9f07cfb4f6c46c79186dd6fc14fa389~mv2_d_2048_1365_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_f3ad14ba95074e99a6e42930e3473e5a~mv2_d_2048_1365_s_2.jpg/v1/fill/w_479,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_f3ad14ba95074e99a6e42930e3473e5a~mv2_d_2048_1365_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_6741d2e2939044e3a139e89a1af8b20d~mv2_d_2048_1365_s_2.jpg/v1/fill/w_479,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_6741d2e2939044e3a139e89a1af8b20d~mv2_d_2048_1365_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_c83d64049afa49748e46abb17c45389f~mv2_d_2048_1366_s_2.jpg/v1/fill/w_478,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_c83d64049afa49748e46abb17c45389f~mv2_d_2048_1366_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_43db0d9609c2449281f49a10705a3abc~mv2.jpg/v1/fill/w_478,h_272,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_43db0d9609c2449281f49a10705a3abc~mv2.jpg)

(https://static.wixstatic.com/media/4ae3bf_9fa82603afe14d80bda91a020be1449f~mv2_d_2048_1366_s_2.jpg/v1/fill/w_478,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_9fa82603afe14d80bda91a020be1449f~mv2_d_2048_1366_s_2.jpg)

(https://static.wixstatic.com/media/4ae3bf_aa56179bd7a449ebb1e7c1f5627c0a25~mv2_d_2048_1366_s_2.jpg/v1/fill/w_478,h_319,al_c,q_90,usm_0.66_1.00_0.01/4ae3bf_aa56179bd7a449ebb1e7c1f5627c0a25~mv2_d_2048_1366_s_2.jpg)

https://youtu.be/rVsgWQtX0c4

Full resolution photos are on my website:
http://www.maxbetteridgedesign.com

Check out the article on bikeexif:
http://www.bikeexif.com/ducati-monster-400-cafe-racer




Find me on instagram @max_betteridge_design
https://www.instagram.com/max_betteridge_design/
Title: Re: Ducati Mobster
Post by: stroker crazy on Nov 18, 2017, 20:44:02
So here it finally is - the 'Flat White'

Well done indeed!

(also my favourite coffee)

Crazy
Title: Re: Ducati Mobster
Post by: The Limey on Nov 19, 2017, 10:51:52
That is gorgeous in every way   
Title: Re: Ducati Mobster
Post by: hooligan998 on Nov 20, 2017, 00:52:12
That looks like you should be wearing a tuxedo while riding it.  Nicely done!
Title: Re: Ducati Mobster
Post by: cb250nproject on Nov 20, 2017, 01:46:39
Flawless


Sent from my iPhone using DO THE TON
Title: Re: Ducati Mobster
Post by: Popeye SXM on Nov 20, 2017, 13:10:15
Fabulous bike. Thank you very much for sharing, I have enjoyed watching all your great work. Inspiring
Title: Re: Ducati Mobster
Post by: focusinprogress on Nov 20, 2017, 14:55:13
beautiful results.
Title: Re: Ducati Mobster
Post by: Coopacoopacoopa on Nov 20, 2017, 15:16:22
Saw this on bikeexif and then realized the build thread was here! Stellar work sir!
Title: Re: Ducati Mobster
Post by: johnu on Nov 22, 2017, 13:11:31
Turned out real nice!
Title: Re: Ducati Mobster
Post by: JadusMotorcycleParts on Nov 26, 2017, 16:06:42
Congratulations.  Bloody stunning.
Title: Re: Ducati Mobster
Post by: Sonreir on Nov 27, 2017, 13:34:50
Nominated for BotM.

http://www.dotheton.com/forum/index.php?topic=74905.msg889889;topicseen#new
Title: Re: Ducati Mobster
Post by: Integra99 on Nov 28, 2017, 07:26:03

Stunning.. do you mind me asking what paint code the vintage white is please?
Title: Ducati Mobster
Post by: maxBetteridge on Nov 30, 2017, 14:13:06
Stunning.. do you mind me asking what paint code the vintage white is please?

Thanks mate. The colour is a Ferrari colour ‘Avorio’

The frame powdercoat is dulux matt champagne kinetic
(the colour in the photo is misleading, definitely not that blue in reality)


(https://uploads.tapatalk-cdn.com/20171130/eed895664763cc45b3b13d76cffcfc5e.jpg)


(https://uploads.tapatalk-cdn.com/20171130/29bf4f4078825750433452d8e26f8ffa.jpg)
Title: Re: Ducati Mobster
Post by: Alex jb on Nov 30, 2017, 16:21:27
Cracking work and thanks for documenting and telling the tale so well.
Now make some more parts  from those awesome molds and make your money back!  :)


Sent from my iPhone using Tapatalk
Title: Re: Ducati Mobster
Post by: stroker crazy on Nov 30, 2017, 16:26:42
the colour in the photo is misleading …

More like this?
Title: Re: Ducati Mobster
Post by: brad black on Dec 03, 2017, 04:11:02
i think that's what i had my 400ss frame done in, as close as i could pick to the original early 90's frame gold.