Ducati 1000 DS custom build

[buzzer]

First job has been to address the plastic tank… While it’s not too bad, its already showing signs of bubbling due to the ethanol in the fuel… I hate plastic tanks, so it has to go. Plan was to make an alloy under tank and then make a fiberglass seat and tank cover. However, I had an old Ducati Monster tank that was rotted out on the bottom so I got Arnie the angle grinder out and cut it up… just to see! I was really pleased with the shape and how it fitted! It did of course mean that I would lose that nice Buell filler cap, so instead of using the Ducati one, I made a conversion ring to take the Buell one, it worked a treat.

I made a new bottom for the tank out of some 1.2mm mild steel, and TIG brazed some mounting lugs on, and also a plinth for the fuel tap. This didn’t go well and I got some leaks (good job I pressure tested before putting the bottom in!) The reason was due to my TIG settings… you need both pre AND post gas with braze and you need to flood the weld area with gas before you arc up. The tap plinth brazed on much better. I did mill some shoulders to make it easier as its 10mm thick.

Rather than leave a hard welded edge I planished a 90 degree curve on the edges and then recessed the bottom in.

Next the seat… I quite like the back shape, but not the triangle that hangs down… I decided to use the existing seat as a pattern and make a new one out of fiberglass. The original seat is actually quite valuable so I was keen to keep it nice. I covered it in cling film before covering that with 3″ wide sticky foil tape. It's very thin and moulds to shape, and does a good job of following the contours, its actually fantastic stuff and very sticky! To make the things line up to the new tank I used builders foam, which once dry, I cut to shape with a bread knife. Be a few days before the resin and mat arrives!