Ducati 1000 DS custom build

[buzzer]

Originally Posted by Mr Gazza

they could have got all 4 out of that billet!.. And slitted the clamp.

I didn't slit the clamp as I wanted to be sure it was a nice fit on the stanchion... without a slit I could hold it in the chuck and take a skim out... as it was it was bang on

well it didn’t take long to get it all apart! Engine out and on the bench… frame welded and off to the shot blasters… I have to say the frame is exceptionally nice, the welding is superb, and its very light... dare I say a lot better quality than Ducati!... I have always had my frames powder coated at a company I have used for years… Last year they let me down badley, lots of broken promises, and in the end I went and collected an unfinished frame. I decided to have it media blasted and do it myself… That worked out well so I have done the same this time. It was back today from the blasters and it's an excellent job. *I will be etch priming it, undercoat, then 2k Clear over base

One of the common problems with the sportster engine is leaking cylinder base gaskets, this one had sighs of a slight leak so for the cost of a set of gaskets I decided to replace them… Pistons are very big! its all like new in there as you would expect for 5000 miles. While I looked a the bike, one thing was bugging me… that straight case line on the engine… so I modified the casing slightly…I like it… many won't!

[utopia]

The case looks much better after your modification .. though I can't quite understand its original shape in three dimensions.
From what I can see of the modified case it looks like the bits you've trimmed off were serving no purpose anyway.

[buzzer]

Originally Posted by utopia

The case looks much better after your modification .. though I can't quite understand its original shape in three dimensions.
From what I can see of the modified case it looks like the bits you've trimmed off were serving no purpose anyway.

they just hide the oil pump, and on the sportster it butts up against another cover...

The engine is all back together now… its a BIG old lump! I also finished the frame as the weather looks like it will turn too cold next week to do it under the gazebo.

I etch primed it, a coat of 2K primer, them base silver and 2K clear. I don’t think i will go back to powder coat…