So I broke my hand and it's looking like I won't be able to ride until spring which here in new england is about 8 months away.
S in an effort to stay sane I was thinking of stripping the bike down, a 2002 S4, and performing some tweaks.
The bike is in decent shape but has been ridden hard and could use some freshening.
I would like to powdercoat the frame and swingarm, paint the engine, anodize the forks and a bunch of other parts, like the cyclecat risers etc.
I'm fairly mechanically inclined and do all my own maintenance,incl. valves etc. I have the majority of tools that I think I would need and don't mind buying others as long as I will use them again.
I;m curious to know how people who have done this liked the experience and whether they would do it again? What the major pitfalls were? and what kind of cash was spent getting it done?
(http://i49.photobucket.com/albums/f286/Stefans3401/103_0005_3.jpg)
TIA
Gage
thats a great looking bike,
im planning something along those lines as well...good luck man, should be fun to spend time in garage with the bike during those crappy days
Quote from: gage on September 05, 2008, 07:16:01 AM
I'm fairly mechanically inclined and do all my own maintenance,incl. valves etc. I have the majority of tools that I think I would need and don't mind buying others as long as I will use them again.
I;m curious to know how people who have done this liked the experience and whether they would do it again? What the major pitfalls were? and what kind of cash was spent getting it done?
it's not too hard to pull everything apart. i think the last frame/swingarm i got powdercoated was <$200.
Can't think of a better way to spend 8 months of winter [thumbsup]
Most people take things apart and either
1) Never get them back together
or
2) put them together wrong and it's never right again.
Does it start up? Does it work fine? It's not broken-don't fix it.
If you *must* violate something, go find a bike that doesn't work-get an ancient jap bike and make a badass cafe racer. It'll cost a fraction of the duc, and be cool as hell.
Im doing it
(http://i251.photobucket.com/albums/gg305/truckinduc900/SANY2142.jpg)
i broke my knee and femur. Bike was just about fine. I took it as an oppertunity to make it my own. Ill be putting less than a thousand dollars into it.
Quote from: truckinduc on September 05, 2008, 03:28:01 PM
i broke my knee and femur. Bike was just about fine. I took it as an oppertunity to make it my own. Ill be putting less than a thousand dollars into it.
You have a lot of tools that the average person probably does not.....
Thats true, but im doing more to it than most people too
Go for it. I rebuilt a Ninja 250 last year, and I didn't know squat before I started. The DML walked me through the whole process. And some guy (not someguy) took apart his entire bike without a manual and the DML and Norm walked him through the whole process. It was excellent.
Be prepared to spend more than you anticipate. You'll need to buy tools and parts you didn't know you needed. And as we all know, mods happen. We can't stop them. They just happen. ;)
Someguy has a point. You may take on this project and it could end up in disaster. At least you would know more about yourself and your limitations though. I look at this project as having the potential to be one of the most liberating yet focused experiences of your life. A singular vision that only you may be able to see.
I say, take this journey see how deep your passion for this machine reaches 8)
Take lots of pictures as you disassemble.
Take notes.
Make a list of parts you need to replace, as you go, so you don't get hosed during reassembly.
Put bolts or whatever into ziplock baggies as you go, slip a note into each baggie, like 'rear rotor bolts' or 'front fender bolts'.
Get plastic tote boxes to put parts and baggies into.
Clean all of the parts before you pack 'em away, otherwise it's a mess and your assembly schedule blows to hell.
Label parts with blue painter's tape and a sharpie.
Keep kids and critters away from it all, lest they scramble/lose/ruin stuff.
Winterize the gas tank.
Get the CF parts clearcoated, they likely need it.
Get the header and S-pipes polished.
Clean, inspect, and grease up the swingarm and suspension pivots.
If there's any brackets you don't want on the frame, trim 'em off before powdercoat.
Make the powdercoater painfully aware of the necessity if *not* obliterating the VIN# stamped on the head tube, if they sandblast it and powdercoat over it, it'll be like it was never there, and that really sucks.
Also, tell 'em to plug the threaded holes, otherwise you get to run a tap through 'em afterward, or bugger things up at assembly.
On a lot of stuff, you can thread the bolts back in to where they were after you disassemble.
Make a plan or a flowchart or Excel spreadsheet or*something* to schedule and track the project, what stuff is done, which vendors have which parts, etc.
Helps avoid the realization that the fork legs are missing, and you talked to ten vendors, and don't remember who has 'em...
Wrap the bodywork and shiny parts up so they don't get rashed.
Put the radiator in a box so it doesn't get pranged.
Take lots of pictures as you disassemble (did I say that already?).
Don't forget to do something about that [puke] yellow spring.
Also, make sure you have Speeddog's and Duck-Stew's cell numbers on speed dial. ;D
Six things:
1) guestimate your expenses and then double them. Most will go to tools which are an "investment" of sorts.
2) instead of tape (which gets messed up) use zip-ties to mark your electrical connections. Get three different colors and intermix on both side of the connectors. Fastest and easiest way for a newbie to reassemble a wiring harness correctly as everything is color coded then.
3) take lots of pictures
4) build an engine stand to properly hold the engine up. You can make in metal, wood or whatever. (do a search on what others use) You won't regret doing it.
5) create a "game plan" BEFORE you tear everything apart ala colors / parts / etc. Follow your plan then and don't let friends talk you into changing things as you go along -- it will turn into a mish-mash of sorts then. Do a mockup in Photoshop to visually create if you can.
6) Loctite and torque wrenches are your friend -- use them and use properly
and the most important item:
- remember to have fun while you are building your bike!
I did that last winter: I took apart a perfectly good Monster just because. It was a little stressful, and I made a few mistakes, but overall I enjoyed it so much that I'm looking for another project bike for this winter! BTW, I have roughly the same wrenching experience as you.
(http://farm4.static.flickr.com/3181/2831312681_386884ff89_o.jpg)
(http://farm4.static.flickr.com/3195/2832147832_493a93320e_o.jpg)
(http://farm4.static.flickr.com/3207/2831312721_b8ccdba201_o.jpg)
(http://farm4.static.flickr.com/3174/2832147898_51c99bb1ce_o.jpg)
(http://farm4.static.flickr.com/3293/2831312753_6299da8f5e_o.jpg)
(http://farm4.static.flickr.com/3001/2831312771_69f795af22_o.jpg)
(http://farm4.static.flickr.com/3101/2832147970_67e85f5c72_o.jpg)
(http://farm4.static.flickr.com/3210/2832148002_fc55f46457_o.jpg)
(http://farm4.static.flickr.com/3146/2831312825_b953efca25_o.jpg)
All great advice! I'm thinking there is a pretty good chance that I tackle this.
like I said I have a lot of tools and would really only need to buy the tools which are specific to ducati.
I have done projects similar to this before on cars but never on a bike and since this bike is rust free I am hoping that the process will at least be easy in that respect.
As for torque wrenches I've got them from 12 in lbs up through 250 lb ft so I should be good there.
I've already rebuilt the forks so I have those tools too
The only things I don't have would be a press or any special tools needed to remove or drive in races.
Keep it coming!!! It is helping
(http://i251.photobucket.com/albums/gg305/truckinduc900/SANY1784.jpg)
Cheap and easy engine stand i made
I tore mine completely done and replaced the engine. I put a good deal of money in it but as I said I replaced the engine. The engine was the reason for my rebuild. I got a 900 engine (with the good V2 heads) with an oil cooler and carbs plus a Cycle Cat sprocket and clutch cover for $400. I couldn't pass up the deal.
Without replacing a lot of parts, it won't cost you that much. I powder coated the frame, shock spring, swingarm, and other small bits for about $300.
As many have said, pictures and properly labeled hardware containers will make the process much easier. I took a few pictures for electrical components, but I didn't feel the need for much more, but they are a good reference, especially if you don't have a good memory. Pictures are must for ground connections though. But for the most part, bikes are so simple, you can look at a part and know where it goes.
Also, heed Speeddog's advice to clean everything as you take it off. It just makes everything look better and makes reassembly much cleaner (this is something that I did do for the most part). I also replaced a lot of the bolts.
The only races I remember removing were from the head tube. You just need something to use as a drift and a hammer to get these out. I used a 2x4 and a hammer to drive them back in.
My bike is carbed, so it was a little simpler than an injected 4V. The electrical system on those bikes will be your biggest obstacle and most likely is where a mistake will be made when/if you make one.
Take your time, do it right, and have fun.
I did it on my bike - twice. I did everything aside from removing the engine or wheels, I completely redid my cylinder heads the first time, did every single little maintenance item, fixed a bunch of flaws and did some basic tuning. Second time was basically a refresher, installed MBP collets and re-adjusted everything. Both times I did it in less than 2 weeks, tinkering with it during the evenings (both times I was using borrowed garages that I had to travel to). So in other words it wasn't much of a winter project because it was done relatively quickly. But then again I've worked as a mechanic, so 2 weeks seems quite long to me when you have all the parts on hand and don't have to wait for stuff to come on the slow boat from Italy. If you are new to it I strong suggest taking your sweet time. I know my bike inside and out, I can identify a stray bolt just by how it looks. It's worth learning the processes, though, if you are a competent wrench monkey, and immensely satisfying to get your bike setup just so and running like never before. Of course there is a lot of potential for catastrophe in that.
go buy a shitload of small plastic boxes like Gladware and larger ones for separating things.
that's the only way to do it unless you have a huge dedicated space. baggies to separate very small parts.
it is doable. just make sure to "measure twice and cut once"
Quote from: truckinduc on September 05, 2008, 06:50:08 PM
(http://i251.photobucket.com/albums/gg305/truckinduc900/SANY1784.jpg)
Cheap and easy engine stand i made
i like that swingarm pin mount.. rofl.. what is that just a 8mm headless bolt?
the swingarm pivot is above that. And its a stainless rod about 4 mm
(http://i251.photobucket.com/albums/gg305/truckinduc900/SANY2135.jpg)
SEE
Quote from: truckinduc on September 06, 2008, 09:32:16 AM
the swingarm pivot is above that. And its a stainless rod about 4 mm
i can see that (the "real" swingarm hole) i just thought it was funny to have a tiny little swing pin [laugh]
Quote from: NeufUnSix on September 05, 2008, 07:37:49 PM
I did it on my bike - twice. I did everything aside from removing the engine or wheels, I completely redid my cylinder heads the first time, did every single little maintenance item, fixed a bunch of flaws and did some basic tuning. Second time was basically a refresher, installed MBP collets and re-adjusted everything. Both times I did it in less than 2 weeks, tinkering with it during the evenings (both times I was using borrowed garages that I had to travel to). So in other words it wasn't much of a winter project because it was done relatively quickly. But then again I've worked as a mechanic, so 2 weeks seems quite long to me when you have all the parts on hand and don't have to wait for stuff to come on the slow boat from Italy. If you are new to it I strong suggest taking your sweet time. I know my bike inside and out, I can identify a stray bolt just by how it looks. It's worth learning the processes, though, if you are a competent wrench monkey, and immensely satisfying to get your bike setup just so and running like never before. Of course there is a lot of potential for catastrophe in that.
+1 this will also give you an amazing sense of confidence when/if you are taking road trips. If something does start acting up on it, you know "I've been through this entire bike, there is nothing here I don't know". I had this happen to me about 30 miles from nowhere, I knew a shop in the next town I'de rented a Jeep from once, I nursed it there pulled in and asked Billy if I could borrow a couple tools for a minute. 15 minutes later on my way again. Totally recommend doing the build, Monsters are a joy to work on. I've owned a lot of bikes and I've felt a feeling of satisfation working on them, but never the joy I've felt working on my Monster. 3k since rebuild and running strong...... BTW mine was totalled with a broken frame though.
(http://i219.photobucket.com/albums/cc260/WannaDucBad/motorcycles/DragonResurrection053.jpg)
Nothing crazy in what you're thinkin as far as I'm concerned. I'm going to be doing the same thing (herniated disc in my neck no riding til spring)
Good Luck and let's have some fun ;D
Cheers G