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DB7-11 VLX MULE resurrection
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Gavin944888



Joined: 29 Jan 2014
Posts: 296
Location: Essex....way South of Scotland

PostPosted: Tue Feb 06, 2018 5:32 pm    Post subject: Reply with quote

Still cannot get the hang of these damn buttons! I submit when I should be previewing....Ho Hum


Anyway back to the tales of woe.

The Bimota DB7-11 VLX MULE is being rewired and fitted with a MotoGadget control unit which in turn does away with the ignition key.


The bike ignition is activated via a fob held to the receiver, which is mounted in the old ignition switch position.



IMG_0747 by Gavin Robertson, on Flickr



From MotoGadget sketches I have machined up a replacement ignition switch thingy to house the receiver....here's hoping it works!




IMG_0747 - Copy by Gavin Robertson, on Flickr



Once the ignition side was complete I could turn to finally fixing the fairing bracket and sizing off the attaching components...mainly the tank.


The Fuel tank could be finally positioned, supported and secured.



IMG_0689 (1) by Gavin Robertson, on Flickr



A section of 10mm thick alloy with some extra supports as the tank sits 10mm higher than standard...also some foam pads were added to the inside of the frame



IMG_0688 (1) by Gavin Robertson, on Flickr




These modifications in turn, allowed the seat positioning to be completed




IMG_0740 by Gavin Robertson, on Flickr



I had decided to incorporate a Suburu fuel pump and extra volume fuel filter. These are mounted in their respective cradles and fixed to the seat unit subframe.



IMG_0741 by Gavin Robertson, on Flickr



Well away from the heat of the exhaust but still downward from a gravity point of view from the fuel tank.

The elastic bands will be replaced with HOOVER belts as the thing progresses.


Two 1/4 inch BSP fittings one supplies and the other returns fuel from the tank via thermal protected hoses.



The overhead drive belt assembly has had a return edge added and vent holes introduced to assist in cooling the Ducati belts as fitted.

This unit will be powder coated satin black with S/Steel mesh bonded to the inside of the cover.....I had planned this return edge, from the very start of the fabrication and it is why there was a step in the profile of the belt cover.




IMG_0743 by Gavin Robertson, on Flickr




IMG_0744 by Gavin Robertson, on Flickr



Here you can see the step..........the weld has yet to be dressed



IMG_0742 by Gavin Robertson, on Flickr



So with this done....it allowed another piece of the jigsaw to be finished.


Both side plates and belt cover are now ready to go to the Powder Coating for some Satin Black finishing....same as the frame.


Without a doubt, the most difficult bit so far is the AirBox and everything attached to it



IMG_0748 by Gavin Robertson, on Flickr



Here you can see that the extra vacuum sensor hole HAD to be used M6 drilled and tapped into the S/Steel hex plug and the blue silicone reducer leads onto the by-pass valve.


It works like this.....................a vacuum is created in the air-box once the throttle (on the bars) is closed


BUT the Supercharger is still pumping as it has not caught up with the decreasing turbines......the air is dumped from here


IMG_0754 by Gavin Robertson, on Flickr



Air leaves the Air Box via the blue silicone reducer into the air bypass valve



IMG_0750 - Copy by Gavin Robertson, on Flickr




Which is opened by this vacuum controlled valve...which is operated via the tube coming from the M6 nozzle to the diaphragm side on the valve.



IMG_0751 - Copy by Gavin Robertson, on Flickr



The valve is mounted by a bracket which took 3 hours to make and find a suitable working position (using the bolt holes on the injection plate) these

were originally designed by DUCATI to hold the Stepper motor between the cylinders....hope I don't need that motor!....3 painstaking hours of skinned knuckles



IMG_0753 by Gavin Robertson, on Flickr



Anyway...........the diaphragm lifts the pull bar at a given mercury drop and that pull bar opens (via a cam) a butterfly valve in the bypass ..........

letting air out and creating a loop, before being fed back in to the supercharger in front of its own throttle valve....as intake air!


Untitled by Gavin Robertson, on Flickr



Don't ask.....all I know is that someone else thought this system up and it still seems alien to me....and I am working with it!


Here you can see the by pass valve angled under the throttle bodies and pointing back to wards the air intake side of the bike



IMG_0748 by Gavin Robertson, on Flickr



At this point I am working blind................I think I am doing the correct thing and in the correct order but who really knows!


There are no workshop manuals, so I have to refer back to last Easter and the photographs taken when the unit arrived and as it came out of the box.


I assembled this on a table shortly after it arrived from Australia.

This lay out was designed for the DUCATI HYPERMOTARD not the Diavel ...oh lordy!


Untitled by Gavin Robertson, on Flickr


STILL....what is the worse that could happen....undeterred we carry on!!










Next up pegs and stuff........



IMG_0746 by Gavin Robertson, on Flickr





IMG_0745 by Gavin Robertson, on Flickr



and the penultimate chapter prior to wiring.....hope that you are still enjoying this.......I am not sure if I am.


regards

Gavin
_________________
On an Island in the Thames.

Cagiva Elefant 944/ST2 engined
Cagiva Elefant 888/955 engined
Cagiva Elefant 999r engined

BIMOTA DB9 1198 engined
BIMOTA DB7 VLX MULE (project build)
a Zues Book, French fag packet and hope.
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TVRRICH



Joined: 05 Feb 2016
Posts: 106
Location: Coventry UK

PostPosted: Tue Feb 06, 2018 9:14 pm    Post subject: Reply with quote

Thanks for the update Gavin, fascinating stuff, cant wait for the next update
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djt77



Joined: 27 Feb 2008
Posts: 362
Location: Perth, Western Australia

PostPosted: Wed Feb 07, 2018 12:46 am    Post subject: Reply with quote

Keep going Gavin, it's always highlight of my day when i see this thread being updated. Doing a magnificent job
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quikduk



Joined: 13 Aug 2016
Posts: 156
Location: Southern California, USA

PostPosted: Mon Feb 12, 2018 10:22 pm    Post subject: Reply with quote

Absolutely fantastic Gavin! Keep going (uphill all the way I would imagine). Cool
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Gavin944888



Joined: 29 Jan 2014
Posts: 296
Location: Essex....way South of Scotland

PostPosted: Fri Feb 16, 2018 1:01 pm    Post subject: Reply with quote

Okay, this is the last but one posting prior to the ECU and wiring section.

All hardware has been 98% completed only cables and hoses have to fitted along with gear lever rods and final foot assembly areas.

The body work has been cut but not fitted yet although the seat tank and supports are all ready.

So..........like everything detail is an issue and all bolts have to be checked and gaskets fitted.....here we go.



IMG_0759 (1) by Gavin Robertson, on Flickr



The fairing/dash support had to be finalized and I wanted to incorporate an addition fixing point for a alloy fairing support section I had designed.



IMG_0760 (1) by Gavin Robertson, on Flickr



What you see here is addition support for the dash bracket and the 2 alloy rods will have some lugs welded on them to link up with the planned bracket.

You might also pick out the lack of a steering lock hole....the frame had been plugged and welded!



The radiator from a Ducati MTS 1200 (these are straight and not curved giving more room where needed.....I have used these before on other builds) this could now be fixed and the 12V horn added into the equation.



IMG_0762 (1) by Gavin Robertson, on Flickr



The gasket was cut and fitted allowing the closing off of the top section of the air box............long 30mm bolts at every corner and 20mm bolts in between........and the badge of honour!



IMG_0755 (1) by Gavin Robertson, on Flickr



I looked at this belt cover and drove the welder mad.........he had taken so much time, to weld (just) the inside only.



IMG_0742 by Gavin
Robertson
, on Flickr



IMG_0784 by Gavin Robertson, on Flickr



But I was not sure about the look and the delays in powder coating just added to my questioning......over the 2 week wait...I had decided

Devil makes for idle hands........and the devil is in the detail




IMG_0785 by Gavin Robertson, on Flickr



From this old photograph, you can see that there is very little room between the supercharger and the frame.



IMG_0517 by Gavin Robertson, on Flickr



This dictated that whatever design was chosen it would have to be able to slide into the frame and be bolted up from outside the frame.

The photographs from BIMOTA VLX prototype shed no light...that area was covered by a K&N Pancake style filter last seen on a VW beetle.

So a lot of head scratching went on and a layered approach was considered.



IMG_0763 by Gavin Robertson, on Flickr



First off start with a blank 10 mm thick plate and match the turbine area profile BUT only 5mm deep.


IMG_0767 by Gavin Robertson, on Flickr


Then machine through the alloy plate BUT for only half of the profile.



IMG_0769 (1) by Gavin Robertson, on Flickr


Finish off the outside profile and you are left with this.



IMG_0771 (1) by Gavin Robertson, on Flickr



Flip it over (on the mill) and relieve the outside section making the profile look stepped from an above view.



IMG_0772 (1) by Gavin Robertson, on Flickr


It now looks like this and can be slide through the gaps and line up with the Supercharger.



IMG_0782 by Gavin Robertson, on Flickr



The air chamber is the full depth of this side and a 5mm deep recess on the other turbine..........this is the first layer!



IMG_0781 by Gavin Robertson, on Flickr



You might visualize that the air comes on via a throttle body and is compressed after it is drawn into the turbines. The area this side of the turbine creates the plenum area.

Here we have the next Layer!



IMG_0774 by Gavin Robertson, on Flickr



IMG_0779 by Gavin Robertson, on Flickr



And here you can see how it all builds up ....allowing the manifolds to fit the frame and leave a clean area for another air inlet layer..



IMG_0778 by Gavin Robertson, on Flickr
_________________
On an Island in the Thames.

Cagiva Elefant 944/ST2 engined
Cagiva Elefant 888/955 engined
Cagiva Elefant 999r engined

BIMOTA DB9 1198 engined
BIMOTA DB7 VLX MULE (project build)
a Zues Book, French fag packet and hope.
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Gavin944888



Joined: 29 Jan 2014
Posts: 296
Location: Essex....way South of Scotland

PostPosted: Fri Feb 16, 2018 1:23 pm    Post subject: Reply with quote

Hit the wrong button...AGAIN.


This is the chosen throttle body and it is being readied for a transition section.



IMG_0776 by Gavin Robertson, on Flickr



It is being placed for the correct fitment but also the line.



IMG_0775 by Gavin Robertson, on Flickr



The transition section is prepped and positioned on the air intake side of the Supercharger




IMG_0773 by Gavin Robertson, on Flickr



The transition section is cut into the Layered plate and tidied up.



IMG_0787 by Gavin Robertson, on Flickr





IMG_0789 by Gavin Robertson, on Flickr



There was much concern over the air intake opening BUT 50mm dia is the correct area by volume (I am told) and this slot matches that volume by area.....

The machined plate is offered back onto the Supercharger



IMG_0790 by Gavin Robertson, on Flickr



IMG_0791 by Gavin Robertson, on Flickr



So the air enters via the slot and is distributed along the plenum area and compressed by the turbines running at 3.2 times engine speed.

Pushed upwards into the manifold and shaped air box where it enters the Ducati throttle bodies before having the fuel added in the inlet track.



IMG_0792 by Gavin Robertson, on Flickr



Here is a view all bolted up and a K&N fitted to the end.

This not the final design just a end to this side of the machining.

The next section includes some air inlet pipe going to the front of the bike.

With the inlet facing straight out to the air ducts either side of the headlamps and fairing.




IMG_0793 by Gavin Robertson, on Flickr



But for the time being and until the other sections are finalized, this is how the airbox and supercharger are closed off.



Almost there..............what's the worst that happen?


Thanks for the support and kind words....we all need them sometime....believe me!

Gavin
_________________
On an Island in the Thames.

Cagiva Elefant 944/ST2 engined
Cagiva Elefant 888/955 engined
Cagiva Elefant 999r engined

BIMOTA DB9 1198 engined
BIMOTA DB7 VLX MULE (project build)
a Zues Book, French fag packet and hope.
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stockcar



Joined: 07 Apr 2011
Posts: 636
Location: in the shadow of the "angel"

PostPosted: Fri Feb 16, 2018 9:33 pm    Post subject: Reply with quote

Stunning
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Admin
Site Admin


Joined: 22 Oct 2007
Posts: 381
Location: Stafford, UK

PostPosted: Mon Feb 19, 2018 7:45 pm    Post subject: Reply with quote

Wow.

That is a lot of work

Katy
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rpo83



Joined: 28 Oct 2008
Posts: 269
Location: Melbourne, Australia

PostPosted: Tue Feb 20, 2018 4:52 am    Post subject: Reply with quote

Great work, love the Range Rover badge Smile
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Cheers

Steve

1988 YB5
1995 SB6
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2bims



Joined: 03 Apr 2010
Posts: 4516

PostPosted: Tue Feb 20, 2018 9:04 am    Post subject: Reply with quote

Good eyes there....is that where the superchugger badge comes from...and seems the ideal size also...I'd love to comment more on this amazing thread...but like others...am just in awe of one mans passion to get what Bimota wouldn't/couldn't provide......its all complete Dutch/Swaheli in language to my simple knowledge though...hence not being able to comment further.... Crying or Very sad
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