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DB7-11 VLX MULE resurrection
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Gavin944888



Joined: 29 Jan 2014
Posts: 342
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 River Thames (sounds wonderfull...doesn't it)

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

BIMOTA DB9 (with DB11 rear end)
BIMOTA DB7-11 VLX MULE (project build with no end)
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TVRRICH



Joined: 05 Feb 2016
Posts: 127
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: 375
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: 176
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: 342
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 River Thames (sounds wonderfull...doesn't it)

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

BIMOTA DB9 (with DB11 rear end)
BIMOTA DB7-11 VLX MULE (project build with no end)
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Gavin944888



Joined: 29 Jan 2014
Posts: 342
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 River Thames (sounds wonderfull...doesn't it)

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

BIMOTA DB9 (with DB11 rear end)
BIMOTA DB7-11 VLX MULE (project build with no end)
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stockcar



Joined: 07 Apr 2011
Posts: 724
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: 503
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: 316
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: 5436

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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Number2



Joined: 25 Jun 2017
Posts: 38
Location: South Carolina

PostPosted: Fri Feb 23, 2018 7:46 pm    Post subject: Reply with quote

I just hope it runs otherwise you will have a huge paper weight. Truly excellent work
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Gavin944888



Joined: 29 Jan 2014
Posts: 342
Location: Essex....way South of Scotland

PostPosted: Fri Mar 09, 2018 3:35 pm    Post subject: Reply with quote

Number 2 ...........you are not the only one that hopes that it works!

So ..........we are where Bimota were.... as in air intake area but I have some different views on intake and this is where the system changes.

In an ideal world the air intake would be at the front....so that is what I am going to do....
the BIMOTA option was a large pancake filter, which was one of their issues encountered.


IMG_0793 by Gavin Robertson, on Flickr



So we go from this method to this...by means of.....



IMG_0836 by Gavin Robertson, on Flickr


An air-intake tube is machined and extra sensors as recommended by Davide Commandini are fitted to measure air pressure and temp.

In addition an air excess or bypass valve has to put the excess somewhere, hence the inlet tube into the intake pipe.



IMG_0837 by Gavin Robertson, on Flickr


This was bolted to the throttle body as such....awaiting a foam filter which should nestle up to the air intake on the fairing nose cose



IMG_0839 by Gavin Robertson, on Flickr


The by pass pipe was fitted to the intake and silicone hoses take up the vibration...the colour WILL BE CHANGED!


IMG_0840 by Gavin Robertson, on Flickr


That alloy pipe runs back to the bypass valve again with a blue reducer....this is the vacuum operated valve.


IMG_0841 by Gavin Robertson, on Flickr



The next area was the rear sub-frame which was fitted and welded.


IMG_0812 by Gavin Robertson, on Flickr



The sub-frame incorporated the battery box and space for all the electrics...hopefully.



IMG_0831 by Gavin Robertson, on Flickr


Whilst waiting....I sent the metal parts off for powder coating.


IMG_0828 by Gavin Robertson, on Flickr



A better view if the battery box......made to suit a lithium sized battery of the correct rating.



IMG_0829 by Gavin Robertson, on Flickr



The 2 feet at the rear locate on the number plate assembly- rear indicator holder, whilst the front single foot locates the front of the rear carbon seat section.


The belt cover was painted rather than powder coated and stainless mesh was glued to the air inlet holes to keep out intruders....and small fingers.




IMG_0842 by Gavin Robertson, on Flickr



The pullies were mounted and the belts temporary tensioned by cable ties!



IMG_0844 by Gavin Robertson, on Flickr



Some cam shaped adjusting pullies were machined fro stainless and aluminium and adjusters added.



IMG_0835 by Gavin Robertson, on Flickr


The front one is the stand-off pulley(clutch side) whilst on the other, you can see how they are adjusted.


IMG_0834 by Gavin Robertson, on Flickr


This is the final positioning prior to the engine running.


IMG_0845 by Gavin Robertson, on Flickr


And again.......the belt runs on the pulley guide which picks up the outside of the belts.



IMG_0846 by Gavin Robertson, on Flickr



And here is the shot of all belt assemblies in place with their respective outrigger bearings fitted



IMG_0847 by Gavin Robertson, on Flickr
_________________
On an Island in the River Thames (sounds wonderfull...doesn't it)

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

BIMOTA DB9 (with DB11 rear end)
BIMOTA DB7-11 VLX MULE (project build with no end)
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Gavin944888



Joined: 29 Jan 2014
Posts: 342
Location: Essex....way South of Scotland

PostPosted: Fri Mar 09, 2018 4:10 pm    Post subject: Reply with quote

Sorry................once again ......hit the wrong button.


The air intake side was completed to a fashion....good enough for DYNO and the bike looks like this...you can just see the fairing section behind the bike.


IMG_0851 by Gavin Robertson, on Flickr



The oil pressure switch was obstructed by the supercharger clutch drive



20170414_094535 by Gavin Robertson, on Flickr




and replacement was found



IMG_0819 by Gavin Robertson, on Flickr


This is from a DUCATI 1199 but I could no where to mount it.

Another solution was sought....by means of a T section and tapping one side.


IMG_0818 (1) by Gavin Robertson, on Flickr


30 at the local hydraulic company and the OEM Ducati (too long) oil lines were shortened and a new T section introduced.....(best money spent)

I just had to drill and tap the 'blank end' to suit the thread on the oil sensor and fit.


The finished oil lines and right hand side of bike .....not happy with exhaust line or length.... but.....for now it will do....I have a set of RaceFit units that might be fitted...not sure..but the line is wiong

The GRP seat base has to cut, upholstered and fitted... but I will give the DYNO guy a cushion to sit on ...for the meantime.



IMG_0850 by Gavin Robertson, on Flickr


And that is about it..........water hoses have been, fitted throttle cables cut and soldered, there are no fluids on the bike......it needs another day to go over every bolt and torque everything.....but it is at home now and waiting to be wired.


IMG_0857 by Gavin Robertson, on Flickr



I have decided to use the OEM DB7 dash.........I felt that the flatscreen TFT colour dash option, was like putting mag alloys on a E Type.


IMG_0093 by Gavin Robertson, on Flickr



The forecast dyno runs start in mid April.....but when dealing with someone else.......who knows.......plus I keep adding things!


Thanks for the support and those forum guys from down under

This project is done ...stage 1.....engineering and hardware...

next stage 2 .............wiring and fettling.......

then stage 3 bodywork and finishing....colour schemes etc


Still..... it is better than wiring...I HATE WIRING


regards
Gavin


My engineers reference book, hole sizes including thread details and PCD calculations..............



IMG_0026 by Gavin Robertson, on Flickr



The Supercharger reference book, pulley sizes, mercury drop activated valves and oil choices...........



20170414_132020 by Gavin Robertson, on Flickr



The BIMOTA DB7-11VLX workshop manual.........!!




20170414_093121 by Gavin Robertson, on Flickr



The actual inspiration...........the engineers' dream



2 by Gavin Robertson, on Flickr




keep dreaming.........'What is the worse that can happen?'
_________________
On an Island in the River Thames (sounds wonderfull...doesn't it)

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

BIMOTA DB9 (with DB11 rear end)
BIMOTA DB7-11 VLX MULE (project build with no end)


Last edited by Gavin944888 on Fri Mar 09, 2018 4:35 pm; edited 1 time in total
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Gavin944888



Joined: 29 Jan 2014
Posts: 342
Location: Essex....way South of Scotland

PostPosted: Fri Mar 09, 2018 4:11 pm    Post subject: Reply with quote

Sorry................once again ......hit the wrong button.


The air intake side was completed to a fashion....good enough for DYNO and the bike looks like this...you can just see the fairing section behind the bike.


IMG_0851 by Gavin Robertson, on Flickr



The oil pressure switch was obstructed by the supercharger clutch drive and replacement was found



IMG_0819 by Gavin Robertson, on Flickr


This is from a DUCATI 1199 but I could no where to mount it.

Another solution was sought....by means of a T section and tapping one side.


IMG_0818 (1) by Gavin Robertson, on Flickr


30 at the local hydraulic company and the OEM lines were shortened and a new T section introduced.....(best money spent)

I just had to tap the blank to suit the thread on the oil sensor and fit.


The finished oil lines and right hand side of bike .....not happy with exhaust line or length but.....for now it will do....I have a set of RaceFit units that might be fitted.

The GRP seat base has to cut, upholstered and fitted... but I will give the DYNO guy a cushion to sit on ...for the meantime.



IMG_0850 by Gavin Robertson, on Flickr


And that is about it..........water hoses have been, fitted throttle cables cut and soldered, there are no fluids on the bike......it needs another day to go over every bolt and torque everything.....but it is at home now and waiting to be wired.

I have decided to use the OEM DB7 dash.........I felt that the flatscreen colour dash option, was like putting mag alloys on a E Type.

The forecast dyno runs start in mid April.....but when dealing with someone else.......who knows.......plus I keep adding things!


Thanks for the support

The project is done for stage 1.....hardware...

next stage 2 .............wiring and fettling.......

then stage 3 bodywork and finishing....colour schemes etc


Still..... it is better than wiring...I HATE WIRING


regars
Gavin


My engineers reference book, hole sizes including thread details and PCD calculations..............



IMG_0026 by Gavin Robertson, on Flickr



The Supercharger reference book, pulley sizes, mercury drop activated valves and oil choices...........



20170414_132020 by Gavin Robertson, on Flickr



The BIMOTA DB7-11VLX workshop manual.........!!




20170414_093121 by Gavin Robertson, on Flickr



What is the worse that can happen?
_________________
On an Island in the River Thames (sounds wonderfull...doesn't it)

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

BIMOTA DB9 (with DB11 rear end)
BIMOTA DB7-11 VLX MULE (project build with no end)
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2bims



Joined: 03 Apr 2010
Posts: 5436

PostPosted: Fri Mar 09, 2018 5:11 pm    Post subject: Reply with quote

Again...I'm at a loss for words...and I ended up reading through old posts of this thread without realising.....as its all stratospherically above my knowledge and ability.....Nice to see a couple of shots of the proposed full bike.....I can see its a bike now...most shots are wonderfully explicit, but pure engineering....I think its a new master criminal war machine being made until I get shots of wheels, handlebars and petrol tank...and then I recall..oh yeh...its a bike hes building...liking the faithful recreation of what was to be, should have been, but never was...and choice of dash also...you only really need to know if the engines getting hot...how far you've gone so you don't run out of fuel...and speed for when theres cameras around...these new fangled dashes are wonderful with their 3 million combinations and read outs but Jeeso....aren't you supposed to be riding a bike and enjoying it...and watching out for other road users????..Rather than a display fot for an arcade machine where theres zero danger????......Partly why me likes KDX220...speedo...and total mileage read out...and that's it...a button to stop the engine...one for lights on/off...and a horn...KISS......
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