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DB7-11 VLX MULE resurrection
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Gavin944888



Joined: 29 Jan 2014
Posts: 327
Location: Essex....way South of Scotland

PostPosted: Fri May 05, 2017 10:47 am    Post subject: Reply with quote

Hello...............my flickr account does not look like that and does not have the BBcode button to hit. It does go into a blue text in the box, but, if you copy and paste.
..(all good so far)..all you get is the code in text line as per the above message.

Trying to find a teenager to help explain and show me the way....if you don't hear from me...it has all gone wrong and I have been arrested

Paid someone 20 to set up my iPhone last weekend...technology is a costly past time.

regards
Gavin
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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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brian



Joined: 22 Aug 2011
Posts: 2447
Location: QLD, Australia

PostPosted: Fri May 05, 2017 11:31 am    Post subject: Reply with quote

I use a photo bucket account to share photos on here. It's clunky and not very user friendly but it works... most of the time. In fact my photo bucket account is playing up at the moment, won't let me upload photos Mad
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Current rides - '99 Bimota DB4, '96 Bimota SB6, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250,
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rpo83



Joined: 28 Oct 2008
Posts: 289
Location: Melbourne, Australia

PostPosted: Fri May 05, 2017 11:34 am    Post subject: Reply with quote

Everyone's flickr is the same... you need to click on the image you want to share so it is in it's own window, then it will look like my image, well, it's all black around the image until you click the share arrow down the bottom...

When in flickr, click on 'you' then 'photostream' this will show thumbnails of your images, then click on the image you want to share....

You're almost there...
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Cheers

Steve

1988 YB5
1995 SB6
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Gavin944888



Joined: 29 Jan 2014
Posts: 327
Location: Essex....way South of Scotland

PostPosted: Fri May 05, 2017 11:48 am    Post subject: Reply with quote

Gentlefolk......I am NOW ....tech savvie!

IMG_0029 by Gavin Robertson, on Flickr


Prepare for some nonsense.

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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brian



Joined: 22 Aug 2011
Posts: 2447
Location: QLD, Australia

PostPosted: Fri May 05, 2017 11:50 am    Post subject: Reply with quote

Nice work Gavin! Welcome to the 21st century Laughing
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Current rides - '99 Bimota DB4, '96 Bimota SB6, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250,
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Gavin944888



Joined: 29 Jan 2014
Posts: 327
Location: Essex....way South of Scotland

PostPosted: Fri May 05, 2017 12:09 pm    Post subject: Reply with quote

Thank you to RPO83 and Brian.............once pointed in the right direction it still didn't make sense.

But the teenagers of Canvey Island are safer and can get back to cider, fags and lovebites...ahh wonderful Essex!



IMG_0030 - Copy by Gavin Robertson, on Flickr



Among the items of the latest BCP box was the rear suspension assembly



IMG_0028 by Gavin Robertson, on Flickr



The quality of the items is up there with the price!



IMG_0029 by Gavin Robertson, on Flickr



Each section wonderfully machined and packed with care.

The black alloy billet sections attach to the engine and support the three

black spindles for the rocker arm and linkages for the shock.

The whole assembly is then kept in place via alloy end caps and utilizes the

same linkage assembly as the HONDA ProLink system.....although with

probably anti copyright changes.


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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Gavin944888



Joined: 29 Jan 2014
Posts: 327
Location: Essex....way South of Scotland

PostPosted: Fri May 05, 2017 1:10 pm    Post subject: Reply with quote

Sorry for the delay, BUT as I am now a TECCIE, I thought I would buy some

roller blades and a baseball cap!

Whilst the OEM frame was being re powder coated I shifted the attention to

the engine, and in particular to the injection system.

I had already purchased with the frame the compete Diavel injection unit and

Air Box, but this OEM Ducati systwm is Fly-by-Wire as I have only just learned

how to upload an image to the website...F-b-W throttle bodies was kind of

pushing the envelope.......a set of 1098 units were sourced.

This allowed me to put the Diavel air box and throttle bodies complete with

fuel rails on the Ebay......I thought I will sample sell some other parts to see

if buying a complete bike and stripping it was an option


It wasn't...not a sausage...no takers....not even a bid.

I spoke to my Ducati guy only to find that Diavel owners really don't do

modification unless it is comfort ot exhaust...they do store or hold

parts...they are just not that kind of owner!...this alone made me decide to

build it from contacts and parts rather than a Donor Bike.

First up was the injection trumpets from the 1098...these had to change.


IMG_0025 by Gavin Robertson, on Flickr




The originals were cut down to 6mm and these are what was left!



Untitled by Gavin Robertson, on Flickr


The 6mm sections (the bits cut down) were used to enter some alloy bell

mouths needed for the supercharger. These oval bellmouths were fabricate

on 6mm alloy plates and placed over the original injection brackets.


Untitled by Gavin Robertson, on Flickr


These were formed by cutting and welding air intakes trumpets readily

available on Ebay...I bought 4 and made the 2 sets....the 5mm holes on the

plate match up to the OEM bell mouth-throttle body plate.


Untitled by Gavin Robertson, on Flickr



The other plate..........sitting on a clip board...health and safety!


Each plate mounts to this...you can see the 6mm upstands.


Untitled by Gavin Robertson, on Flickr




Untitled by Gavin Robertson, on Flickr


This shows the room to work with.


Untitled by Gavin Robertson, on Flickr


This is the front side...injector plate....all the welds have to be dressed yet.


The fit was tight....and each plate had to have one side machined back.



Untitled by Gavin Robertson, on Flickr




Untitled by Gavin Robertson, on Flickr



The next shots show the bridge and the cut back sections



Untitled by Gavin Robertson, on Flickr



Untitled by Gavin Robertson, on Flickr


These shots show the bridge in place and its final position.



Untitled by Gavin Robertson, on Flickr


The bridge is now ready to have the new alloy air box fabricated around it.

The Supercharger sits under the bridge (in the gap) and forces the air up

and into the air box via a machined vent (not done yet) in the bridge!

Untitled by Gavin Robertson, on Flickr



I am taking the OEM DB9 air box that I have and using it as a pattern and

then trying to marry up the two fabricated sections together.

Once I have the shape I can start playing with the air by-pass valve and sensor locations.


More to follow soon.....


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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rpo83



Joined: 28 Oct 2008
Posts: 289
Location: Melbourne, Australia

PostPosted: Sat May 06, 2017 12:39 am    Post subject: Reply with quote

Congrats Tecchie Smile

There is no stopping you now, can't wait to follow this journey, it's going to be EPIC!!
_________________
Cheers

Steve

1988 YB5
1995 SB6
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vort28



Joined: 22 Mar 2010
Posts: 1803
Location: Northwest , UK

PostPosted: Mon May 08, 2017 6:41 pm    Post subject: Reply with quote

Coming along at a fair pace there Gav , you must be on speed dial to BCP bank by now !! Shocked
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Gavin944888



Joined: 29 Jan 2014
Posts: 327
Location: Essex....way South of Scotland

PostPosted: Tue May 09, 2017 8:26 am    Post subject: Reply with quote

HHmmm...BCP...great products, great service but as per BIMOTA... pretty expensive..... I am using them for most of the NEW parts.

Although I have found a series of good second hand sellers of parts. Most know the value but also most know the limited demand.

Managed to get a Bimota DB7 sidestand for 20 Euros and a gear lever for 30 euros but these finds are few and far between.

The Benelli TNT 1130 wheels were a good find and once the bike is built, they can be swapped over for the OZ items of the same design.
It helps limit the spend which is creeping upwards like a Greek national debt.

Other than this, I have opted for the Diavel forks as these are black and I will re sleeve with the Matris cartidges as fitted to the DB9....it was quite an inprovement,
I would recommend this conversion to anyone, over the OEM Diavel Ohlins forks.

I had the supercharger apart last night and tried to formulate some arrangement which was more suited to a bike rather than a car...not easy.

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)
Back to top
View user's profile Send private message Visit poster's website
Gavin944888



Joined: 29 Jan 2014
Posts: 327
Location: Essex....way South of Scotland

PostPosted: Thu May 11, 2017 9:35 am    Post subject: Reply with quote

I split the build project into different sections as each of the sections required different time frames.

The first project section was the engine....sourcing a 1198 Diavel engine of low mileage started in late November after returning from my fruitless visit to Rimini.

The next section was finding an Australian to help source the Supercharger...this was done in December via this, very FORUM and DJT77 after it was discovered that he was closer to Perth (OZ) than Shay001 (also from the forum)


The parts were split into big sections, making it easy to assemble in pockets of the bike, whilst other pockets were being fabricated, ordered, machined or whatever.

....keeping the build moving even when bits were awaiting machine time or fabrication...a typical example of this was the forks and headstock/yokes arrangement.


I was utilizing the forks from a Diavel, coupled to Brembo M4 radials and the a custom top yoke to which Bimota DB9 bars and swivel top handlebar clamps would be bolted....giving it a OEM feel


So, first up... make the Tope yoke and steering head pin.



Untitled by Gavin Robertson, on Flickr



The Diavel top yoke is chunky and a bit too generic.....although I like the centre sleeve nut



Untitled by Gavin Robertson, on Flickr



It took two hours in the oven and a large copper mallet to get it undone
.

This allowed the replacement of OEM ball bearings with proper taper bearings to take the load and fit in the newly machined cups.


It also gave me the opportunity of machining the stem to my spec rather than use the Ducati standard.


Untitled by Gavin Robertson, on Flickr



The stem will hold the bearings and these will be tightened up using a lock nut collar rather than just the Ducati alloy sleeve nut as used on the Diavel.

....I'll use the Ducati sleeve nut but only really as decoration rather than any mechanical use.


Whilst this assembly is being machined, the injection base plate is being fabricated and I can turn my attention to the Supercharger.


More soon,

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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View user's profile Send private message Visit poster's website
Gavin944888



Joined: 29 Jan 2014
Posts: 327
Location: Essex....way South of Scotland

PostPosted: Thu May 11, 2017 12:06 pm    Post subject: Reply with quote

The engine was a carbon model Diavel with 1500 miles on it.

It came from a 2013 non twin spark model and included the wiring loom and injection system.

The engine was delivered to Ducati Proteam in Strood (KENT) who took off all covers (clutch alternator alternator included) and check the engine over using a draw down test.

The engine came back to Essex and I started with a lump of 12mm best aluminium......put it on the bandsaw and shaped some sidecover arrangement....leaving clearance for the take off.



20170414_095043 by Gavin Robertson, on Flickr



The take off utilized the layshaft and twin cog assembly of the Ducati engine although we did make a new tougher layshaft.


We were going to extend the layshaft but though better after everything I had read on the VeeTwo Supercharger and their SuperSqualo.....




20170414_132020 by Gavin Robertson, on Flickr


The Xmas list had included all the books I could source on Supercharging as well as technical reports by Sprintex and VeeTwo.

Family hated me by Xmas eve .....as they were the ones soucing these boks and reports....including a VERY rare Corky Bell book from the States


VeeTwo had used 3 different drive designs on the power take off and then another 4 designs on pullies and drive shafts.

I had made a power take unit only to scrap in in February after reading a new techical report written in 2010.

Bimota used this new design which Davide Comandini confirmed via email ....a clutch type drive pulley.

This was basically a slipper clutch design but mounted on the lay drive shaft........not easy...this spins at half engine speed AND anti clockwise!


At this time, I had no idea if the Supercharger (which was still to arrive ) was a clockwise or a anti clockwise running charger!



20170414_095039 by Gavin Robertson, on Flickr


This was the second PTO design, sourced from Australia...but machined and modified in Essex.



20170414_094535 by Gavin Robertson, on Flickr


Here you can just make out the front section which is the clutch unit.....mounted to a threaded shaft which screws into the layshaft.

The allen socket bolts adjust the springs which alter the slip on the clutch.

This is so the Supercharger (revolving at up to 16000rpm) cannot over spin the engine and break the layshaft....a very common inition fault.

This can be viewed just like a clutch anti locking device....reducing forces travelling down the belts to the engine....causing lock up.



20170414_094531 by Gavin Robertson, on Flickr


There is also a bearing section for the outrigger support to locate onto....the newly machined (tougher) layshaft should be propely supported.


The VeeTwo outrigger unit did NOT but have this clutch type unit ....so their outrigger has to be extended or a new one made....I think I can add upstands to the side cover to suit ...we will see.



20170414_094420 by Gavin Robertson, on Flickr




You can see the basic plan taking shape....with the help of images of the Bimota DB7-11 stuck to the workings as a constant reminder.




20170414_093121 by Gavin Robertson, on Flickr



The alloy plate is shaped better to siut the Bimota frame and uses the lines of the frame and the engine as a sight line.....I traced around the Bimota side plate.



20170414_093019 by Gavin Robertson, on Flickr



Here the side plate has been cut to follow the Bimota side plate.



20170414_094510 by Gavin Robertson, on Flickr


The black pen lines were there as a indicator to the frame line and the potential 'cut off' section.....I did not want the side cover looking too blocky.


I also had to drop some plumb lines to cark out pully centre lines and once done cut go on the Milling maching to be plotted and programmed.


Once finished ....it will be relieved all over the surface area.....anodized black and then machined again, over each edge, to the 'finish' outline....following the engine outline.




20170414_094452 by Gavin Robertson, on Flickr





More fun to follow....soon

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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View user's profile Send private message Visit poster's website
brian



Joined: 22 Aug 2011
Posts: 2447
Location: QLD, Australia

PostPosted: Fri May 12, 2017 7:05 am    Post subject: Reply with quote

Loving this Gavin. I'd like to be able to comment, offer advice or ask questions... but this is WAY out of my league.

Suffice to say, I'm sure everyone else is enjoying this thread as well. Keep up the good work mate.
_________________
Current rides - '99 Bimota DB4, '96 Bimota SB6, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250,
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vort28



Joined: 22 Mar 2010
Posts: 1803
Location: Northwest , UK

PostPosted: Fri May 12, 2017 9:14 am    Post subject: Reply with quote

Quite impressive to say the least.
I barely get time to ride a bike never mind build one from scratch !!!
Although I do long for the day when I have time to build a man cave with a lathe and miller in it and go back to my roots of a machinist/toolmaker.
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Gavin944888



Joined: 29 Jan 2014
Posts: 327
Location: Essex....way South of Scotland

PostPosted: Fri May 12, 2017 9:20 am    Post subject: Reply with quote

Brian...........

without the help of the OZ contingent this 'thing' would still be on a 'wish list'

You have no idea what I have gone through to get the Sprintex.

Firstly emailing VeeTwo...over months and no answer

Next emailing Sprintex Aus ..as above...no answer

Then Sprintex UK...'We supply car kits only'

...then a Spintex agent in the Phillipines....no answer

Then Sprintex USA...'we can do it, but we are not sending it the the UK' (dealer agreement) followed by 'I know a Derek Duggan... a ginger guy fron Scotland...Do you know him?'

Then...an supercharger boff (now retired) in Somerset England...lovely guy...tea and garabaldi biscuits...keeps bees now...' like the idea, great idea, but can't do it '

and so on and so on.

Every email ..wait 4-5 days and try again....you imagine...or not.

I have an Australian son in law...from Melbourne (what a disapointment) but hey ho ...surely, he can help.

He drinks my wine and smokes my fags...but even this individual, is unable to prise the Supercharger from Sprintex.

It was not until Shay001 offered and then, DJT77 (who was closer to Perth) approached Sprintex on my behalf ....did something happen.

BTY...I bought it (in Australia) for 25% of the price quoted by the British supplier who never came back to me after the price was finally emailed.

I got the impression...they quoted a crazy price hoping it would shut me up!

Anyway, ask away...I won't be able to answer it, but ask away...

2Bims is still reading posts ...so he may be able to answer any questions.....we got to try to get him back.

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)
Back to top
View user's profile Send private message Visit poster's website
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