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DB7-11 VLX MULE resurrection
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Joined: 22 Oct 2007
Posts: 482
Location: Stafford, UK

PostPosted: Mon Jun 19, 2017 7:31 pm    Post subject: Reply with quote

Hiya

Err, wow. That is a lot of work. Impressive

All the best

Katy
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who



Joined: 10 Nov 2010
Posts: 329
Location: Melbourne Australia

PostPosted: Tue Jun 20, 2017 9:04 am    Post subject: Reply with quote

Just read the post from the beginning. Can't believe Bimota sold the bike you had paid a deposit on?
Anyway tagged.
And intriguing
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Gavin944888



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

PostPosted: Fri Jun 30, 2017 3:24 pm    Post subject: Reply with quote

Okay, just got back from the Elefant rally in Luxembourg and back to see where and who the bits have got on. Made the trip on a much modified 999r engined Cagiva Elefant ......another Tamburini designed bike.


The Ducati Stepper motor was deemed redundant after discussions with folk of Supercharger knowledge.


Truth be told non of them have ever encountered a Euro 4 or 5 engine with and supercharger conversion BUT after studying even more Internet sites BIMOTA did not use the Stepper motor.



IMG_0188 by Gavin Robertson, on Flickr



The Stepper motor sits between the cylinders (underneath the injection throttle bodies) and takes....some of....the excess air or un-burnt mixture and sucks and pumps into the next cylinder on the next cycle and so and so on...thus reducing emissions.



The rear section of the swinging arm - rear shock - engine interface had arrived from Italy and I took all the bearings, screw adjusters and part assembled.



IMG_0158 (1) by Gavin Robertson, on Flickr



Thanks to the DB7 and DB9 workshop manual it took SOME but only some of the guessing out af the assembly.



IMG_0159 by Gavin Robertson, on Flickr



All this section had to be pressed together and offered up to the rear section of the Ducati Diavel engine.



IMG_0160 (1) by Gavin Robertson, on Flickr



Everything has to be oiled, greased and assembled by press or copper mallet and the magical hands of a 6 year year old...........I have 57 year old hands more akin to a Scottish sausage.....my hands ached after each assembly.



IMG_0198 by Gavin Robertson, on Flickr



Undeterred, I collected the alloy sections from the anodizers, they also coated the new front spindle (made to fit the Bennelli TNT 1130 wheel and Diavel Forks)



IMG_0169 by Gavin Robertson, on Flickr



It turned out better than I thought and the Beringer disc carriers and bobbins came up at treat.

You might also make out the new footpeg bracket....the same as the DB9 version on my bike to accommodate my twisted ankle (from being pinned)

My feet sit at a strange angle after many old injuries and I am more inclined to machine and custom every bike to suit........rather than be in pain



IMG_0187 by Gavin Robertson, on Flickr



What we have here is the machined Supercharger manifold plate....the one with much marker pen on it.



Untitled by Gavin Robertson, on Flickr



This is what it looked like before the machining.



IMG_0189 by Gavin Robertson, on Flickr



This is the other side after 4 machined bosses (to run in the slots of the bridge) were pressed into a interference fit hole and welded into place.



IMG_0200 by Gavin Robertson, on Flickr


The Supercharger manifold bolts to the supercharger and this whole assembly hangs from the Bridge and can be aligned in the slots.



IMG_0201 by Gavin Robertson, on Flickr



Here you can see the Bridge partly machined but with the slots and air outlet from the Supercharger all in show.

After this the Bridge will be reduced in size.....have some location points added and then coated with something fuel resistant PRIOR to the custom air box being fabricated.

This section of work has been the most time consuming....on and off the engine many times and then in and out of the frame to check measurements and clearance as well as location issues.


IMG_0199 by Gavin Robertson, on Flickr



IMG_0196 by Gavin Robertson, on Flickr


I had to kick on with the rear section whilst the bearing cups and spindles were at the anodizers.....this meants locating the rear wheeel and using a very non standard 220mm rear disc from a VOR at a fraction of a BIMOTA item.

Likewise I had an issue with a Ducati rear caliper...nothing serious...I just had to Helicoil the caliper.....so that the Bimota bracket was on FULL view rather than the Ducati way of bolting into the carrier not the caliper....ahh BIMOTA

This was then all assembled with washers and spaced...... before custom alloy spacers were machined and matched the wheeel to the OEM 269GBP BIMOTA rear spindle

Next week the front will be on and then some makeshift bars before it goes to Electro34 the wiring company.



Whilst it is away the air-box has to be fabricated in alloy sheet.....strong enough for 5 bar pressure


Untitled by Gavin Robertson, on Flickr


It has to replace this shape and design....from my DB9....it may be a bit of a challange


Untitled by Gavin Robertson, on Flickr



Still...............what can go wrong?

More after the front wheel is in and the wiring is sorted....have I mentioned....I HATE ELECTRICS!


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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GeeKay



Joined: 29 May 2009
Posts: 1491
Location: West Yorkshire

PostPosted: Fri Jun 30, 2017 6:48 pm    Post subject: Reply with quote

errrrr - WOW !

preferred the black marker pen to that fancy milling though Very Happy
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Bimota SB6 and SB6R road bikes.
Project bikes:- Suzuki V4 500, TS185 rural cafe racer, XR11/71, Kettle/Katana, TDRGV250, OR50, Gag125,Triumph T595 and a Triumph X75 Hurricane replica (with a difference).
Too many projects...............
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Gavin944888



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

PostPosted: Fri Jun 30, 2017 7:31 pm    Post subject: Reply with quote

Well thanks GeeKay".......I am grateful that you like the project

A big day getting it up onto its hind legs......so to speak.

More machining this weekend.......swarf and white water .......great.

Got a couple of bits left over........might have to double check the drawings again..........I'll get my coat!

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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Gavin944888



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

PostPosted: Wed Jul 05, 2017 3:05 pm    Post subject: Reply with quote

Gentlefolk of Bimota tinkering .....

Sorry about the size of the images..............still getting to grips with Flickr and uploading.

However .......the supercharger and its adjustable manifold, are nearing completion.


IMG_0206 by Gavin Robertson, on Flickr


Here you can see the supercharger bolted to the manifold and then the assembly mounted in the bridge.



IMG_0208 by Gavin Robertson, on Flickr


Above another view but not the best, this is the air inlet side..............where as below .....it makes more sense....the spinning side with belts and stuff!.


IMG_0203 by Gavin Robertson, on Flickrm


The silver Duct tape in the photo No 2 covers the air inlet and DIRECT access to the turbines....must be kept clean at all costs!



IMG_0209 by Gavin Robertson, on Flickr



In this image you can see the unit UPSIDEDOWN...but it shows the super charger and the sliding arrangement of the manifold and how it clears the OEM Ducati 1098 throttle bodies.


The bridge will take the weight associated with the supercharger and will be bolted to both the engine and the frame.

The OEM air inlets manifolds (still with their rubber flexible inlet tracts) will absorb any vibration...... but NOT the weight.



IMG_0212 by Gavin Robertson, on Flickr



This is the underside of the assembly where it mounts into the air inlet manifolds and is secure by jubilee clips!


The 2 hoses are meant to link up to the OEM Ducati Stepper Motor.


The OEM throttle bodies are DUCATI standard but are bolted to a customised fabricated alloy bridge and oval alloy bellmouths.

Now everything fits it is time to clean the wels and cut off any excess metal.

After this has been done the AIRBOX proper...so to speak...has to be fabricated......before that, it has to have its wiring positioned and ran from front to back.


More to follow.

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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djt77



Joined: 27 Feb 2008
Posts: 370
Location: Perth, Western Australia

PostPosted: Thu Jul 06, 2017 12:44 am    Post subject: Reply with quote

looking good there Gavin, keep up the impressive work
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Gavin944888



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

PostPosted: Tue Jul 11, 2017 4:46 pm    Post subject: Reply with quote

Hello.........again.


The weekend was full of machining...white water and swarf.


Took me back to the days, when we heated the scotch pies on the bearing heat plates....aaahhhh the smell of mutton and penetrating oil.



IMG_0224 by Gavin Robertson, on Flickr





The yokes were dismantled and the pin copied, but with additional detail and measurement.



I am not a lover of ball bearing steering heads….they should all be oversize taper bearings.



Here is the steering new pin...next to a machined lay shaft and drive cogs plus some super charger pulley bits.





IMG_0225 by Gavin Robertson, on Flickr





And here we have the steering pin in its final position and with ring nut...a machined boss with dowel hole to tighten everything up!





IMG_0240 by Gavin Robertson, on Flickr




This shot shows the finished assembly...the 2 machined bosses on the yoke are earmarked to take the lithium battery box.




IMG_0237 by Gavin Robertson, on Flickr





Once the Supercharger had been assembled, final measurements could be taken in situ on the engine and in the frame.






IMG_0226 by Gavin Robertson, on Flickr




The black marker line shows where the excess metal can be removed.





IMG_0228 by Gavin Robertson, on Flickr



Here you can see the unit from a different angle.




IMG_0230 by Gavin Robertson, on Flickr





The boring side.....this is where the air enters the twin screw turbines...currently covered by duct tape.




IMG_0232 by Gavin Robertson, on Flickr






The air box dimensions were reduced to a max size of 360mm long X 215mm wide and 130mm at its highest point.


The next time you see it the BOX will have built around it ......along with pressure and temp sensors





IMG_0234 by Gavin Robertson, on Flickr







The wheels, both front and rear, were positioned with the new spindles and spacers.






IMG_0246 by Gavin Robertson, on Flickr






The initial measurements were good..... that all was required was the turning around of the sprocket so that the spacer was at the front and not the rear on the engine spline.






IMG_0241 by Gavin Robertson, on Flickr








Once everything went together I was unhappy with the offset…..less than 21 mm and definitely not good given the Bimota steering head angle.





All okay with a Ducati Diavel rake but not so good on the one here.


But it did give me a chance to see how it was all coming together…..and I will need something to do, when the bike goes off to the wiring company.


So now I need to fabricate some yokes to take the strangely sized Diavel forks.




IMG_0244 by Gavin Robertson, on Flickr





The top yoke was so wrong anyway…so much so that I had made my mind up to make a new one….only now I was making the complete set.



At the moment the bars and yokes are only there to help move the bike about.



Some alloy sections were bolted together to give some indication as to where to mount the electrics, bearing in mind that the supercharger and air-box will be taking up most of the space.



IMG_0249 by Gavin Robertson, on Flickr




Not your usual Bimota stance.....granted, but close to my initial ideas



bimota-impeto-concept-sketch7 by Gavin Robertson, on Flickr




And here is the version that BIMOTA said they were going to build.........hhhmmm





Bimota-Impeto-DB11-DB13-Illustration by Gavin Robertson, on Flickr





Slowly but surely................it is biking season.


I am off to Germany in a week or so then France,......things will be slower now.


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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Gammaboy



Joined: 25 Feb 2016
Posts: 15
Location: Brisbane, Australia

PostPosted: Wed Jul 12, 2017 2:51 am    Post subject: Reply with quote

What size are the diavel legs that makes them "strangely sized"?
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JRH



Joined: 21 Jan 2013
Posts: 213
Location: West Mids/North East

PostPosted: Wed Jul 12, 2017 2:20 pm    Post subject: Reply with quote

Is the Tornado wheel on backwards?
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Gavin944888



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

PostPosted: Wed Jul 12, 2017 8:37 pm    Post subject: Reply with quote

Hello".......

The forks are 20 thousands of an inch different in diameter between top and bottom yoke position

20 thou......l mean why bother .....unless you made a mistake

The wheels could be on backwards....but I think that they are OK and that the bike is the wrong way round.......l best check!

That is the kind of comment GeeKay usually makes.

Thanks

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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JRH



Joined: 21 Jan 2013
Posts: 213
Location: West Mids/North East

PostPosted: Wed Jul 12, 2017 9:54 pm    Post subject: Reply with quote

Gavin,

Apologies, your project is awesome, and way ahead of anything I would attempt....... I have 2 Benelli's and I hoped mine weren't on wrong 😄
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Gavin944888



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

PostPosted: Thu Jul 13, 2017 4:35 am    Post subject: Reply with quote

JRH"......hello,

No apologies needed and no offence intended by my reply.

Scottish sense of humour added to reading the posts after a crap day at the office.

Still can't sleep ......and by the way you are correct....the front wheel is on back to front.

Everything is dry build at the moment and as long as the supercharger is fitted the right way round ......it should all be okay

Always wanted the 900-6 by the way.........and the 650 tornado

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
Gavin944888



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

PostPosted: Fri Jul 14, 2017 9:06 am    Post subject: Reply with quote

Okay..........I have to coat the bridge and manifold and I am thinking of Cerakote or something similar.

Has anyone had any UK experience of this type of coating. I know that some of you have coated exhausts but this is a bit more tolerance important.

It is imperative that the Supercharger and manifold are flat and each have a mating surface.......but the manifold has to be treated for fuel and oxidization


Any info or contact details very welcome.

thanks
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: Fri Jul 14, 2017 3:13 pm    Post subject: Reply with quote

I had mentioned before the bike I had tried to get built.

In fact ....there is an image of it above BUT the obsession which started it all off was this bike.



B by Gavin Robertson, on Flickr




This was the original MULE DB7 with the Diavel 1198 engine I witnessed at the factory in June 2014.




2 by Gavin Robertson, on Flickr




Davide Commandini, was busy testing and you can clearly see, the electronics strapped for easy access to the tail unit.




1 by Gavin Robertson, on Flickr





There were 2 versions eventually....the high mileage DB7-11 MULE and the exquisitely finished DB11 VLX version.

I was promised the VLX version...but it did not work out..... followed by the promise of the MULE version...... which vanished!


This bike was the one (which as an engineer) I wanted..... full of marker pen marks and 'on the go' prototype stuff.


Thanks to contacts on this forum and in Italy....the obsession seems to be taking shape.



Labour of love


BIG thanks to those who helped

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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