Recipe for dirt monster

Discussion in 'Some Assembly Required' started by Wadester, Apr 28, 2012.

  1. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    Thanks for that. I didn't want to hijack the OP's thread.
    #41
  2. Wadester

    Wadester Rides a dirty bike

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    I finally got my butt in the shop and peeled back some wiring harness to get the old frame free - also had to pull the injector set:
    [​IMG]

    Can you tell which frame is which?
    [​IMG]

    Now, I need to put the "new" frame and wiring harness back on - and start mounting the front forks.
    #42
  3. Ted.audia

    Ted.audia n00b

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    fantastic progress and glad you are back working in the shop! Keep us posted on how things are going

    I need to take inspiration from you on my own monster conversion/money pit

    cheers
    #43
  4. jbcaddy

    jbcaddy Long timer

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    How much trouble is it in NM to change the frame? titled as a different bike? or changed numbers on registration?

    What are ya doin' with the old frame? I have yet another project looming and could use some bits off it :evil
    #44
  5. Wadester

    Wadester Rides a dirty bike

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    I was patient/lucky enough to get a frame with title, so it's just another bike to the DMV.

    What devious plans ya got for a bent Duc frame? Or maybe it's "what bits?"
    #45
  6. anonny

    anonny What could go wrong?

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    Good stuff! :lurk
    #46
  7. jbcaddy

    jbcaddy Long timer

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    I have been wanting to make a roadrace style street kneeler sidehack that is Ducati powered for some time. A titled frame to cut up and redo would be the perfect start. already have a 900 Monster motor and enough wheels and other bits to add to the project. :evil
    #47
  8. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    I keep threatening to build a tubro Hayabusa powered roadracing kneeler if I get too old and rickety to properly terrorize the neighborhood on a normal bike.

    I say go for it. :deal
    #48
  9. jerdog53

    jerdog53 Crop Dusting Everywhere

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  10. Wadester

    Wadester Rides a dirty bike

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    Hmm. Older style frame with integrated rear section (like the 695 vs the newer 696), which includes the vertical shock with linkage vs inclined w/o links. This is pretty much the TerraMostro, or my intended Dirt Monster.

    "Some 230 hours of customization was done to make the 1000cc Monster off-road capable for a customer who is going to race it in the Timbuktu Rally. If you're interested, the motorcycle will cost you €16,000.

    So far Ducati have not shown any interest, but that's maybe because they're making their own....we can only wish. "

    Thanks for the pic/link! I'll measure their swingarm length vs what I come up with.
    #50
  11. 1derer

    1derer Sh*t Where am I?

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    always love the dirt monster idea but couldn't ever justify it... Just seems that a manufacture already made a model that also suits about the same weight more power, suspension at a lower cost. Now its discontinued but can still be had for reasonable investment.
    [​IMG]
    #51
  12. jerdog53

    jerdog53 Crop Dusting Everywhere

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    Your missing the point, that is not a Ducati.......
    #52
  13. Wadester

    Wadester Rides a dirty bike

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    I made a small bit of progress - Zach at Woody's got my wheels ready and I picked them up from him last weekend at RMAR. The front fits the KTM front forks I'm adapting, but the rear wheel is custom 18" rim spoked wheel to replace the cast 17" stocker.

    Oooooohh
    [​IMG]

    That's a RAD cush drive hub for a KTM 690 - but that's the stock Monster axle. Sweet.

    Aaaaaaaaahhh
    [​IMG]

    Goes right where it should - sprocket and disc line up. Can't beat Woody's Wheels!

    Awwwww
    [​IMG]

    The one fly in the ointment. Caliper interference. Zach was concerned about this, and we had gone back and forth about it - but there it is. I'll be making a new caliper adapter from plate to move things outboard a bit, and I'll have to space the rotor over to match - but that was always the contingency plan.

    Something else I was messin' with
    [​IMG]

    The Monster has rearsets - not good for dualsport. I had been surfing parts catalog and pictures of Multistradas, and I could see that the peg/control mounts bolted to the side of the engine cases on both - but the Multi has a frame extension that picks up the end of the swingarm axle and the peg mount ties to that for the top attachment. You see the Multi mount bolted to the engine - the bolts line up perfectly, and so does the swingarm axle! I've got a Multi swingarm axle on the way to check diameter/fit. If it works like I hope, I'll have better peg location, and support the ends of the swingarm axle a bit more. There will be an adapter plate to tie the mounts to the Monster frame tabs as well. This moves the pegs forward and down by about 6". I'll post a better pic later.

    Now if I can just get a good block of time and get the new frame on!
    #53
  14. Wadester

    Wadester Rides a dirty bike

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    The stock caliper bolts weren't long enough to space the caliper back - so today I went into town and got some longer bolts and some washers for spacers.

    Here's 6 washers:
    [​IMG]

    Each washer is about 1.5mm, this is 9mm. Clears, but close.

    So here's 10.5mm for the win:
    [​IMG]

    I recall that Zach milled the rotor flange down to match the monster - I'm gonna laugh if it was 10mm!

    Now to pull that adapter out and design a new one with caliper tabs and speedo pickup 10mm over. It looks like that will put them in line with the axle base, and a simple piece of plate will suffice. Makes me wonder why they tucked the caliper over like they did. Because they could with a cast wheel? Save weight on the hub by adding weight to the caliper adapter?

    Also, the Multistrada/Hypermotard peg mount fit up well - except that they use different spacers at the block. Monsters are all the same, these new bits are different at front and back holes.
    #54
  15. Bambi

    Bambi Been here awhile

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    Hello Wadester,
    at first: great idea building an off-road Monster!
    Concerning the footrests and their hangers: Have you had a close look at the Riverground Ducati shown above? Maybe, there's an idea for yours ...
    Kind regards, Bambi
    #55
  16. mbrick

    mbrick Been here awhile

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    Heck of an accident. Amazing you walked away too!

    The axles are really thin and light. I also bent a Ducati front axle in a front end collision... However in my case luckily the rest of the bike was still straight and unscathed.

    Why didn't you want to weld the frame back up? You are already building an off road bike, could have cleaned up and welded the front end back in place at the steerer. I went back and looked at the pic and it is pretty bent in at the bottom tho. You could have set a custom rake angle though.

    The wheels look great. That caliper spacing is a bit bush league though :rofl
    #56
  17. Wadester

    Wadester Rides a dirty bike

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    Thanks for pointing that one out. Beautiful footrest supports - way above my skillset/tooling to fabricate.
    #57
  18. Wadester

    Wadester Rides a dirty bike

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    Yeah, I walked away because I personally did not impact anything - except maybe my shoulder took out their windshield via my jacket armor.

    Looking at the damage done to the head area of the frame, I would have to replace everything forward of the front engine mount to get back to straight. I do have some concerns about front geometry - clearance at the head when turning, total offset - and these could be corrected with a custom head on the old frame.

    The caliper spacing pictured (stack of washers) was for evaluation only. Final fix is a new caliper adapter incorporating that offset. I'm also adjusting the speedo sensor location to make the bracket more compact.
    #58
  19. blainerides

    blainerides Adventurer

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  20. dpforth

    dpforth no inline fours

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    I just picked up this 04 800 with the express intent of building a dirty monster. I'm hoping to end up with something that works like a 3/4 scale version of my previous loved/feared Super Enduro.

    [​IMG]

    [​IMG]
    #60