5 Weeks ago I began with Ducati 999 V(olume)2 .One of the most complicated Items of course the Titanium-header-System is (here spot-welded)

Durbahn 999 V2 - Exhaust detail.jpg (103024 Byte)

here mounted :

Durbahn 999 V2 - Exhaust detail 2.jpg (95191 Byte)

......that's the spot where you have to start,raw adjustment of Fueltank-dummy and Monocoque-Tailsection:

Even I have not seen the OEM Duc Fueltank for a while,it does not look nicer in a review .

That's how I began with the Fueltank . To check all clearances I put the front on block .
With some Aluminum sheet-metal I made the interim-model,which I filled later with with Glassfiber from inside to get the raw contour.
.....at this Time the Canister was still located behind the sump :

Modelwork Airbox+ side-canister 3.JPG (106186 Byte)

Well,that was not one of the funniest moments,when I noticed,that the front upper Section was a bit too high and too broad,so -not thinking too much -I cutted the Section and repositioned it
Cut :

Durbahn 999 Fairing cut1.jpg (91525 Byte)

Bond:

lot of things happened,but it's simple too little Time to type everythin in German and English,so.... a short Note : It's done .

I've got a meeting with German Press on 17 May on the track, where I will shoot some Pictures too, which I will release here approx May 20 .

March 8 : no space left for a simple breather-tube so I had to create a special Carbon Breather-tube .
The OEM Breather valve I've removed and exchanged by a fully open racing-gasket which needed a bit of rework/reweld to pass the header (click thumnail below)

25.Feb. I gave up the underswingarm-muffler Idea. One hand the muffler is extremely complicated to manufacture ,other hand ( Ithink that was the main reason ) the headers have been kind of "in the way
" regarding the whole Optics of the Bike .The new canister (nearly done ) will vanish inside theTailsection , and from the rear/sideview you will not detect a can and not even Outlets of the Can
(moreless same style as the GP-Bikes ).

Mounted my CCC ,new rearsets and prepared the 999 with a pressure-sensor .Went for GP-Shift which wasn't so easy to manage,because the Alternator Cover was in the way. But ok, removed somewhat 3 mm at the section,where the cover was disturbing..........

2004 December 21: got the frame back ,reassembled the 2nd 999 and started with the wire harness .

Incredible : I got the service book of the 999 including wire harness diagram , but 30% of the wire-colours shown in the diagram didnt match the actual wire-harness,and also the colours are even changing from female to male plug ...incredible. Well, I do not care too much about that. I have teared apart the OEM wire harness for some wires I need ,then mounted RC51 Ignition coils and the RC51 CDI -Converter,located everything testwise right side ....think around x-mas I'll bring the first tone out of the Motor .

December 2004,bought another slightly crashed 999s.The frame will be checked for straightness,and when I get back the Frame I will reassemble the Bike "originally" except the whole wire harness. The main objective why I bought the Bike : I can install the Motec into this Bike and test it on road and dyno to develope the whole Motec-Programm,which will take approx 2 months.

So this 2 months I won gives me the opportunity to finish the other one without beeing in a rush .

received the Titanium-stuff for my Bike...axles,screws,specials . The belt leading drums are not finished yet,but I hopefully receive them in about 2 weeks .I think I'll be able to offer those Bits (well, some of them might be already available on Market.........? ) contact me: info@durbahn.de

....and also I received my shock,especially built for me,180 gr less than Öhlins :

Oktober 13 : porting Job done,combustion-chamber slightly reworked....and sent a bunch of steel-Parts to a friend ,means screws, belt-leading-rolls(wheels?)+adaptors ,axles ...... to a friend,to copy them from Titan .

Oktober 09: Fuelpump-Bracket .My friend Peter has managed to create a very small and light cap which hold's the Fuelpump and also has a opening for the Fuelpump power-supply-plug .

The Intake/Outlet for fuel are somewhere else at the top/rear end of the Fueltank .

...food for thoughts: now the plastics are done so I disassembled the Bike and disassembled the engine.
Have found Shiftdrum at

After some kind of machining through a 52 years old Milling machine,which is still reliable
and works with high-precision .....!....

......I'm now at 659 gr ,exactly 1 gr less than a OEM RC51 shiftdrum (5hrs it took)

More soon :transmission /Race transmission weights comparison w/Pics ,Titan conrods weights comparison,primary gear weight ,Frame weight...etc.

September 15th 2004 : the drudgery of modelwork moreless has found it's end - the last big Item,upper fairing model,is done . Today I will demould everything and Monday at the latest I will build the first positive from Carbon. So main parts are done:

Snorkel
Air-Connectors
Airbox
Fueltank-dummy
Tailsection (concepted as monocoque....no Subframe necessary)
Side saddled Fueltank
Fairing lower
Fairing upper

....missing,but not that big deal :Carbon fairing-stay,Carbon Instruments bracket (housing)

Close before !! Only 100 hrs which I still have to spend into the fairing upper model,then I can do the mould,then I can laminate the first Carbon fairing upper.
Means: whole plastics will be finished end of September .

Moreless my comment,when I watch the Bike now ,looks like : "now Time at all....like...there's no Time left to arrive somewhere very soon..."

I've reshaped the l/r airducts from Snorkel to Airbox a 2nd Time to make the sealing easier.A disadvantage : you have to lower the fork-legs to mount them . But you do this only once, and if you should destroy those connectors (mounted inside the frame front end triangle) the whole Bike will be destroyed also.

I also reshape the Snorkel at present for more Air-Intake cross Section,so a new mould again..

And: received the tool (a copper bell ) today to be able to re-groove the race transmission axle.
It's because my clutch-assy (basket + hub) runs 20 mm more inside Engine I also have to reprofile the grooving for the hub on the race transmission-axle 20 mm more towards crankcase.

I :Both halfs of the Fueltank are out of the mould ,built from Carbon-Kevlar . The scale said somewhat 1.5kg (3.3 lbs) for approx 15 Liters . But including Filler and mounting Hardware for Fuelpump it'll be ~ 1.9 kg in the end.I can live with that value.

II :I've built the 2nd Tailsection (monocoque,so tailsection and Subframe in one) now in Carbon-sight with a few less layers carbon, which brought me from 1377gr for the first one down to 1164 gr.

III: A basic weights sum up

390 gr or 0.86 lbs Carbon-Airbox (w/Dummy approx 32 Liters Airbox-Volume)
1260 gr or 2.78 lbs Carbon Monocoque Tailsection incl. Seatpad
600 gr or 1.32 lbs Carbon Fueltank-dummy
1900 gr or 4.19 lbs Carbon/Kevlar Fueltank
2200 gr or 4.85 lbs calculated for Carbon Fairing incl. windshield,fairing-stay and headlight
250 gr or 0.55 lbs Carbon Snorkel-Setup incl.Airducts from Snorkel into Airbox
-----------------------------------------------------------------------------------------------

...........re-enact,what I have then :the cpl. plastics including an Airbox,Snorkel and Fueltank for a value of weight ,which probably has got the OEM Fueltank only !

July 1. 2004 :back from the track with my RC and no major problems to solve I found the Time to start again with the Duc. So at present the model of the Airbox is done ,so we only have to fab the mould and the first positive from Carbon.Of course the Airbox will be a 2-pcs Assy,otherwise you wouldn't be able to bring it in .

Latest news 0: By fortune I'm connected now ! With the guy who has developed the QAT Fork...
which means ,he'll built a special rearshock handmade for my Duc ! And that leads into: I finally can get rid of ALL the Öhlins stuff which is on the Duc,so Öhlins-Fork cpl.,steering damper and shock are left over and available.As I've mentioned somewhere else before ,Öhlins is no bad stuff,it's working fine,but of course it's mass-production,so that's why it doesn't fit for a Project like I have here with the 999

Latest News I : the Air-Intake is done. Click here to have a look at those Pics

Latest News II : I received the Carbon Valve-Cover,shiny gloss and very light(128 gr ,0.28 lbs), I think half of the Ducati Corse Mag Equivalent ,each 342 € .I'm not interested in to copy those,each manufacturer should have his own field of playing . If you're interested in a Set,contact me : info@durbahn.de

First is : the front section wire harness

...............hehe,840gr (1.85lbs) . As far as I remember it,my whole RC51 wire harness is less than half of only that front Section of the OEM Duc

And next: the headlight-housing incl. headlights (WITHOUT the mirror-stays)

Headlights incl housing.JPG (78548 Byte)

...you wanna guess ?

Better you don't . It's 3.4 kg (9.93 lbs) . As far a I know for half of that I'd be able to realize a cpl. fairing incl. headlights .Which Theme leads back to my .........

...........new Snorkel,which I've also on the scale.It's cpl.incl. the 2 inside frame ducts 330 gr (0.72 lbs). So,and now add the OEM Duc-Airducts onto the 3.4kg mentioned above ! I guess this OEM Setup ends at 5kg !

This Text will stay a while here on the first page,moreless to admonish myself whenever I update this web to force a very special project .

It is: an Alternator + Rectifier
.......that doesn't sound very special you may say,but it's indeed the most crazy thing I ever attempted to put on a Bike.The whole Story is,that this Alternator (from point of of intended concept) has been not really one,but a friend of mine did not give up past 18 months and built one and the next one and the next prototype until he got the first one working.But this is only half of the story . The other partition is the rectifier,because there's no rectifier existing worldwide,which is able to switch such variable high Ampere and Voltage produced by the Alternator.But by fortune my friends neighbour is something like Doctor of Electrodynamics,and he spent close to 200hrs into the development of this rectifier. From what I understand,this rectifier is switched with 90kHz to be able to manage the A/V for a output of 14.5 V.

That you can re-enact,why I'm so euphorcic ,the Alternator dimensions are:

2" x 2" ALL IN ALL !!!

....the special thing is,that it's running with Neodym-magnets,which give up above 100°C .
But this is not of concern anyway,because all the Time I thought about this setup I intended to let it run outside and Air-cooled,driven from camshaft-sprocket with a 8mm belt-drive and a ratio of 2:1.

So,if this setup works reliable,then I'll go addittional for a electrical waterpump,which means,then I can cut or machine the whole Alternator-cover nearly down tothe ground,then I can cut the crankshaft ... and so on. From what I assume: the weight I shave by cutting the crank only is close to be the same as the weight of my Alternator !

Feb.19.04:
I have not been lazy even I have not updated this Site for about 14 days.I think I've have spend 50 hrs into the Air-Intake (Snorkel),but yesterday night I put it under filler,so moreless -from point of view of modelwork-it is done .Only the fine-grinding Job today and we can start with the mould.
The decission was made 10 days ago,when I started,I'll go for one Intake hole assymmetrical left side,not really shaped into fairing,even if it'll look like in the End.

It'll look funny and it requires a clear window to see the Frame-Id,because the Snorkel is sealing and covering the whole steering-stem.From what I can estimate now it'll be around 380 gr (0.83 lbs).

1:The clutch is at the machinist,and as far as I can foresee i'm able to post pics and weight here in about weeks.

2:I received a FRP Ducati-Fueltank (only the upper Section),which will be the Airbox cover,or Fueltank-dummy.... .At present it's not sure if I leave the design 100% or if I will reshape it slightly but one thing I know: It's 4 cm too long ,or 4cm to far mounted towards the tail. I've had a strange feeling,when I sat on the Bike,before I dissasembled it,somehow I've been remembered my old FZR 1000.

3:race-transmission I hopefully will receive within 2 weeks,somehow urgent,because I've to machine one axle for my clutch-Setup

5: Carbon-valve-covers I hopefully will receive soon. I thought about to fab them myself ,but they're at 350€ each,and I know ,what for a work that is,so I thought it's ok to order them . 117 gr each (0,25 lbs)

I've been able to track down another QAT Fork incl. QAT triple clamps with adjustable Offset ,but I had to buy a Bike to get the Fork (a race-Kawasaki ) !!! So ,one QAT at the RC30,one at the RC51 and now also one for the Duc . Ok,still a bit work to modify the Internals for correct lenght,but that's done soon. Also pics soon. If you like to see how a fork with NO Springs looks like : www.honda-rc51.de/front_fork.htm . That's a main precondition to reach something like 360 lbs full fuel incl. Starter ,because the Fork is 6-8 lbs lighter,then every other Fork on Market ! And built in German armaments Industry,they know something reg. tubes.

NEW 999s Öhlins-Fork for Sale,incl. triple-clamps/Fender/Clip-ons : info@durbahn.de