Building A Ducati 749 "bono"

Discussion in 'Builds & Projects' started by Jacques_wood, May 12, 2018.

  1. Nope, That's not a typo, simply an idea.

    This post is going to need some background.

    After years of saving money to buy a house (as all millennial's are told we should), I got fed up, and instead "invested" my money in the bike that was a poster on my bedroom wall as a young kid.

    A genuine, Yellow 749S Mono.

    [​IMG]

    I've bonded with it greatly over the last few months. And was all set to take off for a morning ride today when something about the exhaust looked awry.

    Further investigation found this:

    [​IMG]


    Not the start to the day i'd been hoping. I had done my research prior to purchase, and felt I'd checked the subframe thoroughly, but sadly, mine sheared in a big way.

    So, what to do?

    Ducati kindly informed me that the part was still available to buy at £550+VAT. Damn, i'd have to dip into my house savings that I bought the bike with.....oh B&*$£@KS.

    What does Ebay have? Nothing significantly cheaper.

    Hmmmm those Biposto subframes look similar, and I might just be able to afford it, but i'll loose the adjustablity, and it won't hold the mono plastics on the back of the seat.

    So then I decided that I needed to build a "Bono", a Biposto subframe, modified to fit the function of a Mono.

    So, removing all the components from the subframe I’m left with the following:

    [​IMG]

    With large fatigue cracks that through the tubes themselves.

    [​IMG]

    So, after looking at pictures of Biposto subframes, I think I can make some jigs that will bolt to the Biposto that will allow me to modify the Biposto and create a steel Mono.

    OK, if you’ve read this far, you’ll note the rambling. The rest of this is going to be a bit tongue in cheek, but it’s helping to cheer me up.

    Recipe:

    Take one laser scanner, and scan the components to create a digital, 3D model.

    [​IMG]

    Using that data, extrapolate hole axis’ and planar faces in relation to one another, and design some parts using a CAD program that will allow jigging, fixing and marking of a Biposto subframe to give it the use of a Mono.

    [​IMG]

    Using a 3D printer. Print your jigs.

    [​IMG]

    What we’re making is a drill jig to give the 3 seat locations points.

    [​IMG]

    When those holes are drilled, we’ll use that feature to locate the slotted tabs that bolt the seat unit from the underneath (old tabs will have to be remove and new ones welded on).

    [​IMG]

    Finally A jig at the rear that will locate a strip of steel that will go on to holding the mono plastics (this jig is revision A to ensure the angles work, I build design and build outriggers to hold it torsionally when I get physical measurements of the Biposto subframe).

    [​IMG]

    [​IMG]

    [​IMG]

    There have been a lot of assumptions made on the similarity of the two subframes. This may not work first time, but I’ll post my success and failures along the way.

    I intend to remove the extra length of the subframe for aesthetics as well as trim the pillion peg pick-ups and lock locators, but I’ll assembly everything back up for then to see if anything fouls, And report if it’s possible to keep the Biposto fittings (I don’t see why you couldn’t, but I’ll confirm).

    Obviously, I’m very fortunate to have access to such phenomenal equipment to create this, and when I’m finished, I’ll create CAD models of the jigs as well as dimensioned technical drawings and make them free to everyone.

    In the mean time, I’m lucky to be able to do things like this for a living, so if anyone is interested to learn more about industry grade laser scanning and 3D printing, post below or DM me and I’ll answer any questions I can.

    Thanks for reading.

    Jacques

    IMG_1547.JPG
     
    • Like Like x 14
  2. Bien fait mon pote, bon boulot! Je pense celui-ci était tellement compliqué que moi-même, j'avais chaud en le voyant. J'espère que ça marche pour vous!
     
    • Agree Agree x 5
  3. Clever stuff, mate! Bet you sort it sharpish.
     
  4. What I said!
     
  5. Nice work :)

    Where are you based?

    Do you scan for a living?

    :)
     
  6. Merci mon pote ! C'est les outils qui font le travail, je prends simplement la gloire
     
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  7. Sev,

    I work near Silverstone Circuit in Northampton. I run a department of industrial grade additive manufacturing machines (read; 3D printers).

    We do get to do a lot of cool projects, but we're branching out into "Historic Engineering" where we take take an existing component that typically you can no longer buy, and create a new one from scratch.

    I've attached some case studies below for those who are interested:

    https://kwspecialprojects.com/wp-content/uploads/2017/11/KWSP_AlfaTipo_A4_4pp-002.pdf

    https://kwspecialprojects.com/wp-content/uploads/2017/11/KWSP_Amilcarcasestudy_A4_4pp.pdf
     
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  8. Wow - those examples are brilliant examples of technology bringing back heritage - fabulous :upyeah::upyeah::upyeah:
     
  9. That's really interesting and very helpful!

    I've got some scanning to get done you see (999 frame, engine cases and swingarms, bodywork etc.) , and cloud is ideal, as then I can import it into Catia to surface.

    I'll need to speak to you more about rates etc. :)

    What scanning system do you use?
     
  10. Love all those old race cars.....re sub frame why didnt you just stick some new tube up the centre of the old stuff and weld the stress fractures?
     
  11. I have a mono subframe replaced foc from Ducati years after the warranty had finished and the bike did not have full dealer history.
     
  12. I had a mono subframe replaced foc from Ducati years after the warranty had finished and the bike did not have full dealer history.
     
  13. It's a fair question, and there are two reasons that are stopping me, the first is that the fracture is in the middle of the mandrel bend, which gives a little bit of a head ache trying to slot a tube down the centre.

    Secondly I could spend hours trying to jig it by eye with everything in place, closer inspection the fracture has obviously been "flapping" for a while, and there's no clean break, and I just don't fancy tacking and checking over and over.
     
    • Useful Useful x 1
  14. I've pleaded to no avail so far.
     
  15. do you want a mono rear subframe? I've got one in the garage :)

    then you just need a tame welder to weld a couple of stifferner gusets either side where the weak point is.


    he he... I said gusset :blush:
     
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    • Face Palm Face Palm x 1
  16. Outstanding!

    Do you use Handyscan 300 or 700 for this job?

    Also, if you don't mind, can you tell me which CAD and solid printers you use?

    Thanks
    Nikos
     
  17. Fuck I feel utterly thick, hate been thick
     
    • Agree Agree x 4
  18. Thread moved
     
  19. Yep - me too....work in the IT department at an engineering design consultancy and i still have no idea what most of them do (after 16 years) of working here...all i do is fix catia, NX, solidworks/keep it all running etc etc - absolutely no idea how to use them...!

    Impressive stuff when its turned into real world solutions to problems that face the average joe...
     
    • Like Like x 1
  20. Hi Nikos,

    We've got the Handiscan 700, we tie that in with Solidworks or Catia (typically Catia for surfacing) and then I run 3 Fortus 450 FDM thermoplastic printers on the same site, and on our other site we run DMLS and EBM machines.