Putting the Duc back together

[Camp]

Well, the nice weather last Saturday finally inspired me to start taking pieces off the Duc to determine what is really in need of repair from the last crash. I haven't gotten far yet but, did manage to pull the clip-on off the left side and assess what it would take to repair it.

It is broken in half, between the grip and the turn signal switches. I'll see if I remember to grab a picture or two tonight. We are going to weld it back together and see how it works out. Obviously it is aluminum so, it will be TIG work to make two pieces, one :D It will also probably be chucked up in the lathe and turned back down so it is un-noticable.

I thought about just buying a new set but, after looking at prices of them, we will try this method first.

Also, originally I thought the forks were twisted in the triple or bent. After looking closer at the clip-ons on both sides and adjusting the right hand throttle, it may be an illusion. I haven't put a straight edge on it yet to really see but, things are looking up. I'll still strip this thing all the way down to check everything out before it goes back on the road but, my pocket book is starting to sweat less now :D

I need to do an oil change and valve adjustment before it goes back out too but, if it is stripped down, that makes it much easier.

[Camp]

Here are some pics of the clip-on that we are going to try to weld and turn back down.

[CLYDE]

I hope you have the utmost faith in whoever welds that, Im thinking it would always worry me.

[Camp]

I hope you have the utmost faith in whoever welds that, Im thinking it would always worry me.

I am going to try to replace the insert in the short end with a longer sleeve so it is not just butt welded. I do have faith in the welder on this one but, I will also probably test it well before putting it back on the bike.

[CLYDE]

yeah, having that snap off again at speed, would really suck.

[Jeffro600]

I hope you have the utmost faith in whoever welds that, Im thinking it would always worry me.

X2! Clipons arent THAT expensive...even for an overpriced Italian ride... :flipoff2:

But even welded and turned down, id still question its structural integrity vs a brand new one.

I dunno...call me anal but doing a repair job on a critical component of a motorcycle like the frame, swing arm or controls just sounds a little scary...even if the repair is over done.

[Camp]

I'm not willing to spend $325 for that piece of aluminum. We weld the buggy back together with this method all the time between events and have never had it fail. Sleeving and welding it the way we will do it will acutally make that area stronger. It does result in the forces generated by the load on them to be concentrated on a smaller area then but, it should be just fine.

[Jeffro600]

If its just the tube that broke, why try to fix it and not just replace it with a piece of high grade aluminum tubing?? Im not familiar with your particular Ducatis clipon system but im assuming that bar just clamps on to it somehow? I just cant see them charging 325 bucks for a piece of tube...unless you have to buy the entire assembly? Is that a stock clipon? Good after market ones that are leaps and bounds better than the stockers are cheaper than that!

[Camp]

If its just the tube that broke, why try to fix it and not just replace it with a piece of high grade aluminum tubing?? Im not familiar with your particular Ducatis clipon system but im assuming that bar just clamps on to it somehow? I just cant see them charging 325 bucks for a piece of tube...unless you have to buy the entire assembly? Is that a stock clipon? Good after market ones that are leaps and bounds better than the stockers are cheaper than that!

These are not stock and replacements for the Duc, at least the ones I was finding, were from $300 to $350. I couldn't find anything but entire assemblies.

If I could replace the tube only, I would consider it but, there is a few machining spots on the tube that would be a bit of PITA to duplicate. For instance, there is some sort of insert in the outer end of the tube, where the gold plug is, that is a different ID and is threaded for the plug bolt. The plug helps hold the grip on. There is also a cross drilled section that the clip on clamp bold feeds through but, it is only half a bold diameter and does not peirce the ID of the tube, only a notch on the outside.

[Camp]

Well, we welded the clip on back together on Friday. Scott took some aluminum bar stock and turned it down to fit inside the two pieces. Each piece had a different ID since there was an end cap in the short piece. He then cleaned up the break and TIG'd it back together. I have since put it on the bike and gave it a little testing and it doesn't give at all. I am sure it is stronger now than it ever was since it is now solid.

Saturday I took all the fairings and tank off the bike to begin inspection. Other than a cell on the battery being broken open, causing some nice gowth on it, everything appears to be in tact. I will be doing full torque checks on everthing and have to do a valve adjustment and oil change before it hits the road but, overall it looks good to be on the road by next week. I would say this week but, I don't think I can get it all done tonight and tomorrow night after work, and with the snow coming on Thursday, that puts me off until next week :( Besides, I have Stupidru work to get done tonight. Too many projects and too little time :(

[Camp]

Well, got it back together last night and although it isn't pretty right now, it was nice to ride it to work this morning.......before the snow that is coming tomorrow :mad:

[CLYDE]

Good deal. Ive got the harley ready to roll, now I just need to get the carbs balanced and adjusted on the 750

[Boostedxt]

check out woodcraft clip ons. Call faster/Tk they should have them. They are awesome...I had them on my bike and when you crash again you can just replace the bar.

If you have questions let me know....what kind of Duc? I have a 749S

joe

[Camp]

Thanks, it is a 916.