Strip a Superduke down to a frame!

Well i was gonna do a How-To on stripping an SD down to the chassis ready for powder coat! I thought it maybe a useful resource for anybody wanting to do the same thing, however, other than showing a few pics if various stages a cant really write a How-To other than, strip bike down to frame, get frame powder coated, rebuild bike with various new parts as you go along as needed

The only thing that may help you is various pics along the strip/rebuild process with how long each stage took me and any problems encountered and total time for the project

ps. dont ask what colour the frame is going to be cuz youl have to wait an see, needless to say most will hate it and it wont be orange (soz KTM, i dont want yet another SDR lookalikey )

So, 1st off, tidy your work space you scruffy git -



Its amazing how quickly these SDs come to peices, so1.5 hours had the bike looking like this -



Called it a night after this.

Next day and another 1.5 hours had the bike looking like this -



Coolent out as im going to do the water pump rebuild whilst im at it.

So for 3 hours work youl end up with a garage resembling this -





Engine to be dropped out next along with wiring loom and drop the rear subframe off and shes bascially ready to go to powder coat.

Gotta order various parts from KTM ready for the rebuild such as bearings, water pump parts, front brake pistons and seals as they are gonna get a rebuild also !

So, any problems so far? nothing, everythings easy and straight forward and ive taken a load of pics along the way for reference for such things as wiring loom routing etc

Il update this thread as and when i get time to work on the bike but im expecting 4-6 weeks in total (maybe )

Hope your not going to fook with color on the "bell"

Bloody hell Stew that's a major job. Good luck m8 and look forward to seeing her in the new paint job.

LOL - show stopper (for me) at Step 1: "So, 1st off, tidy your work space you scruffy git - ".

It would never happen ...

And another hours work done and your looking at this -



Half hour later and your basically left with a whole load of parts scattered round the garage , an engine looking sorry for itself and several parts ready to go off to powder coat -




So now the list is made of KTM parts that are needed and im just waiting on a date to drop the frame, swingarm, subframe, rear spring and maybe brake calipers!? to the coaters. (only the frame is being done in a special colour, all other parts are just being redone satin black )

Problems thus far, no real biggies, all wiring was labled and photographed as i went along. Biggest problem is balancing an engine whilst lifting a frame off single handedly

Next jobs, water pump rebuild, valve check, considering having the heads off to replace gaskets and head bolts

This thread will now be quiet for awhile till frame etc comes back, hopefully not too long

Well if you ain't changed you mind on the colour since our conversation at Silverstone,you will def get a reaction.

Pink?

Nice job mate. Always harder to put back together though!

Nice effort, I know how hard it is to take photos step by step after getting the hands dirty.

I agree with bic though, good luck putting it all together nice and fresh.

Keep us in the loop.

Nice work

Barbie pink frame coming up

while the engine is out... why dont you paint it a matt or crackle black? Keep all bolts same colour and all machined surfaces free of paint (and a colour of your choosing for the cam cover)... i think it would brilliant and a have not seen it done yet

Everything sorted, bolt holes filled and all bearings etc removed ready for powder coat tommorow -

new frame colour looks awesome! When is it going back together?

You getting your chain powdercoated then? Pink will it be? Is the colour still a secret?

Haha, that's fookin' awesome. I can't wait to see this done and I believe there's a little bit of me going in there
Nice work!

As i said before im going to be without cylinder heads for a few weeks so started with the basics and cleaning and checking things like head/swing arm bearings as i go, re-greasing ect -





Loom to be cleaned and drop back in place next then i really am stuck till the motors back in 1 piece

WOW! Wow! I'm lost for words!

I was joking too.

updates please?

No updates - im still waiting on Dave for his cylinder heads so they can be sent off with mine for head work. When they all come back the motor will be rebuilt and slotted back into the frame - i cant really do anything until the motor is back in im afraid

My girlfriend loves the black-pink combo so I'm afraid I'll have to do the same if I show these pics

I think it looks awesome by the way!

Well bro..???? Any updates..??? I don't have much of a designer's vision soooo...Can't wait to see it comin' together..

Remember and post up dates if your doing a few trackdays dude. I'm planning a good year of it in 2011. Looking to do around 1 per month. It'd be good to meet up with a few more SD's on track.

oh i hope you're going to coat the cam covers the same pink!
these things are pretty easy to put together, you should be fine seeing as you actually pulled it apart and marked stuff like wiring etc!
pink! i still can't believe it, hope you're prepared to pass round the outside on your next track day, otherwise all the guys will be blowing you big wet kisses!

paul

handlebar streamers. now that's a mint idea!

Replaced a bent frame on my 08SD last year. Took some pointers from Paul with his build. Bike bench which raises the bike from the floor for one. Other major ,would do it again item, is to use a motor stand to support the motor at trear down. This "A" frame stand supports the motor that stays put on the bike bench. Every thing can be removed / replace with the stand still connected to the motor. The frame can even be pivioted into place by using one rear frame bolt. The sub frame can also be piovoted into place. I even left the air box and TB inplace with wire harness and TB cabiling. I did all of this by my self. I will have to post some pictures of what I did to give back to this very helpfull site. Some times I might come across as a know it all...not the intent...I just want to share my knowlege or lack of it ..Got more than 300K miles on sport bikes and do most of my own wrenching. Will be 60 in May and started the bike bug before teen age. Will post later,,,going out now on my 300KTM 2 smoker for a 40 mile loop. FYI my gal had to bust the ice on the bird baths this am..Ride on

So...any updates bro.???
Still want to see her all together...

Mike

Still nuthin yet Bro - still tryin to get the engine back in 1 peice (its only a 2 hour job then it can go straight back in the frame) but time has not been on my side over christmas what with family etc.

I had put aside the whole of new years day and then ended up with a 36hour stomach bug which is now doing the rounds in our household My lil boy has only been back at school 1 day and now hes off again for 2 days with illness (bloody schools wont let the kids back to school with in 24 hours of havin a illness - let them all have the shits i say!!!!) so now im lookin after him and our little girl for 2 days which puts me back with my own work so that means i can fookin write off anytime i had at the weekend to play catch up

Im determined to have the fookin bike 80% back together by mid jan then it will be just the small parts like replacing brake seals, fluids etc.

Somebody pray for me

ps. anybody got any pink Dainese leather s for sale

nice

Engine is finally complete and just needs a clean down in places. Frame is already hovering over ready to drop on plus i have a few hours to myself tomorow

Updates to follow

With pics, gotta see this bad boy frame

3 more hours shes cumin along!!!

Orsm!!

That is fooking awesome Stew.

Was a beautiful day here today. Really wish I'd been able to get out on the bike. That's not going to happen for at least another month.

Where's that "unsee" button when you need it!?

I approve.

Black sub-frame

nice mate.
fun isn't it!

That colour is awesome!

not sure if I likes it.... should've gone kawi green!

lookin' good!
(the fork bottoms could use some black paint)

I see you have a bell.

I also have a bell.

Just wait till you get on that thing and give your bike a proper ringing!

Nearly there bud. Could be the test ride at the weekend of the weather holds

Howzbout some moly grease on that output shaft spline They like that lubed up

I feel real Gay right now. Please someone show show me a girl in a hot dress...quick quick! Out of all the powder coating colors out there may I ask why? They dont even make a leather racing dress.

Maybe put some tits on it..??????
lol
They say a real man can wear pink...

Isn't it a passive color though.????
doesn't it take the animal out of the man.????

No humming and singing going round-i-round I hope....

And no fookn one piece leather dresses...
Maybe a nice set of GarneGP1 pumps..????

Still can't wait to see 'er done bro...All kidding aside...

A mate of mine did the frame of his kawa Z1000 cc custom (forgot what the model was exactly) 30 years ago in the same colour.
While he was rebuilding it everyone gave him stick about it. But when it was finished it looked damm good.
It was a black bike so this might work out nice too.

Isitdoneisitdoneisitdoenisitdoneisitdoneisitdoneisitdoneisitdoneisitdone.???????????????????????????


Ohhhh...thinkin a little ka ka brown next year.?????? lol...
anyone can wear ka ka though...I got a little in my pink panties right now...lol

Dude it's March now...Getn close..???

little by little she keeps progressing

Another little update guys, this is the last photo i took but i now have the tank on and a few other bits and the big pink beast lives and breathes -



Left to do -
Bleed brakes & clutch
Fit air filter (it left California yesterday so fingers crossed its a quick delivery) and finish breather off
Set quick shifter rod up
set chain
Panels on
Tyre pressures
Road TAX
Dyno set up
TRACKDAYS

Nice Stew! really like the frame.

Is it more of a dark pink? or just the camera/light?

Oh boy!

Looks like it's coming together nicely! I think this will look really nice with the bodywork on. Just showed this to my girlfriend al she could say was: WOW!

That's cool as fook! Turned out really well with the black.

Is that ceramic coating on the exhaust? What's the story with that, does it wear ok and keep its colour?

Have you got a link for those bars? Are they the streetfighter ones?

Gutted now I didn't send the handlebar clamps to powdercoat with the rest of the stuff. Looks miles better.

LSL drag bars I believe, quite a few guys running them.

Bit further -

Well she very nealry finished.

Just waiting on the Air filter, it managed to get from California to Heathrow in the UK in less than a day and now has just sat in Heathrow customs wating for clearance - fookin lazy bastardzzzzz So now im stuck till thats here

Threw a panel on it just to see what shes gonna lookie like when all buttoned up -





Im more than happy with it!

So there you go, let the pi$$ taking begin

Let me be the first to say..... I actually quite like it. Good one.

Is that quickshifter set to change down when you go over speed humps?

I think it needs more pink! Sweet.

Looking good dude Bet you're gagging to get out and play.

Nice! Looks like the pink works out!

wow...finally soemthing to look at..!!
Nice dude...
Maybe some pink rim tape would set it off..???
Seriously..that one wasn't teasing...
A bit more pink would be the ticket...
Good job..!!!!

Thats looking pretty nice!
Just being nosey but what's the yellow ring on your fork leg?
Cheers

Should probably read "this side down"

We should actually hand out vinyls with that printed on to all Crashfest attendants

......i was expecting ....more pink ...It look really good.......better than I imagined

I was waiting for a picture of the clocks......or did you give up on the inserts

Finally had a chance to check this beast out on the laptop to get a good look at it.

I like it. Doesnt look too much, really suits it. I see you've opted for white panels, apparently thats the fastest colour for 2012.

Just going over the pics checking all the little bits you've changed to black. Doesnt look like much at 1st glance but there's loads. Makes a big difference.

Looking good. I think I speak for a few of us when I say the pink looks better than expected!

I knew what the yellow rings on the fork tubes are used for but the black ones on the exhaust cans? What's that about? Have you had the chance to put some miles on your handle bars yet? I like flat bars. I think my stockers have too much pull back.

Black ones on the cans are there in case he decides to part company with the bike mid corner. These things can happen on the Crashfest.

sorry to bring an old thread up but i really like this..

Has anyone else done this?

this winter I'm going to do the same!! just a different colour.

"Has anyone else done this?"

Yo...still around if you need any pointers...

Sure like the way I did it.

Support the engine, hinge / lift the frame off.

One man deal, EZPZ.

Took a 510 Husky motor out of a frame and dropped it, fooked the compression release shaft, learned my lesson via the school of hard knocks.

Any specific tools required.

Any useful techniques as mention above.