Ducati 998s FE Final Edition (REPLICA but MODIFIED FAR BEYOND the Original) Build Thread

[DesmoAndrew]

Have you seen the videos of DesmoWerx on YouTube? He has a series that addresses building Ducati engines (748, 749, ST4, 1098 as I recall). I find his knowledge to be excellent and have learned much from watching his content.

https://www.youtube.com/c/DesmoWerx/featured

In particular he addresses crank and transmission shimming.

 

[BMW Alpina]

Have you seen the videos of DesmoWerx on YouTube? He has a series that addresses building Ducati engines (748, 749, ST4, 1098 as I recall). I find his knowledge to be excellent and have learned much from watching his content.

https://www.youtube.com/c/DesmoWerx/featured

In particular he addresses crank and transmission shimming.

Thanks so much DesmoAndrew,
These YouTube video will surely help. I will review it, and maybe my son and I will be installing the lower part of the engine.
I am still not sure about measuring squish and setting the timing though...
I should study more

By the way a part arrived which is the spacer inside the rear upper shock link:

 

[BMW Alpina]

More parts arrived for this project today ,

First, Motocorse TITANIUM Sprocket Nuts for Panigale V4, yes Panigale V4,... but why? well because I am using the AEM Factory cushion drive which uses the same thread pitch as the Panigale V4 12 points TITANIUM Sprocket nuts (along with some ProTi) as usual:


Here how it looks before with AEM Factory Aluminum 6 Points Gold Nuts and AFTER with Motocorse's 12 Points TITANIUM Nuts:


More from different angles:




Then, I bought my SECOND Oberon Clutch Slave Cylinder, but this time in Red Anodized so I can choose which one will fit my bike better:


And 12 pieces of K-Bike Titanium Cylinder Head Nuts:


More updates during this long weekend

 

[BMW Alpina]

Literally a BAG of Titanium engine hardware and some suspension hardware arrived from Germany today :


Oh, it came from a small manufacturer shop called IM Manufaktur:

Some of the parts is very interesting like this Pin that hold the rear brake caliper from spinning:


Or, the rear wheel axle pin (that goes into the wheel):


The Rear Ohlins Shocks Titanium Upper and Lower Bolts that is kinda special in shape and sizes:


The Engine Head Stud Nut in Titanium (too bad no one made Titanium Head Stud for 998 only 998RS engine:



But that is not all of the parts... a second box containing Ducati Original Parts mostly for the rear swing arm also arrived today:


Now this one is purchased after our kind forum member @Araitim informed me about lightened primary wheel from Ducati 1098 that can fit 998 engine Thanks so much @Araitim


Then... this one is actually 848 rear brake caliper that will not only fit 998 but allow 998 to use larger rear brake rotor:


That is it for today, as usual more coming soon

 

[BMW Alpina]

Just sold and shipped my 998 wheels to our forum member @M900GP
Thank you so much for buying the wheel from me

 

[BMW Alpina]

I did many things this weekend, unfortunately, most are just cleaning the used parts for sale from the 998, or actually shipping the sold parts.
Now, I was about to clean my old radiator when I decided to test fit the 2 fans on the Febur... there are some issue with the location of the welded mounting tabs for the fans which are manageable,
however, the one that is not manageable (at least not easily) was the upper inlet on the Febur were located on the WRONG sides compare to the stock 998 radiators.
Luckily, no one had purchased my old stock 998 radiators so I can still do a comparison and if I have to reuse this for a while.
I am contacting Febur now to see if they can fix this issue.
When they emailed me a long time ago, the lay out of the inlet are the same as the stock 998, I wonder how come they arrived wrong...
Here are the pictures to compare between stock and Febur (Febur is at the bottom, stock at top):

 

[BMW Alpina]

Did some more cleaning using Ultrasonic Cleaner, and it's really effective on aluminum like the height adjuster bar at the center of the basket, also with stainless steel like the braided line and the 2 oil cooler nipple fitting. Less effective on Zinc coated parts though:

 

[BMW Alpina]

USPS just delivered huge package from Italy, I am posting this picture directly from my iPhone so I can write forum tutorials on how to post pictures from iPhone


I will open the box later

 

[BMW Alpina]

I finally have a chance to open the box and these Certificates came out:


But for what...
well
for
these:

Original MS Production Left and Right Carbon Fiber intakes with provision for mounting turn signal (Strada/Street Version).
But why Street version, well first, the larger intakes means it will require the larger inlet on the front fairing/cowling so that will not be the original Ducati 998 plastic front cowling,...
Wait why I like plastic front cowling,... well because I want it to look like a stock 998s FE from fairing point of view. I actually like the fairing to be in red color outside and inside surface.
Second the larger inlet also do not have provision for mounting the turn signal, and I do want a turn signal because I am building a street bike not a race bike.
So I might lose some potential top end of my big bore 999 engine... but that is ok... I don't need ultimate power, just ultimate looks that I love


By the way, look at the quality of those threaded insert for the turn signal. so so nice...



For the record, I actually ordered a matte carbon color of similar intake from Carbon4US through Bellissimoto, but Carbon4US from Italy had not deliver since 6 months ago... with no news to Bellissimoto as well.
So hopefully sooner or later Bellissimoto can get them from Carbon4US and depending on how they look, I will either keep them for display or sell them on eBay...

Second...
now this is also related to another Italian company, EVR.
EVR made the only larger volume carbon airbox that is compatible with Strada version of intake (like the above) for 998, however as you guys recall, it was delivered with deep marks (like wrinkle skin) due to their vacuum bag mark imprinted on the surface.
Some area actually have extra layer of carbon fiber that is NOT oriented properly to cover some cracks. Then they do not deburr all the holes and edges so it was sharp everywhere...
And they also do NOT include the clip for holding the intakes in place, meaning I need to buy those from Ducati and RIVET them myself...
I could have a paint shop refinish the surface to make it looks nice but long story short, I decided to return them to Bellissimoto which provide exemplary customer service and issue me a store credit (I asked for store credit) which I spent right away on other items.

Then, I was thinking of buying an original Ducati 998R Carbon Airbox, but then I saw this MS Production Airbox which was the manufacturer that made the airbox for Ducati anyway... so I buy it together with the intakes above and here are the pictures.
Please note that this is the same size as the original Ducati 998 plastic airbox or 998R Carbon Airbox, however, it also make it easier to access part of the engines because the large EVR airbox cover many area around the throttle body making it difficult to do adjustment if needed.
So, everything happened for a reason. Again, I might loose some of the air buffer from a larger airbox, but... as long as my eyes are happy, that is what matter the most :





It came with the important clip to hold the intakes:


And the HISTORIC Logo of MS Production :

 

[Andy7]

Never heard of that company. Are MS production still producing carbon components?
Quality looking pieces, will be epic seeing them fitted to the bike where they belong

 

[BMW Alpina]

Never heard of that company. Are MS production still producing carbon components?
Quality looking pieces, will be epic seeing them fitted to the bike where they belong

Hi Andy, they supposedly no longer in business, but someone must buy the right to that company name or maybe the old owner start building again, but their website is not running yet..
Their main competitor CM Composite (also supplier to Ducati of that era) now is back in business with a different name (I forgot the name now... but I bought some part from them for this 998 projects... I just forgot what is that part... I bought too many parts hahaha)...
I am seriously losing track of many things because I am also busy with the multiple projects at work...

 

[HKMP7]

Wow!
I remember my buddy had Ms production carbon for his full carbon 996. Circa 2004.
I’m glad someone is keeping them alive.
This is awesome.

 

[BMW Alpina]

UPS deliver the big bored Cylinder Block back from Millennium Technologies today
This means, I can ship the Pistal Piston along with the crankshaft for Lightening, Balancing, Knife Edge and Super Polishing to Boulder Motor Sports soon... well as soon as I can extract the crankshaft from the old crankcase of the 999S engine
Hopefully this weekend...

By the way, pay attention to how thin the Cylinder Block wall now




Millennium Technologies even MARKED the cylinder block with code to match it's matching Pistal Piston (for precision fit):


And this is with the Pistal Piston inside:

 

[HKMP7]

Awesome! That seemed to be a pretty quick turn around? How was the experience?

 

[BMW Alpina]

Awesome! That seemed to be a pretty quick turn around? How was the experience?

I believe it was a month or so, they told me 35 working days when I paid them.
They are a very busy company but I am happy with the result and service.
After I take out my crankshaft from the crankcase, I plan to send my gearbox (and other gears) to be MICROPOLISH (like what @Araitim recommend )

I also tried to sell my robots to them, and on that one, unfortunately, the owner never responded back to me though

 

[BMW Alpina]

Spent half a day mostly doing selling/trying to sell the remaining original parts from the 998.
Sold the engine 2 weeks ago by the way, and today another happy buyer, pick up my left lower fairing for bargain price
Want to ride the good sales momentum I cleaned the 998 Brembo front caliper and also prepared the clutch cover plus the alternator cover so it's ready for sale.
Then,
Spent the remaining time to start taking apart the Crankcase assembly:
First, uppack the crankcase with the help of my puppy


Unpacked and ready... this is a 2005 999S engine, deep sump of course


Start with the oil pump assy:


Oh, my younger son also helping me taking measurement and notes of all the bolts so those can be replaced with ProTi Titanium:




Also, took notes of all the gea rs that later can be Micro Polished :





And here is the crankshaft after the oil pump assy. removed:


And its a wrap for today... will try to continue more tomorrow

 

[BMW Alpina]

As part of the crankcase disassembly, I need to take out the layshaft gear... using this tool from K-Bike below:


The only issue is...
on K-Bike website, they show this tools with the center castle nut socket tool, like in the picture below:


And I believe K-Bike use to either offer them as a package, or at least offer this center castle nut socket tool separately..
Unfortunately, K-Bike NO LONGER sell this center castle nut socket tool.... and the other K-Bike Castle Nut Socket Tool for the Camshaft timing gear is too big to fit...
So... I need to buy a separate layshaft castle nut socket tool...
I was about to buy it from HDESA who is located in San Jose... but.... they are now on vacation to Europe and won't return until April 2... so another delay...
In the meantime, I also order some nicer looking castle nut tool from Laser Tool in UK... hopefully arrive in the next few days...

Then I move on to try taking out the camshaft gear timing with the K-Bike Castle Nut tool for it...,
but they are so tightly torque, I was forced to used my Makita Impact Wrench to take them out, left picture, that in combination with the K-Bike camshaft gear holder tool (right picture):


I manage to take out 3 castle nuts...


but unfortunately this K-Bike castle nut tool is not strong enough and the 4 tooth broke, right when I was using it to open the last (forth) castle nut tool, which means, I am also had to stop mid-way and need to way until I buy a new castle nut tool for the camshaft timing gear (also from Laser tool UK arrive):


In the meantime, Bellissimoto ship me some parts:
Rizoma Corza Turn Signal in the Gorgeous Anodized Red:


The last of several Wheel Cone Nuts assortment, and this last one is the Slate Grey Color, so later I can choose which one looks the best with the BST Carbon Fiber wheel and aluminum colored hub:


Motocorse Titanium Bolt originally for side stand sensor but I am going to use this to hold the Carbon Fiber Exhaust Heat Shield to the Motocorse 60.5mm Titanium Exhaust system:


Bunch of ProTi Titanium Bolt for Project 998, all in Titanium Silver color:


And last, Rizoma rear view mirror adapter, so I can use my Rizoma Veloce L Mirror that I originally bought for my Panigale V4 25° Anniversario 916 project to this 998:

 

[BMW Alpina]

I decided to make sure the Motocorse Titanium bolts for the exhaust heat shield works with the Motocorse 60.5mm Titanium Exhaust Piping and of course the Carbon Fiber heat shield it self:



Well... right away I notice something is not right
The hole location is way off... so this Carbon Fiber Heat Shield by CM Composite (now speed carbon) was the right fit for the latest 998 Termignoni Piping, however, the Motocorse was made following the 998RS or the older 996 type bolt spacing, thus the reason...


8cm spacing on the Termignoni vs 13 cm spacing on the Motocorse:


Which means, I got to order another Carbon Fiber Heat Shield... but the good news is I can order the MS Carbon version now ... will take a few weeks (hopefully)...
in the meantime test fit just with one hole:
Yap, of course it is gorgous... oh, will also need to add spacer (and some heat shield washer):



Then I found out, that i need to buy one more of this Motocorse Titanium Bolt (around $64 each... but well they are so beautiful so what can I do... but to buy them )... so I need to buy one more for the bolts that connect the 2 Motocorse exhaust piping:
Yeah baby, you are so gorgeous :



Ok, now I now the problem and solution for Motocorse, now time to move on to Rizoma... meaning test fit the Rizoma mirror adapter for Ducati 1198 (yes this is for 1198, so I might need to do more "adapting" when I install it onto the front fairing of the 998, but I am sure it's doable ).

Notice, that the Rizoma Veloce L rear view mirror currently connected to the Panigale V4 Rizoma mirror adapter:


First unpacked the Rizoma mirror adapter for 1198 and assemble them:


And yes, they FIT PERFECTLY , so someday when my 998 is ready, this will be the Rear View Mirror on it
By the way, I am now thinking of painting those black upper and lower part of the rear view mirror housing in the same Red as the 998... but I am not sure yet... so I will decide once I install them on the bike.


Next are the switches... so I buy so many switches because initially I was having a hard time finding a brand new switch since Ducati no longer make them... (eventhough I finally able to find New Old Stock, but it was one of the hardest parts hunting I ever done)...
Ok, now, I bought a switch from an eBay seller in UK... his switch is quite nice and from the 916 generation thus the "unique symbol/lettering". However, the lower housing pin had been filed/grind down, must be to be used with aftermarket handle bar without the hole for this pin (anti rotating pin)...
Well, I am not happy with this so.... I will use the lower housing from the original switch that came with my 998 and switch it around (swap maybe the right word, swap it around )... but first, I got to install the starter button cover that had been rejuvenated with USMC Red Cerakote :

The left switch is the original switch from my 998, the right switch is from UK eBay seller and it came from an old 916... but amazingly, the old 916 is in better condition than the newer 998 switch.


This after I install back the Red Starter Button now in USMC Red Cerakote finish, notice how brilliant it is:


Now, I am comparing my old 916 switch with the brand new ST4 switch. Yes, the left switch is a brand new ST4 switch... wait why Ducati ST4?....


Well... Ducati no longer make the right switch for 916/996/998... but I found this ST4 switch on sale on eBay someday... brand new condition of course... Initially I was worry the wiring would be different, but after taking a look at the socket style, they are exactly the same.
So even if the wiring is different, I can easily swap the wire if I have to. Turn out, the different between an ST4 switch to a 998 switch is just the ST4 came with a much longer wiring harness hahaha
You guys don't know how many nights I spent, browsing on the internet just to find a brand new right switch for 998... it drive me insane... but the solution is so simple, just buy an ST4 switch and they are the same...
Well, if anyone read this, the ST4 switch is almost run out too. so you guys better hurry if you want to buy a new switch for your 998
Here is the picture showing the different in wiring length:


But even when I compare to the brand new ST4 switch, I still like the 916 switch better, so I will use the 916 switch for this build (and the ST4 switch for spare). You can see on the picture below on why I like the 916 switch better.
Oh by the way, I cleaned that 916 switch very well, that is why it look brand new again. It wasn't this clean when I just bought it from that UK eBay seller :

Next, pack them in a plastic to make sure they are safe until I need them:




Next, the tough choices of choosing between the collection of the left switches I have :
Well, no, it wasn't that hard to choose...
so the left is the original switch that came with my 998 and it is USA version meaning, headlight always on, no switch to turn off the headlight,
in the center is the switch also from the same eBay UK seller, which again came from an old 916 that have headlight turn on/off switch, and the right switch is a brand new switch for 998 UK version with headlight turn on/off switch


Of course I will NOT use the left switch since it is US version without the ability to turn on/off the headlight so it will be going to eBay for sale soon .

And again compare to a brand new 998 switch... I still like the older style 916 switch so for this build the 916 left switch will be used and the brand new 998 switch will be for spare:
Ups, I hit the limit for posting picture so will continue below:

 

[BMW Alpina]

This picture clearly show the extra headlight switch on the 916 and brand new 998 switch compare to the BLANKED US 998 switch on the left:



More comparison between the 916 and new 998 switch... notice the lettering/symbol is very different (oh, I also cleaned them very well today):


Ok, will do some more works tonight and hopefully I can get further update post here soon

 

[BMW Alpina]

The GP4-MS caliper arrived today and I also do a "comparo" with my GP4-RR caliper on this thread: The Obtainable Brembo GP4-MS, GP4-RR, GP4-PR, GP4-RS, GP4-RX and Unobtainable Brembo new GP4 caliper