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

[BMW Alpina]

Next, I open another box, this from Ducati Omaha containing many parts, and one of them are a pair of #1 stickers (original from Ducati Panigale V4 25° Anniversario 916 side fairings):


Why?
Because I plan to add White Painted Area on my 998s Final Edition Tail Fairing so now it can have a place for the black #1 stickers above.
These White Painted Areas will be similar to the 916 SPS Carl Fogarty Tail Fairing like in the picture below:






And here are the approximate area where all the #1 stickers will be:


I also plan to add "DUCATI" sticker at the end of the tail:


So it will looks like this:


By the way, I also thinking of using the BMW MINERAL White color for the white painted area because they have that glittering pearly white and not too wash out white to make it a bit "RETRO" looks

 

[BMW Alpina]

Next is Airbox, the MS Production Carbon Fiber Airbox finish is "decent" but it is not up to the level of @Peter Lieb of course,
so I will use the rear carbon fiber license plate bracket cover from the Ducati Panigale V4 25° Anniversario 916 that @Peter Lieb made long time ago for me as sample color

Now, just making it a SATIN Finish is not good enough but I want to make it look like this bike where the red color continue from the tail fairing to the carbon fiber side covers of the airbox. This is the inverse of the normal Ducati 998R paint scheme where the carbon fiber continue to the tail fairing instead.
Here is the picture that inspired me (circled in blue is what I meant by continuation of red color), but instead of glossy carbon like in the picture below, mine will be SATIN finish:

 

[BMW Alpina]

Move to the front of the bike,
I received the Ducati DIAVEL wire mesh intake cover today:


Then I test fit to cover the LARGER 998RS style Carbon Fiber Fairing intake opening:




And they are PERFECT FIT, look like it came from Ducati factory :



Plus their hole spacing is a bit larger than the stock Ducati 998 fairing wire mesh so they should allow better air flow.

I want to paint them exactly like the 916 SPS Carl Fogarty front fairing:


the white painted area shape is slightly different then the latter 996 and 998 style. This style is more rounded and smaller, but I think looks sweeter and retro
Beside the rear tail fairing white area is already 916 SPS Carl Fogarty so front and rear better match

I also purchased the original Ducati #1 sticker from the Ducati Panigale V4 25° Anniversario 916,
and I taped it for test fit:


Last, of course the Ducati Logo on the right side (left side of the bike):

 

[BMW Alpina]

More box arrived today, and this time is from my good friend, Bob at New England Gear Polishing NEGP :


I will let all the pictures below speaks for it self on the quality of NEGP Micro Polishing, and as we all know SMOOTHER is FASTER :

 

[BMW Alpina]

Ok, belated weekend update :

First, I gather all the parts needed to assemble the Gear Change Lever mechanism, from the main levers that had been micropolished, to some pin, springs, washers and ProTi Titanium Nuts:






So it looks like this (and comparison between the old and the new set:


I also reassembled the gears inside the oil pump that had been micropolished:

and it become like this:


Unfortunately, I found out I still missing some parts that need to be ordered from Ducati, so the micropolished outer gear cannot be secured yet:


But once I have the C-Clip, it will look like this:


Then I work on test fitting the layshafts with the center pulleys:

using K-Bike large washer/separator (titanium of course) and also Titanium spacers from IM Manufaktur Germany:

But then I found out, I forgot to purchase special M15 locking nut from Ducati... so can't secure them yet...

I then move to the other end of the layshaft and test fit both the titanium nuts from IM Manafakture and the special washers


Then I add the micropolish gear on to the layshaft:


And here is the final assembly:

 

[BMW Alpina]

After that, time for the adjustable and non adjustable tension roller (which again I forget to buy the brand new studs for it).
First the adjustable roller:
I also found out that the old roller that came with my 999S engine (on the left) is different then the new Part from Ducati, noticed the left old part have 2 lips, while the right part only have 1 lips.
So that pentagon shape Titanium adjuster from IM manufakture will NOT fit the new style on the right... But after carefully looking at the design, I prefer the New parts since it does not require any spacer and also have more loading area to the center stud...
which means that Pentagon shape Titanium Adjuster is now not usable.




Below is the non adjustable rollers, where I still need to press in the bearings, maybe this coming weekend:


Next I jump to the camshaft rollers, assembling it with the ProTi Titanium Bolts and K-Bike Titanium Washers, oh, by the way all these rollers are the Ducati Performance ERGAL light weight rollers:




Some comparison between the old heavy steel roller and the super tricked titanium/ergal light weight combo , nothing compares of course


Pack them up, ready to be paired with the 999R camshafts currently being micropolish at NEGP:


After that, I am preparing the Stainless Steel Bolt and Washer from Accu UK:


Which then be used to replace the steel bolts for the starter motor (believe me that I look for Titanium bolts but can't find in this size so stainless steel have to be enough ):
Left is half half, and right picture full stainless steel:

some side view:

 

[BMW Alpina]

I am not done yet... next is the old style full diameter 10.9 grade steel engine mounting bolt:


And comparing them with the newer style (have thin waist that I don't like):


Still about bolts, now the new Titanium Bolts from RaceTech Titanium arrived (super fast and great customer service from RaceTech Titanium). They offer me to refund the earlier bolts that was not the same as in their website picture, which I appreciate, but I decided to just keep it. I am sure someday, I can use them.
Now from the top in the picture below:
stock steel bolt
wrong shape titanium bolt by RaceTech
ideal shape titanium bolt from RaceTech
full width no waist at all just like stock bolt but from Titanium by RaceTech:


My choice of course is the 2 bottom bolts in the picture above, but first let's do some weighing:
Stock Steel:


Wrong Shape Titanium:


Ideal Shape Titanium:


and Full width no waist Titanium:


Of course, I choose the IDEAL waisted titanium because it is PERFECT when inserted in the cylinder spacer below:


Of course, don't forget the Cross Drilled Titanium Washers from ProBolt on both side:

 

[BMW Alpina]

Hmmm... I also managed to locate the 2 remaining pieces of special Bolt to plug the non usable oil outlet in the cylinder head that also function as a stud to hold the bracket for oil cooler...
I already have 1 piece used special bolt, but I just want to buy a new bolt if possible, and since it is very cheap, I decided to just buy the 2 last stock available at any Ducati dealer in America just for spare... who know someday I have another engine :


Of course it will also be painted just like the original used bolt that had been painted in red anodized:


I also buy another set of Podium Racing Titanium DZUS because I need it for the MS Production Carbon Fiber Airbox RS style side cover:


Talking about RS Style MS Production Carbon Fiber side air cover...
I decided to give it more spice by adding official sticker from WSBK governing body, please note the white square is just the backing, the sticker is just the RED arrow (from letter "K) and that small white SBK sticker.
It will be protected under satin clear coat soon at SpookyFast paint shop




Ok... more updates coming soon

 

[BMW Alpina]

I just finished packing up the RS Carbon front fairing, the RS style airbox and the rear tail fairing in 3 separate large boxes. Will ship them to SpookyFast for custom painting in Arizona tomorrow.
They quote me very close to $3,000 for custom paintings these 3 parts, but they are the best painter that I had found so far (and by far), so it's ok. This is a one in a life time project
I can only ship them today because that "DUCATI SUPERBIKE" sticker finally arrived from Ducati Omaha yesterday :


Yes, they are very large boxes :

 

[PanigalePilot]

More bolts arrived,
First the Stainless Steel Accubolt from UK for the starter motor (I can't find Titanium Equivalent, so Stainless Steel it is) :
View attachment 10031

Then the RaceTech Titanium Bolt for the main bolt holding the rear suspension to rocker arm arrived along with matching Titanium Drilled Washer and Locking Nuts (12 points) from ProBolt:
View attachment 10032View attachment 10033

View attachment 10034

Here is how they will be configured:
View attachment 10035

But then I realized there is an issue... as shown on the red circle in the picture below. The "SLIM WAIST" area on this Titanium bolt is just too long,
this is the similar issue I was having with KBike Titanium bolt for engine mounting. I just don't trust the very small engagement around the thread area,
so I am ordering a different bolt from RaceTech Titanium that should arrived maybe next week...
View attachment 10036

I also found out it was not my mistake, but apparently the bolt used as picture on the RaceTech Titanium website is not the exact bolt I received, no wonder I was confident when ordering this bolt,... but oh well, this happened, so no big deal, just need to order a few different bolt so I can choose which one I like the most...
View attachment 10037

Oh, I also ordered some extra Snap-On Torque Adaptor to complete my previous kit... only to find out, I forgot to order the 21mm to truly complete the kit,... so order more today at Snap-on website:
View attachment 10038View attachment 10039

Nothing like nice tools

 

[Shanner22]

Fantastic build

 

[PanigalePilot]

I am not done yet... next is the old style full diameter 10.9 grade steel engine mounting bolt:
View attachment 10160View attachment 10161

And comparing them with the newer style (have thin waist that I don't like):
View attachment 10162

Still about bolts, now the new Titanium Bolts from RaceTech Titanium arrived (super fast and great customer service from RaceTech Titanium). They offer me to refund the earlier bolts that was not the same as in their website picture, which I appreciate, but I decided to just keep it. I am sure someday, I can use them.
Now from the top in the picture below:
stock steel bolt
wrong shape titanium bolt by RaceTech
ideal shape titanium bolt from RaceTech
full width no waist at all just like stock bolt but from Titanium by RaceTech:
View attachment 10163

My choice of course is the 2 bottom bolts in the picture above, but first let's do some weighing:
Stock Steel:
View attachment 10164

Wrong Shape Titanium:
View attachment 10165

Ideal Shape Titanium:
View attachment 10166

and Full width no waist Titanium:
View attachment 10167

Of course, I choose the IDEAL waisted titanium because it is PERFECT when inserted in the cylinder spacer below:
View attachment 10168View attachment 10170

Of course, don't forget the Cross Drilled Titanium Washers from ProBolt on both side:
View attachment 10169

That is a great post. Very nice bolts and details
I always get a kick out of weighing pieces

 

[BMW Alpina]

My 2005/2006 (latest version of 999R engine) camshafts arrived back from NEGP (New England Gear Polishing): New England Gear Polishing - REM Job Shop in CT

As usual, NEGP perform the best job and customer service. Bob, NEGP's President himself, was updating me every step of the way.
Looking at the results of their polishing, well I agree with NEGP motto: "SMOOTHER is FASTER"

 

[Andy7]

Extra 10 horsepower there for sure

 

[BMW Alpina]

Extra 10 horsepower there for sure

Well, the micro polishing will not bring much horsepower but hopefully help generate less friction, less heat, and hopefully longevity from "controlled break in"
The "R" camshaft on the other hand though... might bring another 10 hp at the minimum compare to the "S" camshaft and of course much much more compare to the stock non "S" camshaft...
However, I had been warned that the "R" camshaft due to the profile will make the engine need to be rev up more during low speed riding otherwise it will stall easier compare to the "S" camshafts...

 

[BMW Alpina]

I replace more parts with Titanium Equivalent, such as this Oil Plug:



Oil Filter Nipple:


Steel weight:


Titanium weight (almost half the weight of steel):


Slightly different diameters but still ok:


Of course follow Ducati factory procedures of using Loctite 243 that can withstand Oil:


and tightened it to the right torque:


Voila:


Also install brand new mesh oil filter and O-rings for it:


Install special Aluminum Billet bolt for the gear drum springs/ball mechanism:




This is how the spring looks like:


Then install the Neutral Gear Switch:




Oh, I also purchased a genuine Ducati Corse Swingarm Axle Titanium Bolt:


And after I compare it with the similar but not the same Titanium Bolt I purchase from eBay UK, I decided the Ducati Corse version is better:


To be continued soon, now I need to deal with all the new but unfriendly to use Windows 11 features... wish I stayed with Windows 10...

 

[PanigalePilot]

I replace more parts with Titanium Equivalent, such as this Oil Plug:

View attachment 10355

Oil Filter Nipple:
View attachment 10356

Steel weight:
View attachment 10357

Titanium weight (almost half the weight of steel):
View attachment 10358

Slightly different diameters but still ok:
View attachment 10359

Of course follow Ducati factory procedures of using Loctite 243 that can withstand Oil:
View attachment 10360

and tightened it to the right torque:
View attachment 10361

Voila:
View attachment 10362

Also install brand new mesh oil filter and O-rings for it:
View attachment 10363

Install special Aluminum Billet bolt for the gear drum springs/ball mechanism:
View attachment 10364

View attachment 10365

This is how the spring looks like:
View attachment 10366

Then install the Neutral Gear Switch:
View attachment 10367

View attachment 10368

Oh, I also purchased a genuine Ducati Corse Swingarm Axle Titanium Bolt:
View attachment 10369

And after I compare it with the similar but not the same Titanium Bolt I purchase from eBay UK, I decided the Ducati Corse version is better:
View attachment 10370

To be continued soon, now I need to deal with all the new but unfriendly to use Windows 11 features... wish I stayed with Windows 10...

that was great finding those Ti special fittings pretty cool

 

[BMW Alpina]

that was great finding those Ti special fittings pretty cool

Thanks PanigalePilot,
I bought it from IM Manufaktur in Germany: IM-Manufaktur Motorsport Artikel für Gewinner. Ducati Leichtbauteile aus Carbon, Aluminium, Magnesium, Titan
However, lately, they are not easy to be contacted when I have questions though...

 

[BMW Alpina]

I am very busy these past 2 weeks traveling all over US, from Colorado, Utah, and to Michigan
While I was away, several parts arrived, like this Motocorse steering damper bracket for MV Agusta that I will modify so I can use it for this 998:


Also, the BRAND NEW Fuel Pump Plastic Bracket (inside the gas tank), which Ducati no longer made and WAS the only part of the Fuel Pump assy. that was not brand new finally arrived:


I bought 2 pieces for spare


I also received the Stainless Steel Studs for Exhaust Manifolds from UK:



And I bought extra Fuel Pump and Fuel Filter (I already have a brand new set, but this second set is just for long term spare)


I will do more work this weekend so please stay tune

 

[BMW Alpina]

Ok, today is CHEMICAL Stripping day :

I used this Rust Stain Remover to strip the black anodized finished of 2 items:


I don't like the black anodized finished of Podium Racing Gear Shift Arm:


So soak it for few minutes while using paint brush to help strip the black anodized:


Then it came out clean:


Success bring more success with larger part, this time the IM Manufaktur CNC machined Rear Brake Caliper Bracket for Monster S4RS that also came as black anodized:


The much larger parts takes longer and also create more "bubble" as a result of the chemical reactions:


Then I wash them with water and later with Alcohol:


Now washing them with Alcohol:


I plan to further polish them so stay tune