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

[BMW Alpina]

I noticed that the O2 sensor/Lambda plug that came with my Motocorse 60.5mm full system exhaust was ugly and rusting steel, so I bought the TiCON Titanium Grade 5 O2 sensor bung plug, size M18 x 1.5mm.


Below is comparison between new Titanium and rusted steel:


First, add Loctite Nickel Anti-Seize:


Tightened with Torque Wrench and voila, so much nicer:


Now, I need to do the same with the rear vertical cylinder manifold, look how ugly the rusting steel bung was:



Replace with the new Titanium bung plug:

 

[BMW Alpina]

I still have a lot of updates that I have not posted, but today, I decided to start working on the Fuel Line, so I need to temporarily install the airbox and the fuel tank.
And I was so happy today to see everything looks even better than what I imagined when I chose all the materials and colors:

 

[PanigalePilot]

I still have a lot of updates that I have not posted, but today, I decided to start working on the Fuel Line, so I need to temporarily install the airbox and the fuel tank.
And I was so happy today to see everything looks even better than what I imagined when I chose all the materials and colors:

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Looks great with the tank

 

[BMW Alpina]

I bought a brand new Ducati wire harness for some other Ducati model that has the same Magneti Marelli ECU so I can reuse their brand new ECU connectors:


The bushings to install the taillight also arrived, so I started installing the tail light (note all of these are a few weeks ago):


Unfortunately, the red reflector (cat eye) part of the tail light does not fit properly so the entire tail fairing cannot close because it hit the much longer Motocorse silencers:


So, I took out the taillight again and dremel the protruding mounting point flat:




Here how it looks after I reinstalled the taillights on the bike:


Now it can close properly (fully):


Then I tidy up the wiring harness the way the factory routing is:





But I felt something missing, and I drilled the holes again for mounting the red reflector, but now, it need stand off spacer, so I ordered a vinyl stand off spacer from Amazon:


Here are the assortment of vinyl stand-offs:


I use Loctite to secure them:


Continue below...

 

[BMW Alpina]

I have some extra gold color ProTi Titanium bolts and nuts that I no longer need ex my other bike, so I decided to just use them (instead of ordering the same size but in silver color) because it will take at least 1 month if I ordered a new ProTi bolts from Bellissimoto:




It is PERFECT now:

 

[BMW Alpina]

Miscellaneous updates:

I found out that I forgot to purchase an M4 bolts for this starter switch so I purchase the Mettec Titanium bolts because ProTi did not make it in this size:



Comparison between Mettec Titanium bolts vs. Stock bolts, by the way, one bolt is longer than the other:


Both Mettec Titanium bolts installed:



Installing Podium Racing Titanium DZUS fastener along with the Ducati original female part of the DZUS:


For now, I installed it on the Carbon Belly Pan:



The filler neck for radiator reservoir paint had been cured and ready to be installed on to EVR Carbon Fiber radiator coolant reservoir:




The Ducati original O-Ring for it:


Installed:




Now, I am just waiting for the ProTi Titanium Bolt to secure this red anodized pained filler neck because I previously forgot to buy it.

More updates soon.

 

[BMW Alpina]

Time to install the Stainless Steel reuseable Oil Filter from Scotts:


Add oil to the thread:


The stud for the oil filter in the engine block also have been replaced a while ago with Titanium Stud:


Screw the Oil Filter in:


Installed:


The pins for the ECU connectors also arrived from UK:





I bought the Ducati original insert to mount the lower carbon fiber belly pan onto the 998 crankcase, but somehow it is too large in size, and no way I can press it in,...
So I found an alternative way. Actually an even better way, I bought this brass expandable insert from Amazon:


Which I am going to use with Motocorse Titanium side stand switch bolt:


It fit the hole in the crankcase perfectly:


And it is PERFECT, ready to hole the 998s original Carbon Belly Pan:

 

[BMW Alpina]

Again, this was done a few weeks ago,

First, I collect the tools I need to build the Goodridge Aramid Fiber Reinforced Braided hose for the Cylinder Head Oil Line. Below is the cutting tool:


Cut the end of the hose to get rid of the messy braided fiber:






Apply a bit of oil to the fitting and place it on the plastic jaw to hold it steady:


Insert the hose (turn it clockwise until bottomed) then tightened the nut with special aluminum AN wrench (to prevent marring/scratch of the surface on the aluminum nut/fitting):


Done:



There will be 3 separate hoses, and I am working on the first hose that goes from the clutch cover to the TEE that will distribute the oil to both cylinder heads.
The TEE is made from Stainless Steel and I bought from UK. This TEE had a mounting hole to secure it to bracket and please note this is a 4AN size hose and tee.
Because I want it to have equivalent hose size to the original Ducati oil line. Most of the ready to use aftermarket kit are 3AN (smaller size designed for brake line). I want to make sure my cylinder head received enough flows of oil, thus why I make this custom hose.
I can also buy a stock Ducati hose, but they does not look as nice as this Goodridge



Next, I need to cut the right length to be connected to clutch banjo:


For this line, I need to install the fitting without the vise because once this end fitting is installed, I cannot simply route the pipe behind the engine cover without removing the engine cover:

 

[BMW Alpina]

I have been super busy with my home renovation project (that I can only perform during the weekend) because I am also super busy with office work on weekdays.

Here is another update:

First I connect the hose going to the clutch cover. This is the SOURCE of the oil flow. The stainless steel banjo is hold by a STEEL Banjo Bolt, original from Ducati.
I cannot find any Titanium Replacement, because they have a special flow limiter on it, so on this one, I will use STOCK STEEL Ducati Special Banjo Bolt:


I found the aluminum bracket below from my collection of aluminum parts no longer used by the R&D dept. at my office. I decided to use it to hold the Tee AN-4 for the cylinder head oil distribution block:


I also found some bushing/spacer that will self-centered the bracket:


Then I will use serrated washer to help the bracket stay in place:


And here is how the bracket mounted to the original holes on the engine cover that hold the original Ducati Tee distribution block. The Gold color ProTi Titanium Bolt is just temporary, I will replace it with Silver Color ProTi Titanium Bolt:



For the bolt that hold the TEE distribution Block to the bracket, I used MOTOCORSE Titanium Bolt with ProTi Titanium Nut:


Below are a better views of the whole Tee AN4 Stainless Steel Distribution Block hold by the aluminum bracket with all Titanium Bolts:



Then I connect the AN4 Banjo to the Vertical Cylinder Head using Special Titanium Banjo Bolt with larger flow holes and Drilled on the hex head:


Below, I am comparing the stock steel Ducati Banjo Bolt with the higher flow Titanium Banjo Bolt with Drilled Hex Head:

This is how I routed the hose from Vertical Cylinder Head to the TEE:



Next, I am test fitting the hose to the Horizontal Cylinder Head:


Measure where to cut the hose:


And to be continued...

 

[BMW Alpina]

Ok,... I had been busy digging my front yard, side yard, and back yard these past few weeks. I am upgrading the gas line, main water line, irrigation line, adding dedicated (direct from main panel) 30amp x 4 circuits for my home audio system, and also adding 4 more ground rods points (2 of them 24 feet deep and 2 x 14 feet deep), to make sure my house is properly grounded.
And I haven't finished yet... But I need to keep working on it, especially since the weather is getting colder, and the PVC pipe cement for main water line will not cured properly when the weather is too cold... so I haven't touch my bike at all.



However, I had done so much so I can still post it here. I compare the Motocorse Titanium Silencers vs. the 1198 Termignoni Silencers will I will utilized using adapter:


Then I realize, the Termignoni still have dB limiter on it, and I am removing it:




Now it's full free flow, straight through:

 

[BMW Alpina]

I also added some foam to prevent the longer side kick stand from marring the carbon fiber swing arm cover:

 

[BMW Alpina]

Then I am installing my throttle body along with the choke cable and the throttle cable. This turns out to be a long story because the Rizoma throttle gas is not 100% compatible so more modification needed... but for now, here is the throttle body, all bolts/nuts that can be upgraded to Titanium have been upgraded:




Adding rubber grease to the rubber intake manifolds:


By the way, this throttle body had been modified by Bruce Meyers to flow more smoothly with the rubber intake manifold, plus the limiter had been grinded to allow 100% throttle body opening:




I am routing the choke cable below. My bike will have dual choke function, one is the 998s choke cable, and second is the throttle housing on the grips came from the 748R which have button to hold the rpm higher during cold start, well, it's not really a choke... but you got the point:

 

[BMW Alpina]

Next, the ProTi Titanium bolt to hold the 2 piece design of the Jetprime CNC Billet injector holder arrived, so I installed it:




I then test fit to the installed throttle body to make sure all clearance is good:




And they do looks gorgeous, too bad they will be hidden inside the airbox:




Next, I test fit the Brand New 998 Gas Tank and the Carbon Fiber Airbox, again to make sure the Billet CNC JetPrime injector holder has the clearance:


Ah, my bike start more and more looking like a motorcycle :