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Discussion Starter · #1 ·
Hey guys, been awhile since I have been active on here. Thought I would share my recent project with everyone.

I originally intended to make a simple custom Monster out of it using the parts listed below. You will see that it quickly turns into a crazy project about half way through.

2002 Monster 620 project.
Monster 620 frame
Monster 620 Dark fuel tank
Monster 620 seat
Monster 620 swing arm
800ss Engine package
800ss wiring and ecu
800ss Gauge cluster
800ss forks
800ss wheels
800ss brakes


Should make for a pretty fun cruiser bike. I may go cafe style, or desmo chopper style.

Guy had it listed on CL for $1,500. Ended up picking it up for $1,000 including the original 800ss frame with a clean title, and of course the 620 with a clean title. A box of parts, brembo calipers, ect.



Bike would not run, but after doing some digging, it turns out that the 620 gas tank has a built in regulator, and the 800ss has a fuel pressure regulator on the throttle body assembly. After removing the regulator from the gas tank, switching around some of the wiring, and fuel line routing, it fired right up!



Already ordered the following parts:

Billet mono rearsets to get rid of the passenger pegs
Smoked led brakelight with integrated blinkers
Carbon fiber rear side panels
New seat cover
billet gas cap

Still deciding if I want to turbo the bike, or build a nice stainless exhaust for it. I may put the oem mufflers from my streetfighter on it. We will see.

Also still deciding on a headlight. I may put a streetfighter headlight on it, but will prob go with a cafe racer style one.
 

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Discussion Starter · #3 ·
I was going for an industrial/sporty front light mount. It is incredibly difficult to notch that kind of tubing precisely.
Still deciding if I like it.What do you think?




Also picked up a new set of rearsets. As you can see in the first pics that I posted, that the factory ones are HUGE. they have the exhaust mounts, and passenger peg mounts. These will get rid of







 

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Discussion Starter · #4 ·
Oh yea. Almost forgot about the Speedymoto billet upper triple clamp machined to 53mm to fit the SBK fork sizing.




Then I fabbed up a bracket to mount the new exhaust cans.
I decided on a stock set of newer monster cans. Since this bike will be my hwy9 beater I want it quiet so certain people cant hear me coming.



I decided to return the 999 forks that I hadn't installed, and ordered a set of 996 adjustable Showa forks. These feature a titanium nitride coating and I love the way they look!




They look even more badass mated to the SpeedyMoto.com Billet 53mm upper triple clamp!



 

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Discussion Starter · #5 ·
Ok. So after thinking about how the headlight bracket should look for a week or two I decided to change it to regular tubing. .75" 4130 Chromoly tubing.

I started off by making the new standoff mounts.






After I had the standoff mounts fabbed. I notched the first tube in the Mill. My tubing notcher doesn't hold 3/4" hole saws. But the milling machine works fine.



Here's the first side all welded together.



This project was actually harder than I had anticipated. I am used to doing crazy fab stuff everyday at my shop, but the hard part was getting this odd shaped headlight perfectly centered. I actually had to make 3 different mounts to hold the light in the correct position before I could make the final mounts. Took about 3 hours to get to this point.

Here are both mounts welded and bead blasted.









I like the look, and it keeps with the lines of the frame.
I will send it out to get powder coated when I tear the bike down for paint.
 

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Discussion Starter · #6 ·
So the more I looked at the bike the more it started to look like a hacked up monster. I decided to scrap most of the current work and create something truly awesome.

I ditched the Monster tank and seat.
Decided to replace them with a 999 tank and a cafe style tail section.




One of my biggest peeves was the stock swingarm. I really liked the 696 monster swingarm and decided to purchase one. Found it for about $200 on ebay with the shock, chain adjusters, brake line, bolts. To my surprise it went on without any modifications, and will only req spacers for the wheel and swingarm pivot to work properly. The shock however required me to chop up the frame quite a bit.





Even the 800ss caliper bracket worked with some minor machining.



 

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Discussion Starter · #7 ·
I started work on the turbo system tonight.


Garrett T25 Turbo



Since the factory Ducati exhaust uses a compression style connection for a proper seal, I decided that the tolerances were a little loose since there would now be a considerable amount of back pressure from the turbo. I decided to fabricate my own sealing tubes that had a low clearance fit. Once the engine heats up the thermal expansion of the 304 stainless will create a proper seal. I started with some T-304 sch 40 stainless steel pipe, and machined it down until the proper fit was reached. I then tig welded a bead at the desired position, and then machined that into the ledge that you see in the lower pic. The factory flange will put pressure on that ledge, and it will keep constant force on the sleeve that is in the cylinder head.











Started fabricating the Turbo manifold today.



Sensitive content, not recommended for those under 18 Show Content




 

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Looking good when you starting the turbo end of it?
 

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Discussion Starter · #11 ·
Here is the machining process for the front cylinder connector.

Turned out of T304 stainless with a lip on the middle. The lip will act as a compression point to act as a seal for the factory cast iron exhaust flange. The left side of the stainless sleeve is inserted into the head and features a 37.5 degree taper to then also act as a compression seal.










My GF want's to ride it!



I do also! Did I mention how tiny this thing is? It's like a toy.



Finished up the turbo manifold.



















 

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Discussion Starter · #13 ·
Started working on the frame finally.


I removed it from the engine and prepared to remove what was left of the tubes that had been cut off. It was also an opportune time to remove the unneeded brackets.



An interesting thing is that the tube that holds the rearset wasn't completely welded from the factory. I decided to tig weld those first.





A few hours of careful grinding and sanding later.



After cleaning all the grinding dust out of my mouth and hair I reunited the frame with the rest of the bike.



Now the fun can begin! Adding new tubing.






More coming soon!
 

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