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Old November 16th, 2015, 07:36 PM   #41
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Coated the muffler bracket today in the same powder as the brake bracket -

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Old November 20th, 2015, 09:26 AM   #42
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Started on the wheels.

Before stripping -


After stripping -


Castings ain't that great, so there's a bunch of sanding and grinding to do before moving on to blasting.

Getting there, but still a lot to do -

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Old December 1st, 2015, 07:22 AM   #43
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Did the cast swingarm end-caps in a gold texture to add some detail -



Cagiva was here...
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Old December 1st, 2015, 12:52 PM   #44
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I've always liked that logo. So unique for a motor conveyance.
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Old December 1st, 2015, 01:15 PM   #45
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I've always liked that logo. So unique for a motor conveyance.
Odd isn't it - for a cycle company? Wonder what the origin is.

Evokes thoughts of...weight...and slow movement...

I've done a few older Ducati wheels that have the logo also. It's always only about .010" high, so not a good candidate for highlighting.
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Old December 7th, 2015, 12:59 PM   #46
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The all-silver Derbi logo on the plastic side cover was bugging me, so I painted the inside black and highlighted the logo -



You'll never see it with the fairing on, but still. Good to know it has a "World Champion System", whatever that is.

Also found another Ducati connection -

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Old December 9th, 2015, 02:30 PM   #47
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Old December 9th, 2015, 04:04 PM   #48
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Old December 10th, 2015, 10:42 AM   #49
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Quote:
Originally Posted by jkv45 View Post
Odd isn't it - for a cycle company? Wonder what the origin is.

Evokes thoughts of...weight...and slow movement...

I've done a few older Ducati wheels that have the logo also. It's always only about .010" high, so not a good candidate for highlighting.
In Europe, the elephant was often a symbol for strength and reliability.
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Old December 10th, 2015, 03:51 PM   #50
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Added some detail with a touch of red -

Before -



After -





I put both parts in a drill and spun them while sanding to get a brushed spiral look, then hit the washer part with Anodized Red powder and the bolt with clear powder. Both pieces are steel, so you couldn't actually anodize them. The red didn't photograph accurately, it's actually a bit deeper and has a duller finish.
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Old December 11th, 2015, 06:23 AM   #51
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^^^ I approve of this.
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Old December 17th, 2015, 12:43 PM   #52
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Wheels are blasted and ready for final cleaning and prepping -



Plan to get color on them yet this week (like tomorrow).
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Old December 17th, 2015, 03:11 PM   #53
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Bronze!!
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Old December 17th, 2015, 03:45 PM   #54
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Blue!
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Old December 17th, 2015, 07:57 PM   #55
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drat...
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Old December 18th, 2015, 07:29 AM   #56
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Bronze looks nice, but would be a bit too elegant on the Derbi.

It's got to be something brighter, and more playful, for this.

Eventually I would like the entire bike to be silver, and with the blue wheels and graphics I think it will scream fun! just sitting there.
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Old December 18th, 2015, 06:50 PM   #57
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Nice! For a while, YSR's would swap in a DERBI powerplant to make a Yerbi.

I've wanted a GPR ever since I saw one ride by in Pittsburgh in the mid 90's... Alas, they're a rare breed. And the YSRs, while cool too in a less refined way, are getting dated.

Too bad the NSR's aren't street legal...

I'd get in line to inquire if you ever sell, but I won't be able to afford it -- my Ninja 300 '14 is eating my spare cash.

But if you think motorcycles are expensive, get a horse. Might as well bale cash and feed it to the critters.

Nice work, man! Sub'd.

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Old December 18th, 2015, 07:45 PM   #58
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Thanks Ted.

No plans to sell the Derbi - or start collecting horses.
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Old December 21st, 2015, 08:31 PM   #59
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Finished the front today -



It's official - these are the worst wheels I've ever coated! - and I've done over 100 in the 3 years since I started my business. They also are one of the most difficult because of the super deep pockets cast in the wheels (on the other side of this one and both sides of the rear wheel).

Even after all that grinding and sanding I still only got about 80% of what I was looking for. After a couple hours of "color sanding" and buffing it's about 90%.

I'll be starting on the rear tomorrow. Probably about 2 hours of work to get the rear "done". If I was charging for these they would be really expensive.

EDIT: The actual blue is darker and more saturated than the photo, and looks better.

Last futzed with by jkv45; December 23rd, 2015 at 10:33 AM.
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Old January 1st, 2016, 08:25 PM   #60
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Here's the progression -












Tires go on next week, then the new bearings.
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Old January 3rd, 2016, 10:04 PM   #61
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Looks great
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Old January 4th, 2016, 04:36 AM   #62
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Old January 4th, 2016, 07:05 AM   #63
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Thanks guys.

I'm looking forward to getting things back together. After I get the tires on and bearing in I'm planning to pull the swingarm. It has some tabs on it that I'm not using that I'll trim off, and plan to coat it charcoal with a satin clear.

The upper triple is being milled to open up the pockets on the underside. It was just a big slab of cast aluminum, and looked like it came off a Harley. I'll need to do some finishing when it comes back from the machine shop, then it will get coated in the same charcoal texture as the exhaust and brake bracket.
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Old January 4th, 2016, 07:22 AM   #64
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Old January 4th, 2016, 07:37 AM   #65
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Out of curiosity, what are your costs for all the p/c work your doing with the bike? Obviously if someone wanted to replicate there would be alot of labor cost, but whats it been running you?
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Old January 4th, 2016, 08:12 AM   #66
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Originally Posted by sharky nrk View Post
Out of curiosity, what are your costs for all the p/c work your doing with the bike? Obviously if someone wanted to replicate there would be alot of labor cost, but whats it been running you?
Thousands! Just kidding, I own a powder coating business - www.apexcustomcoating.com.

The wheels would have been very expensive though. I spent at least 2 hours grinding/sanding before blasting and another 2 color sanding/buffing on each wheel.

Normally I would spend the equivalent of just over an hour and a half on each wheel that size (small) to strip, blast, prep, mask, and coat. That works out to roughly $110 each with materials. The misc parts and brackets would range from about $25 to $40, depending on detailing, assuming it was an in-stock powder.

Not cheap like some of the industrial/production shops that will fit-in your parts with their normal runs. Usually they won't do any prep (blasting, plugging holes, or any masking) which causes problems when you try to re-assemble the parts, and many times the parts are not fully cured because they use a conveyor that's set-up for thin parts like shelving. Some production shops also used "burn-off" ovens at around 800F to strip existing finishes. While that's fine on steel shelving, it completely erases the heat treating used on aluminum wheels to get adequate strength. I do a lot of race wheels, and never go into the temperature range where the strength of the wheel is affected.

I'm not in a hurry, and strive for superior detail, as well as the best durability possible. I like to think you get what you pay for.
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Old January 4th, 2016, 10:10 AM   #67
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Son of a...!!!

I was just in Madison two weeks ago and had some free time! If I'd remembered you were that close, I would have penciled in some time to swing by and chat/check out your place!!!!
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Old January 4th, 2016, 10:51 AM   #68
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Originally Posted by choneofakind View Post
Son of a...!!!

I was just in Madison two weeks ago and had some free time! If I'd remembered you were that close, I would have penciled in some time to swing by and chat/check out your place!!!!
Well that sucks. I'm not far from Madison - like a mile or two out west.

Look me up if you get back this way again.
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Old January 8th, 2016, 07:40 AM   #69
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Blacked-out the center section of the 1-piece rotor -



Working on the front now. A bit challenging (and time-consuming of course). Had to mount the rotor down and find the center, then use a compass to scribe a curve connecting the edges of the openings, then follow the line with a scalpel, after laying down some wide high heat tape. Repeat for the other side.

Just didn't look right without some sort of contrast. Need to find some interesting fasteners to replace the stock ones. Maybe yellow-zinc torx buttonheads if I can find them.

A "Before" shot of the front rotor -



Finished the front today -


Last futzed with by jkv45; January 11th, 2016 at 11:32 AM.
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Old January 8th, 2016, 10:22 AM   #70
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Secks appeal.
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Old January 15th, 2016, 02:47 PM   #71
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Got the tires mounted today -



Took a while to find the right fasteners for the rotors and sprocket, but I finally found something I like. Titanium taperhead torx bolts. Should be here next week. Probably order the bearings and a few other misc parts next week.

EDIT: I have to say if I were in the market for tires for a Pregen (16"), I would consider these Avon Viper Strykes. Not sure how they will wear, but they feel like a pretty soft compound. The best part is they were $129 delivered for the set from motorcycle-superstore.com.

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Old January 19th, 2016, 02:31 PM   #72
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Got the Titanium fasteners today -




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Old February 6th, 2016, 09:03 PM   #73
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Old February 12th, 2016, 10:44 AM   #74
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Added some "speed holes" to the rear sprocket, coated it matte black, and mounted it with the Ti fasteners -



Got the bearings in and found an oring for the fork cap to replace the one I chewed-up when I changed the fork oil.

Once I get the upper triple back from the machine shop I'll coat it wrinkle charcoal and put the front-end together. Then I plan to pull the swingarm, buzz-off the brackets I'm not using, and coat it a satin charcoal.
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Old February 12th, 2016, 04:47 PM   #75
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I freaking love this little build
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Old February 12th, 2016, 05:43 PM   #76
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Thanks dude! (you too Alex)

I can't wait to get it back together!
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Old April 19th, 2016, 08:06 PM   #77
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Got the triple clamp back from the machine shop and coated it in the charcoal wrinkle powder -



Then got the wheels back on -



Getting there...
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Old April 29th, 2016, 08:33 PM   #78
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Got it back together and rideable tonight -



Changed the position of the clip on the needle to lean the midrange. Pilot and main jet seem pretty good.

All good, except the starter quit working.
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Old April 29th, 2016, 09:01 PM   #79
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Sigh. I saw one of these on Craigslist in my area tonight. $2400...except, well...yeah.
I don't know what else to say. I wanna punch the owner in the throat.

http://portland.craigslist.org/grg/mcy/5559798429.html

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this 2004 derbi is in excellent condition having less than 200 miles total since
new.It has been lowered to a seat height of 28 inches, and stripped of its fairing.
It's a very small bike and it would be a great bike for someone wanting a small
bike. It has a 6 speed transmission and oil injection, The bike doesn't even has
it's break-in miles completed.
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Old April 30th, 2016, 05:51 AM   #80
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That makes no sense at all. Wonder what happened to the stock parts?

Why would you do that? $2400? Really?
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