Mixed day...

Today I switched gears between two different projects.

The first was to find a suitable battery for the bike. The original Ducati's had a 6V system. A popular modification for these bikes was to resolder the leads from the alternator to make a 12V system. Luckily, the original builder of this bike already completed this task.

Now I was left to find a 12V battery. Since no one would list a 12V 67 Duc, I based the decision on physical dimensions. I spent some time on the Yuasa website searching their catalogue for suitable batteries. I acknowledge there are cheaper options out there, but in my experience, Yuasa batteries are worth the price. Especially considering the low output of this alternator and the demand that will be placed on it.

After comparing all the numbers, I decided to go with the cheapest, highest output, lightest and cheapest battery they offer. I am using the type for a 2001 GSX-R600. With the popularity of this bike, finding a battery will not be a challenge.

The next problem was making a holder for it. The battery platform already welded into the frame was measured earlier to see what the largest size was that would fit. Now I needed to make a cup to hold the new GSX-R battery.

For this, I turned to simple fiberglass. I already had all the materials on hand, so I dove right in. First I used scrap Styrofoam to form a plug the size of the battery. 90mm x 150mm.

Next I trimmed the fiberglass fabric to approximate size. I mixed the resin and started laying sheets.

Below is the result prior to trimming and finishing.

For finishing I will cut away the excess, sand everything to smooth, drill the two mounting holes and paint it all black. A rubber strap will be used over the top of the battery to retain it in the holes. A couple rubber strips will be placed between the platform and cup to dampen some of the vibrations.

Next I moved on to some painting. As much as I would like to use a Colorrite or Sherwin-Williams system, which I have experience with, the new budget simply does not allow it. A comparison would be $350 to $75. Also considering the small amount of actual painting on this bike, I opted for the more economical route. I am just proceeding more slowly and carefully and if at any time the Dupli-Color looks questionable to me, I am saving for the better paint.

Below is a sample color dip to see what I was dealing with. The same sticks were primed before the color coat was added. Note, clear coat was not applied, so that will add the gloss.

The red is darker than appears in this picture. It is not as deep as Ducati Red, but close enough. From here I moved onto surface sanding a priming. It will be a couple weeks before I can actually add the color, but I felt the itch to get some work done tonight.

Here are the pieces that will be painted, minus the battery holder.