Hybrid 899 Track-only Build

Well, I suppose I should go ahead and start this thread now while I've got some down-time.

I've been poking around the forums for quite some time, and finally now I can hopefully add some value.

So, as far as my background, I am an Aerospace Engineer with 17 years in the field of aircraft maintenance/manufacturing and design and development of missile & various weaponry components. I've owned a wide array of bikes ever since I was 15, and purchased my 899 brand spankin' new in 2014. I've been slowly upgrading it since then and have had it to the track multiple times.

So, now I'm building a track only dedicated Panigale.

Having my 899 on the track I know it is amazingly agile, I just wish it had a little more "grunt" to keep up with the liter bikes on the straights. So, I acquired a used 1199 S engine, and am building a very budget-minded hybrid 899/1199 track bike from scratch. I'm keeping my street 899 the way it is.... Just too beautiful to tear apart.

Now, I did think I was unique in this idea, until reaching out to Jarel at Ducati Omaha and I found out he did this exact hybrid setup only with an 1199 R engine and a bad a$$ Magnetti electronics setup. His lessons learned are going to be a huge help along the way. (Thanks Jarel)

So, stay tuned, I have been picking up parts all winter to start building it up. I plan to use this thread to track progress, report any crazy issues to all of you, and also to hopefully add some value to this forum. I've taken so much knowledge from a lot of people here, it's time to give back.

So, goals for the build:
- Stay below $15,000 (I'll be tracking expenses here too)
- Nimble 899 chassis with stock (for now) 1199 S engine
- Keep weight at a minimum without the use of exotic (a.k.a. high $$) items
- First year of track duty will be to tweak & tune suspension, next winter engine will be torn down and built with cams/rods/head work, etc. etc.

Stay Tuned!!!

Quick second post;

I want to build a parts list here, showing what's needed as well as tracking cost: NOTE - These are in no particular order, just as they are coming to my mind

1. 1199 S Engine - $1500
2. 899/959 swingarm - $180
3. 899/959 Main Frame - NEEDED
4. 1199 Subframe (lighter than 899/959) - $75
5. Marchesini Genesi Wheels - $1900
6. Triple Tree - $75
7. Forks - $220 (stock 899 Showa, intend to install Ohlins cartridges)
8. Rear Shock/spring - $500 + $400 electronic to manual conversion Ohlins TTX
9. Wiring Harness - $80
10. ECU & Black Box - $140
11. Tuning - $$$ Unkown, BrenTuning will be doing Tune
12. Dash - $213 1199 dash
13. Ignition module - $400
14. Front & Rear Rotors - NEEDED
15. Front & Rear Calipers - $320
16. Brake Lines -
17. Clutch Master & Slave Cylinder - $270
18. Front Brake Master Cylinder - NEEDED
19. Rear Brake Master Cylinder - $80
20. Clipons - Woodcraft, $190
21. Throttle Assy - $175
22. Switches - $420
23. Rearsets - NEEDED
24. Gas Tank - $200
25. Fairings - NEEDED
26. Seat - Free (ordered a comfort seat for the street 899, used the factory seat from that bike)
27. Front Fairing stay / ram air tubes - $200
28. Front & Rear sprockets - $99
29. Tires - $380
30. Radiators - $240
31. Radiator Support -
32. Exhaust - NEEDED (would like a used Termi race exhaust if anyone has a system just laying around)

I know there's a TON more but that's what immediately comes to mind. So Far Total Cost $8,257 as of 1/10/18

Oh and another note,... I know there'll be someone who suggests it would be cheaper to buy a used bike, and go from there.... To each their own... I want to build it from scratch. The purpose of this thread is to learn and educate, let's not turn it into something else please.

JarHead said:

Oh and another note,... I know there'll be someone who suggests it would be cheaper to buy a used bike, and go from there.... To each their own... I want to build it from scratch. The purpose of this thread is to learn and educate, let's not turn it into something else please.

Click to expand...

Buy a wreaked 1199 then you can swap over the parts, plus have spares and access to those little misc items than you may need.

I think you're on the right track, and actually having a little less power than I had with the 1199R engine will probably be a good thing to keep it more balanced and make it easier to ride. Can't wait to see how yours turns out!

jarelj said:

I think you're on the right track, and actually having a little less power than I had with the 1199R engine will probably be a good thing to keep it more balanced and make it easier to ride. Can't wait to see how yours turns out!

Click to expand...

Thanks man. I'm planning to start posting photos up soon. First thing first is showing lengthening of the swingarm axle slots. And then photos of the stuff I've accomplished so far.

I'm hoping to have it running by mid-February. Then have it up to Chris at BrenTuning at the beginning of March. We'll see if that plans holds up. Work is crazy busy this time of year.

Here is what I am starting with.

First photo is the project, second one is my current street 899 with my daughter twisting the throttle. lol

PROGRESS FINALLY

So I spent most of the afternoon removing the older ball bearing style bearing races from the frame and steering stem. What a pain in the .... Installed the newer updated needle bearing steering stem bearings. Didn't have any special tools to do it, so I fabricated some in my shop.

Anyway, I got the frame mounted to the engine, and temporarily set the front forks on. This enabled me to get the bike off the table, and onto a couple of stands.



So, all the suspension and electronics are 899. The engine is 1199, and the frame is off a 2016 959....coincidently the frame only has 899 miles on it. Lol

I did run into a jam. I took the right side engine cover off, to get a look at everything and make sure the engine was in decent shape. Good thing I did. There is a bolt missing from the oil pump..... looks like the oil pan is coming off tomorrow. I will let you all know what I find.



I also figured out the hard way that the 1199 and 899 tanks are different. I will be fabricating a rear tank mount to adapt the 899 tank to the 1199 rear subframe.



Also got this in the mail the other day.




-Matt-

going to be great!

There's DIY, and then there's DIY.


Subscribed with earnest!

JarHead said:

I also figured out the hard way that the 1199 and 899 tanks are different. I will be fabricating a rear tank mount to adapt the 899 tank to the 1199 rear subframe.

Click to expand...

Not sure if it will work with a stock subframe, but with the Motoholders subframe all you have to do is flip the stock bracket upside down and get some longer bolts for it.

P.S. - Nice to see you're making progress!

How will the 1199 engine go with the 899 single injector setup???

DStyleNZL said:

How will the 1199 engine go with the 899 single injector setup???

Click to expand...

Only the 1199R has dual injectors

Well, dropped the oil pan.... no bolt.



The bolt you see here is the one I put in before putting the cover back on. Still kind of worried as to where the bolt went....






I am SSSOOOOOO happy I decided to put new clutch plates in. Can anyone guess what's the old plate and the new? Talk about riding the clutch....





Also started hooking up the wiring harness today. Talk about a nightmare. I wouldn't wish this upon my worst enemy.....





Also, I'm tired of constantly bleeding my 899 clutch. So I installed this today too.....

Also gotta thank @Phl for this titanium oil drain plug that is also drilled for safety wire!!! Thanks man!!!

Another good update:

Here is what it looks like at the end of the day today:



What's changed? First off, I've got my woodcraft clipons and bars on, all controls except the front brake master cylinder setup.



I managed to mount the front and rear brake calipers and also route all the wiring to each electrical panel.

So now really, I'm waiting on wheels, fairings, brake rotors brake lines and radiator hoses. I will be mounting some of the exhaust this weekend to get the O2 sensors wired up. The I will mount the cans when I get the drip pan installed.

Let me know what you guys think. I hope to have it fired up soon, and then up to BrenTuning to get it properly tuned.

Oh.... I've got some amazing parts on the way. I know I originally said this was a budget build ...... but I got kind of carried away.

I managed to get a hold of a set Gold Marchesini Genesi 7-spoke aluminum wheels, and a full Carbon Fiber set of race fairings. I will be posting up photos as everything comes in and as I get things installed.

Forgot to mention, I'm trying one of these filters... anyone have any experience with these? Seems like a well designed and built product.

These showed up today: Gold Marchesini M7RS Genesi's

I'll weigh them later today and post up weights.

Marchesini M7RS Genesi wheel weight

These weights are with bearings and valve stems installed as well as the rear brake rotor hub.

Front: 7.05lb (OEM - 9.2lbs)
Rear: 10.90lb (OEM - 17lbs)

1 lbs more each one than the oz cattiva.