SR 125 exhaust build.. another BlueNinja project.

BlueNinja · Trackday Trickster Joined: 14 Dec 2004 Karma :

I am currently in the process of producing a new exhaust system for a Yamaha 125. Took me 4 hours to make the small manifold-downpipe section, as I have to cut and weld this from 8mm steel, and 2.5mm pipe.
The exhaust is from a car, and I gas welded a new outlet port onto it, which was also heat treated. The system will be straight through, so pretty loud.

So.. here are the pics!!

This is the old system, it was a bit rusty around the opening, and sounded like pees being shaken in a tin can.. Improvment needed I thought..

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/a9bfc57a.jpg

I decided I would make a completley new system.. this ment even producing the manifold, and down pipe, rather then welding a new can onto the old system.. work starts here:

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/d67383d1.jpg

The old manifold has a gasket which is pushed in by a lip on the pipe, and then a clamp holds the pipe and gasket tightley in. So I would have to get the correct sizes, or it would blow at this point.

Here is the pipe.. and a peice of steel to produce the manifold part from.
The pipe is from a car, and I Oxy welded the end pipe on, and lightley heat treated it to give it some colour.

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/89feef1b.jpg

I will have to get this peice of steel, into the shape of this old manifold.. doh..
https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/b736410f.jpg

So I scribed out what looked about right, and then got a grinder onto it.
https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/b9ba67e7.jpg

Not a bad shape.. after the shape was fine tuned with a file, I cut a strip of pipe out, the correct length to puch the gasket into the head correctly when tightened up.
https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/8aa2e409.jpg

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/90658a8a.jpg
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https://www.theundertaking.com/index.php?showtopic=483

BlueNinja · Trackday Trickster Joined: 14 Dec 2004 Karma :

Then welded the peice of pipe on, drilled out the manifold bolt holes, and began drilling/filling out the exhaust hole in the manifold block.

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/69712303.jpg

Next, welding the pipe off the manifold, into the down pipe
https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/birds030.jpg

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/birds021.jpg

Quickly bolted it onto the head to check.. it fitted..
https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/birds022.jpg

So far, so good.. now it gets tricky... I have to make a bend, without a pipe bender, so I did this by welding wedges together untill I had what looked to me like the rite angle.
So, I managed to cut and weld together this peice

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/birds023.jpg

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/birds024.jpg

Next pipe, the down pipe being fitted here: I alwas pup a little blob of weld on to hold it in place, put it on the bike, check it.. check it again, if its ok, fill the seam with weld. If not, pull it apart.
This fitted.. so it was welded together.
https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/birds025.jpg

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/birds026.jpg

Need to fix the next pipe on now, with a pipe wedge to get the correct angle
https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/birds031.jpg

I now have this:

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/birds032.jpg
____________________
Big Kawasaki ZXR 400 project here:
https://www.theundertaking.com/index.php?showtopic=483

Gazdaman · I did a trackday!!! Joined: 12 Aug 2004 Karma :

Impressive!

Gaz

BlueNinja · Trackday Trickster Joined: 14 Dec 2004 Karma :

Last pipe section to fit now.. this is a bit tricky, as I need to get the pipe to meet where the exhaust is.. so exuse the props (pliers) holding the pipe in place..

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/4c63594e.jpg

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/26296acf.jpg

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/2cdf78b9.jpg

Spot welded it there and then in that angle, took it off, and completed the weld seems..
A rather poor picture of me holding the finished object! (contraption of some sort)

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/53ed06f1.jpg

Finished!!

And wow does it sound good.. pops under engine breaking, roars under throttle, not bad going! the system is completley straight through.
Never heard a 125 as good as this :biggrin:
Please excuse my welding skills.. this is the second time I have ever welded metal together, and the first time I have ever build anyting with weld, not using any plans etc.. just judgment.

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/60d7dbda.jpg

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/e42ad167.jpg

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/d7d688e8.jpg

https://img.photobucket.com/albums/v228/raider2/SR%20exhaust/84102d62.jpg
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Big Kawasaki ZXR 400 project here:
https://www.theundertaking.com/index.php?showtopic=483

BlueNinja · Trackday Trickster Joined: 14 Dec 2004 Karma :

EDIT: double post, sorry..
____________________
Big Kawasaki ZXR 400 project here:
https://www.theundertaking.com/index.php?showtopic=483

mchaggis · World Chat Champion Joined: 10 May 2004 Karma :

Excellent stuff. Very Happy

It doesn't run lean or anything now does it though?
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BlueNinja · Trackday Trickster Joined: 14 Dec 2004 Karma :

Well.. it was popping a lot at the biggening (too rich) but now runs pretty smooth Smile

____________________
Big Kawasaki ZXR 400 project here:
https://www.theundertaking.com/index.php?showtopic=483

palmer · Fiddled Kiddy Joined: 21 Jul 2004 Karma :

any boost in performace?

BlueNinja · Trackday Trickster Joined: 14 Dec 2004 Karma :

Infact yes! low and top end improved.. middle range the same though.

The bike now reaches 65mph on a flat road, rather then just down a biiig hill. Pulls a lot harder at low speeds too. In the process of tweaking mixture settings.. but its running very well.
____________________
Big Kawasaki ZXR 400 project here:
https://www.theundertaking.com/index.php?showtopic=483

cagiva gezzer · World Chat Champion Joined: 17 Mar 2003 Karma :

Excelent, maybe the first bend could be smoother, but and excellent job overall.
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rizo9 · Nova Slayer Joined: 04 Jun 2004 Karma :

you could grind the wels down to give it some more shape and tidy it up a bit Very Happy

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New bike Very Happy

https://www.bikepics.com/members/rizo9/01rs125/

m i k e · Could Be A Chat Bot Joined: 17 Apr 2003 Karma :

Well done mate, just out of interest how old are you? And are you trainging to be some sort of engineer or something, cause you certainly know what your doing in the workshop! Smile

Mike
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Richard1987 · Scooby Slapper Joined: 19 Feb 2005 Karma :

you have done Very well weldingwise if its only your second time welding before? i am doing welding at college, part of my first diploma motor vehicle corse at college and it is quite tricky. once youve got the hang it is quite easy and you ALWAYS find something than needs welding Cool

numark1 · Scared of girls Joined: 10 May 2004 Karma :

I think the dudes 16. Fucking impressive. My dad has a welder and i tried it loads of times. So fucking hard because you can't see. Confused

Good job bing. Thumbs Up

BlueNinja · Trackday Trickster Joined: 14 Dec 2004 Karma :

17 as of May now.. and CBT booked for this saturday.. atlast things are on the way!

So, as said above, Im pretty keen on engineering, but my maths are too poor to move to another level, so I keep it as my hobby Smile

or build exhaust mounts for freinds at college. I am doing a motor vehicle + repair course at the moment, but im not liking the group im studying with much.

As somone sais above, that you cant see when welding, I know what you mean.. if you do it out in the sunshine you can see, but this is England and you dont have that often! Smile

So I grabbed a big lamp, and had it shining at my work.. then you can see it through the visor.

I know the bends should be smoother.. but Il need mre practice I geuss.. still, should have spent more time on it with the sander.

Hopefully il be able to buy a propper MIG welder once I have finished all my bike tests. Rolling Eyes

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Big Kawasaki ZXR 400 project here:
https://www.theundertaking.com/index.php?showtopic=483

Chr!S · Nitrous Nuisance Joined: 17 May 2005 Karma :

You need a pipe bender Thumbs Up

https://www.machinemart.co.uk/product.asp?p=020510900

BlueNinja · Trackday Trickster Joined: 14 Dec 2004 Karma :

Been meaning to buy one for a long time.. I think itle be MIG first, then pipe bender.. should be able to build all kinds of stuff then
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Big Kawasaki ZXR 400 project here:
https://www.theundertaking.com/index.php?showtopic=483

Chr!S · Nitrous Nuisance Joined: 17 May 2005 Karma :

Josh|RD125LC · World Chat Champion Joined: 08 Sep 2004 Karma :

Well done mate. I thought I was doing well by restoring my RD at 16, but you seem to be doing better than me thats great. Good work mate. Thumbs Up

Looks like you also have a nice large room where you work, whereas I'm stuck to work in a tiny shed. Just wish I had a double garage like my uncle. I would love that.
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