Operation Freeflow.

[warped one]

Well as a few of you may remember, i've been putting up a few threads of the past few months about making my own can. And how to pack it.

Well have made a few bits and pieces then put them away to stop them from been scratched, and the bloody tea boy keeps throwing them away, so made another start today and here goes.

Picture 1:

This is one of the 2 face plates on the can, it is made from 4mm stainless steel, with a 56mm internal diametre tube welded in the middle, this is so when I come to fit it, as the bike is still been used I can mark the holes and drill and tap them.

Picture 2:

This one is showing the holes in the face plates and compairing them before and after they were cleaned up using a wiffler, ( sort of like a rotaing file) as the hole's were burnt out using a plasma cutter, the reason for cleaning them up was to ensure a smooth as possible transition between the pipes and can. The left is clean and the right is unclean.

Picture 3:

This is of the cage, to seperate the packing meterial, from the gases, to improve flow and deaden a bit of the noise. It is made from 2mm woven stainless steel mesh, that was firstly bent around the same size pipe as on the face plates, and stitched using 1mm stainless steel wire, all in all this took me about 2 hours to complete as each stitch was done around 5 times before I got the required tension in them.

Picture 4:

This is what you would see if you were to look down the finished article. (Need to clean that plate a bit better )

More will be done tomorrow, with the rather weak attempt at rolling a tube, before looking for one. Doh.

Also had the idea of getting a old back box off a car and chopping that to use the packing, would this work?

Piccy time.

Cheers

Warped
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amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.

[CHR15]

that wiffler thing does a very good job, for packing youd be better buying new stuff, from a shop or ebay.
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Gazdaman]

Meh just use some wire wool for packing, or scotchbright or something.

Got the makings of a decent little job this!

Gaz

[warped one]

Well i'm hopin it is, the way the pipe has been designed is so with a bit of fine tuning it can be converted into and under fairing one. But that's at a later date, or could just make another. Trying to dig up my cad drawing for a better picture of things.

Cheers

Warped
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amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.

[warped one]

Got talking to my workshop manager today, and asked if I could use this as part of my college, he said yes so now i'm laughing.

Picture 1: Pipe in saw

This is the pipe that will be the body in the saw, it has a good thick wall approx 3mm and a inside diametre of approx 135mm, even with these rather thick diamensions, the pipe is still rather light.

Picture 2: About to square off.

Just one for college, and for other people wanting to have a go, if you get a rough piece like I did, just chop about 5mm off the end before cutting your piece, this will make the pipe square so long as the saw is square.

Picture 3:

This is plainly the just cut pipe, it measures 254mm long, as 3mm was taken off each side for the end caps. To make a total length of 250mm.

Picture 4:

This is the old pipe which I rolled next to the cut pipe.

Picture 5:

This is the old pipe, if you look closely at the top it has a peak, which happend during welding. So hence the reason for using the pipe.

Picture 6:

This is a test fit of one of the end caps, if you look closely at the edge of the pipe you can see a step between the pipe and the cap, this is for maximum weld to be holding the cap on and the ppe together.

Picture 7:

This is the 1st run that was laid down on the piece, it was run in with minimal rod, and high amps somewhere around 110 with no weave, this was to literaly burn the pieces together and gic a bit of penitraton, 1mm rod was used where needed.

Picture 8:

After the root was laid down, I cleaned of the oxidization and then laid in the fill and finally the cap.

Picture 9:

Quick picture of what I used to clean off the welds, it's like a scowering pad but on a grinder, give super smooth finishes, but remeoves the grain.

Picture 10:

1st cap finished and cleaned, just needs the grain on it and it wil be complete.

Picture 11:

Same as pic 10, but from the side, can see more clearly where the grain has been removed. by the 3m.

Piccys.

Cheers

Warped
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amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.

[warped one]

Missed of picture 11
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amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.

[Gazdaman]

Good work! I like it!

Now to polish it to buggery, give it a blue flame effect with an oxy acetalene and fit it!

What bike's it going on?

Gaz

[warped one]

Didn't think about the blue flame thing, but good idea, and it will be polished to feck, just got to pack it and the weld the other end on, and design a tail piece. I was thinking of something rather different for that. But it will be revealed with the finished can.

The bike it is off on is a Hyosung GT650r.

Another picture, but to show where the new can will finish.

Cheers

Warped
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amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.

[SoND]

4mm , that's a heavy duty can. Have you got it on the bike yet? Have you any pictures of your wiffler or know where I could get my hands on one?

I like the mesh idea. I'm sure stitching it in was fun.

Did you try hammering out the arch in the one you rolled? Did you stop and cool it every so often or weld it all in one go? Not far off. Good job.

https://www.bikechatforums.com/download.php?id=64755
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Go back to bed - You have no rights - "Streetfighters ~ Mainstream motorcycling's crackwhore sister."

[Welshd1k]

dare i asky why ??

just as cheap to buy a cheapo quill / micron thats been binned and stubby it. probaly be lighter and sound better and 1000000% less hassle

AND SS are you trying to weigh the bike down ? that should be ally .....


just seems a pointless excercise 4mm steel exhaust ..... whats that 2x teh weight of the standard?


nice work etc just seems very pointless
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Current >Cb600fx hornet, ns125rk90 21.7bhp@wheel<
Sold >,zxr400 h2 (33bhp kit) rd350 n1 rd350 lc2<

[BanditsHigh]

^^^ How's it pointless ... I take it you've never had the satisfaction of making your own bits ... anybody can buy something off the shelf!!

Sounds like the can will be MEGA strong ... 4mm end plates and 2mm tubing

Can I ask why you are welding the whole thing together ... what happens if you want to replace the packing at some point?

Started making my own cans a few years back, but I used ally for the end plates/tube.

Inner tube had two circular plates welded onto either end, with three nuts welded on each plate, packing was then wrapped round tube between two end plates.

Next I had two loose outer plates were grooved to sit into the ends of the exhaust body ... inner tube/packing was then placed into exhaust body and three bolts each end then pulled the loose plates in towards the inner tube plates ... result was the entire exhaust was bolted together and could be undone to redo packing.

Nice to see someone making something though instead of just buying off the shelf

[warped one]

Sond - If you get the bits for them then you can put them in a drill on high speed, they are known as rotary files/rasps.

Also the reasons for the 4mm is that even though the bikes have the same hole size as kwaka 636, they produce more heat and preassure and have been known to actually blow up cheap thin cans.

The reason for welding it all together is abit of neatness and making it just generally tidier. With the added fact that I can just lob it and make a new one for free. Not really any point making it changeable is there.

ns125rk90 - If you do the math, yes the outter case is going to wiegh as much as the full on, but the original can has all the packing that mine has but also has a full CAT in the lower half of the pipe. So not really pointless is it? And this is not actually been made for saving wieght, it is more of a thing that I can.

Ok just thought i'd give a bit of a update, got the packing in, deceded to go across the road and get a old back box to pack it, and I must say amazingly there is less packing in a transit back box than in my new exhaust, 8O8O8O. But not really got it fininshed even though it is really about 5minutes off that because all I need to do is weld the other end cap on and then make a tail pipe. But as said i've been busy with other stuff such as a full system exhaust for a EVO X rally race car, and a quad can system for some chavvy car, but suppose it's pay.

Also give me some ideas for a tail pipe, I want something a little different, like if you imagine a crown then extend the points and bend them into the middle and tack them there.

But fire away the more extrovert the better.

Cheers

Warped
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amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.

[Welshd1k]

ok just seemed liek a pointless exercise. and yes bla bla peopel can buy of the shelf bla bla.


but why waste time and money making a far less superior item.


and yes i am for custom pipes etc my dads t595 has a custom setup all hand made. but why do i liek it?? because it has a purpose not just 'because i can ' the custome pipe is lighter / louder and increas preformace,

i guess one way to look at it your brining the weight lower downt he bike ...
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Current >Cb600fx hornet, ns125rk90 21.7bhp@wheel<
Sold >,zxr400 h2 (33bhp kit) rd350 n1 rd350 lc2<

[warped one]

Again not wasting money, as everything is all free

Cheers

Warped
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amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.

[Welshd1k]

just wasting tuime then ? or is it a school project etc?

aslot he whole homemade pipes. not fo the shelf bla bla a few post up . you do realise all the ££ thats spent on R&D ont he pipe for preformance etc ? and you just look at a bit of pipe and rivit it together etc. and just hope for the best . im sure alot more peopel would rather strap on a tried and proven method of power increase? . some cans just decrease power / upset mixtures
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Current >Cb600fx hornet, ns125rk90 21.7bhp@wheel<
Sold >,zxr400 h2 (33bhp kit) rd350 n1 rd350 lc2<

[chris-red]

[Welshd1k]

[Fawbish]

[chris-red]

The 595's only made about 100 standard most modern 6's are what 120/125?
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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[Fawbish]

Hmm, I was working off me dads 955i, makes about 105 at the back wheel I think. Was assuming a little tuning could get that to 110.

And then assuming a modern 600 would make around 100. Youre right though, they probs make 110-ish at the back wheel.


So I retract my statement and replace it with "Modding a 595 so it makes the same or still less power than a modern 600 is pointless."

Talk about insult to injury



True Rear Horsepower Figures

^ Thats a pretty interesting read actually, and theres a table at the bottom with a loada "true" figures.
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"Oh....it looks like Average Joe's is forfeiting the match!" - "Yeah, its a risky strategy but lets see if it pays off for 'em Cotton."

[chris-red]

I think we can both agree we and right and have superior machines


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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[Welshd1k]

rofl . yeah makes more bhp but far less torque ....
its got 122 @ the wheel and 71lb/ft with a power comander / k&n and a nice exhaust which is a boost fromt he 103bhp stanard


and yeah its pointless the same pointless as putting any endcan on a bike for the 2-3 bhp gain :O



and im pretty sure a modern 6 wouldnt keep up with the t595 in a straight line ....

https://i40.tinypic.com/e8ofag.jpg
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Current >Cb600fx hornet, ns125rk90 21.7bhp@wheel<
Sold >,zxr400 h2 (33bhp kit) rd350 n1 rd350 lc2<

[warped one]

Again yes it my seem pointless, but ultimately not.

I am currently on a 4day week, with jobs coming in, in dips a drabs with no real long term stuff, so when we don't have anything going, I whip this out my cupboard and look as if i'm doing something whilst my boss is watching me, and i'm already on his hit list for the lay off crew so got to look busy.

Also with the diamensions and tube size it will actually give about 2 extra bp, and with the abligatory noise and flames out the back.

Cheers

Warped
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amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.

[Welshd1k]

[warped one]

Yer, I do see you, point it would have been easier and taken much less time if I had done what you said and bought a damaged on and then stubbied it.

My reason is making me look busy at work, and it is also ben used as a college project towards my level 3, because I have all the CAD drawings and even a liminar chart for it, showing the difference it will make over the flow of the old can. This was done by having it all tested at college with the old can on, and then built a model in the software and then built mine, it does bloody work, worther wierd but does.

Cheers

Warped
____________________
amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.