Exhaust build for Peugeot ludix lc Stage6 Sport Pro 70cc MK2

[robwelding]

First pictures of the custom exhaust im going to build for my Peugeot Ludix Blaster.

Ive got 15 years exp in welding, 10 with Tig and stainless, and about 5 years with purging gas and thin walled tubes.
Ive bought my own TIG a few years ago, bandsaw, etc. and just added a smal plate bending machine for this project.
Ive also found a lot of freeware programs for pipe desing, and forked out 37€ for the Tuned Pipe program from build and click.
Ill be building this exhaust especcialy for the Stage 6 Sport Pro MK2.
Target is between 10 and 15HP (i wish) and RPM at 13K.
The exhaust wil be welded with Tig and material wil be stainless steel 304 and/or 316L. Ive finshed the flange, found tubes for the header/quick connect system. 
Ill be overhauling the engine next few days, placing new bearings C4, new doppler race crankshaft, and then using the degree wheel to get the timings of the ports. Ill also make a portmap, probably tomorrow.
Engine with airsal bbk, as it is under my scoot now. picure from a year ago, my first build.

The flange is desinged with paper, pencil, callipers and a circle drawer.
Then redrawn it in Draftworks from solidworks, ive sent out the desing to a couple of lazercompanies and awaiting prices.











grtzRob

[spaz12]

very nice

[ryan_ott]

WELCOME!

Can't wait to see the finished product. I'd like to know where you end up getting the flanges from. They are so time consuming to fab for such a small part. The gy6 exhaust flanges are a close match and are inexpensive online.

[niz76]

WELCOME!!

Yessir awesome project! Keep the updates coming!

[190mech]

Welcome to the madness!I like this pipe calculator;
www.underdogsracing.com/fospipe/
Its based on Frits Overmars work with some additions,,Bought a few versions of Build and Click,didnt jive with other programs,so I gave them up..Ideal material for pipe work is the cold rolled 20 gauge(.8mm),you can try other materials,but the old school stuff is hard to beat..We've got a some pipe stuff in the tech section here;
49ccscoot.proboards.com/thread/10395/stroke-pipe-building-information?page=1
Please keep us posted on your build!!
Regards, John

[robwelding]

Some more image, the port map and cylinderhead and inside.
The blok is also opend up, ready for new bearings and the crackshaft.
Trying to get rid of the oxidation with an acid solution, but didnt have nitric acid like before, so dont know what it'l give this time...

[robwelding]

goodies

[ryan_ott]

That slip roll will make rolling the cones nice. They come out so much smoother then trying to do it by hand.

[robwelding]

more goodies, brake cleaner gotta have it, sandpaper rols for the dremel, bolts nuts and spacers, scotchbride, gasket sealant, gasket kit, M6 thread cutter, microclick torque wrench. Assembly time it seems
C4 bearings are installed, crancshaft is wrapped in plastic baggie in freezer...





Fucked up a blok, fixed other one, sandblasted it softly





Also got a price quote for the flanges 10 pieces lazercut + shipping, 5 mm thick stainless steel 316L, with shipping would come to 8€ or 10$ more or less a piece, so those wil be orderd once I have run multiple programs on the final desing, the exhaust header diameter is the only dimension i need to be sure about before I have them made.

[robwelding]

Placed crankshaft, transmission, and intake valve and manifold today, isnt she looking good :DD

[PIG]

Did you do any trench work to the cases?

[robwelding]

I wanted to, but didnt realy find spots that needed to be shaved down, I did do the intake manifold, took some casting lines out and made the corner in the inside bend bigger/smoother.

Installed piston and cylinder, made the degree wheel, just made stopper plate and I now have TDC dailed in.
Time to get port timings...

[robwelding]

First simulaltion , build and click pipe pro 5

Second calculation with program provided by Roost

3rd calculation Fospipe


I would like thoughts on these desings

[190mech]

My thoughts,
Build and Click,,59.4 belly diameter??What a joke!!
Exhaust Calculator 2.0b,,works OK,must plug in the right numbers though,lots of variables..
The underdogsracing calculator is up to date!If you select in Diffuser Type"3 stage experimental" and in the Horn Coefficient 1.50 or less,that should give you a good pipe to build,,
Remember to always check these, header should be 30-32%,header and diffuser is 64-68%,header,diffuser,and to belly end 76.4% of pipe total length(no tail pipe)..
Hope this helps,,
Cheers, John

[robwelding]

Made a draftsight drawing of the pipe im going to build. Now have to make the cuts to make the bends.