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Post by Raizer on May 8, 2020 3:15:38 GMT -5
Finally got sent up the exhaust nut I'd been waiting on   Wasn't fully happy with the header section, cylinder has a 31mm port but the pipe was only 28mm id (less really with all the weld inside), the A100 header I've got is too big (36mm id from memory). So I guess the only way to do it is to start almost from scratch and do it properly right?
Started with and off-cut of 4140 round stock.
Turned down to size (33mm od, the nut had been opened up to suit already)
Not much flow though a solid piece of steel though
31mm id to suit the port in the cylinder
There was no way to tighten the nut up with anything but a pipe wrench, which wouldn't be too good for anything I finish it in, so after facing off the nut it got a bit of time in the mill
Should be easy enough to get hold of a little bit bigger C spanner
It does thread right on, just need to clean the schmoo out of the thread lol
Found a few 4 cylinder Honda bikes use the perfect size gasket ring on their primary pipes, so will order one soon.
Now to attempt getting the rest of the pipe to fit ha
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Post by Raizer on Jul 11, 2020 1:35:10 GMT -5
Way too long between updates, life kinda got in the way lol Anyway, finally got around to continuing on the A50 for a bit this arvo. Take one Stage6 Pro Rep  After 5 min with an angle grinder I had a rough kit-set  Used a bit of tape, a pencil and some cardboard to space it out from shit that it shouldn't really touch and found where it wants to fit  Bit of muff action  May yet replace the masking tape with something a bit more substantial, like a glob or 2 of no more nails or something ha.  Tight, but it clears!    Need to figure out filling that gap, haven't really got the gear to roll a cone to go in there, will give it a go though! Last resort is to see if the local sheetmetal place can make something up. Kickstart is going to be interesting, likely have to make one myself using ends from the OG Suzuki one and some steel bar  The kickstart in the pic is from a Honda Wave and the bit of a backwards sweep it has hits the foot peg after about 1/2 of a kick. |
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Post by Raizer on Jul 14, 2020 5:43:57 GMT -5
Made up a cone of sorts out of some 2" exhaust tube
Finally found a use for SAE sockets, first time using one since I brought my 1/2" drive set a few years ago haha
Had measured the gap at 60mm, so I cut it off at 60mm, then without thinking about it I cut maybe 15mm off the chambers entry so it was the same OD as the 2" pipe.
It was a bit tighter than planned here, but the real problem was at the front
So yeah I'd made the cone a bit short it seems, likely even before cutting the chamber. 
Tempted to heat it and put a bit of a ding in it to gain some clearance for the brake pedal pivot so the pipe can tuck in a little tighter to the bike.
That was yesterday, had thoughts of just cutting the big end of the piece I made and adding 30mm or so more tube, but instead I started again
95mm of tube this time, with 8 relief cuts rather than 4, just to get it closer to round Really wanting a TIG with variable amps! 
Added the internal stinger, 180mm long which is the same as the stock curved one that Stage6 used.
"A grinder and paint make me the welder I ain't" 
Length is spot on now
Going to take a little creative grinding or a tighter radius bend to get the angle right though
Leaving the muffler and mount bracket off until the rest of the pipe lines up.
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Post by aeroxbud on Jul 14, 2020 7:44:49 GMT -5
It's getting there. Not easy doing a custom pipe.
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Post by pitobread on Jul 14, 2020 11:26:29 GMT -5
I need to know why the key is bolted to the engine.
Also grind down that chrome really good outside, Welding/heating chrome is pretty bad for your health, lots of heavy metals that stay in your system.
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Post by Raizer on Jul 14, 2020 21:02:33 GMT -5
It's "The key to speed"  /It keeps the carb vent hoses in place ha Good point about the chrome, had been sandblasting it back before welding (kinda forgot with the stinger), but yeah should have been grinding it right back! |
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Post by tsimi on Jul 14, 2020 22:33:18 GMT -5
Sorry for the off topic question, but how is the Gyro doing? Still looking good and going strong?
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Post by Raizer on Jul 14, 2020 23:02:20 GMT -5
Sorry for the off topic question, but how is the Gyro doing? Still looking good and going strong? Still waiting for me to rebuild the oil pump with new seals, the leak has got to the point where it'll let enough 2t oil into the crankcase to hydra-lock it after only a couple days sitting.
Have got plans to get it back out of the shed and the CVT dialed in in spring, it's just too wet here right now for it.
Really want to get this A50 finished (again) and get my Mrs' A50 painted before spring too.
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Post by Raizer on Jul 15, 2020 3:03:56 GMT -5
Think I got it sussed tonight
Everything seems to clear well, maybe a little bit close to the swingarm, but it'll be fine...
This is a repro A50 kick lever:
Might be able to heat it and reshape it to clear, will see if I can fix the start of the internal spline in it before I bother though!
The Honda Wave one: 
More than enough clearance, but would need to reshape this bend:
And playing with muffler position
I'm heavily leaning towards up-swept, it'll have the curved tip cut off leaving a 1" straight exit.
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Post by aeroxbud on Jul 15, 2020 13:46:43 GMT -5
Good progress.
I like the up swept look. You might have to take the pipe off for removing the rear wheel though.
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Post by Raizer on Jul 18, 2020 2:04:55 GMT -5
Roughed out a bracket from cardboard and had it cut Would love a CNC plasma at home!! Double layer design, much like the Stage6 one, I spec'd 2mm plate but they cut it out of 3.2, still gave it a go I had it made with the legs left a bit long so I had some room to bend and trim to fit nicely, but the plate was just too thick so I didn't go any further than that.
Scrounged up some 2mm plate and started again, changed the shape of the mount a bit to make it a bit more compact etc Stage6 at the back, the thick one and the new one. Fair bit to trim off, but still good! And done! I like the up swept look. You might have to take the pipe off for removing the rear wheel though. Think I'm going to reuse the spring retainer, that way only the muffler has to come off.
Kickstarter is not as bad as I'd thought it'd be, this is the repro A50 kicker again
Only needs to be tweaked out 20-25mm to clear!
Tomorrow I will finish up the muffler mount and attempt the kickstarter and it'll be ready for paint/coating!! Might even attempt a proper first start too.
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Post by aeroxbud on Jul 18, 2020 7:00:28 GMT -5
The latest mounts do look better. 👍
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Post by Raizer on Jul 19, 2020 2:20:59 GMT -5
I'm happy with how thats come out!! Ready for paint/coating now! Used the TIG as a gas torch for bending 
Not too comfortable to get my foot on the peg, but it's just the way it has to be. Power > comfort!
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Post by Raizer on Jul 21, 2020 4:23:25 GMT -5
Cleaned up the kickstart by filling in a few spots with TIG filler then ground it back, swapped out the glass beads in my blast cabinet for some medium grit garnet, that worked real well to key the pipe and kicker. Quick coat of high temp paint finished it up
And old pair of pliers + a chopped up drill bit were repurposed into a pin wrench
Assembled the pipe, pics are a bit crap, we've changed to LED bulbs and my camera isn't loving it.
Ended up grabbing a 32x38x2 copper flat washer to use as the gasket, really needed 32x40 so I used a smear of maniseal to glue it into position on the flange, fingers crossed that it didn't move and that a non-crush washer actually seals!
Bolted the tank etc back on, finally looks like a bike again! Also noticed the other night that the kickstarter is meant to be on an angle backwards, gave it a go and while still not great, I can actually get my foot on the peg now lol
Long rides aren't going to be too comfy hahaha
Just need to fill the gearbox with oil, drain the petrol tank and mix up a couple liters of 2t for it to run on while the oil lines prime and it should be all go to fire up!
Will print off a degree wheel and chuck a timing light on to make sure I got it at least close, might even get a bit fancy and use a dial indicator to find true TDC while I'm at it.
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Post by aeroxbud on Jul 21, 2020 5:56:02 GMT -5
You've done a great job with this. We really need a video of how it sounds now, with the new pipe.
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