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Old 02-13-2011, 08:35 PM   #85
Tommy_J OP
won't drive a car
 
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Joined: Apr 2007
Location: So Cal
Oddometer: 338
Fitting the tubes for the aft cylinder was a slow process for a few reasons. There was no fudge factor, a couple of turns were crammed into a tight space, and there was no spare tubing if I screwed up. Worst of all, both tubes were curved at the intersection.

This tube barely misses the cam chain tensioner boss and goes too close to the brake line to leave unprotected. I wish I has an SE around to see how KTM dealt with this.

.

Same approach as before, the joints were taped in place as an initial test fit. When things looked good joint was tack welded.



Here a little persuasion is used to adjust the gap for the tack weld.



So far so good.



here is where it gets more challenging. A guess was taken as to the shape of the miter for the Y joint.



After about an hour of gradual trimming the joint looks good from the outside.

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