DR 650 project: It's now a Beast!

[Roadracer_Al]

When you get the converters out of the mufflers, take them down to your local metals recycling place -- They contain platinum. Converters have been "the new copper" for meth addicts to steal and sell to recycling places.

The other bonus to independent twin pipes is that they're a shitload easier to package.

Regarding the geometry, you're right to be concerned about keeping the steering head on straight, it's important. Specifically, keeping the steering head axis perpendicular to the axles and swing arm pivot.

Get one of these: http://www.wixey.com/anglegauge/index.html

They're accurate to one tenth of one degree, which is plenty accurate for MC chassis work.

Before you cut, measure the rake & write it down somewhere. Do your cutting. Then, to get everything lined up proper, make your swing arm pivot level, and when you go to reattach the steering head, make it plumb, and rake it to match where it was before. Use lots of little tacks, check it for plumb after each tack, then weld in short stitches on opposite sides to keep things from twisting..

[DRjoe]

that little digital angle gauge is cool.

I have always found the dr to be very slow to turn so i have already raked it in a bit (loads of flex in that top spine)
Dont ask me how much because it was a complete guess I just looked at the frame and changed the head stem angle buy flexing the top spine untill i thought it looked ok. I was a bit scared of the steering stem moving off square from the swing arm but i thought if i fuck it i'll just fix it.

It probably a big no no in the world of motorbike building but i'm not one for sticking to how other people do things.

my new headers are coming along nicely.

[DRjoe]

I've accomplished a bit more work today.

start of the new headers


it took along time to get them matched


I used the tig to weld them this time which left a much neater finish.


The next few pictures show how i made the curves that i didn't have out of straight pipe

first off i used the vice as a highly technical marking device so that i kept the curves the same on both sides


My blade was getting a bit blunt.


Next I used the grinder to surface the pieces so that they would weld easily.


welding


It's a hard way to make a bend but if you dont have a mandrel bender handy it's the only way

[DRjoe]

one header done







Overall I'm happy with how it turned out but the angle of the pipe as it comes from the exhaust port is a bit to steep and the bend round the down tube is quite tight but there no way else to do it that i could think of.

[mcfear]

shit mate, thats dedication.

good work, will have to come up and see the beast once its done

[Gustavo.Ramos]

Originally Posted by DRjoe

one header done







Overall I'm happy with how it turned out but the angle of the pipe as it comes from the exhaust port is a bit to steep and the bend round the down tube is quite tight but there no way else to do it that i could think of.

Looking very nice! Its there any way to smooth those welds on the inner area of the pipes?

Don't know if i had the patience to do so many welds... but then again...

Keep up!

[Wolfdog]

Awsome effort mate !!! its starting to look like a factory works bike with the multi section pipe.

Well done, you deserve a big drink

[mtb_man]

Great work on the headers Joe, looks like a tidy solution.

And respect to you for not taking the easy way out when the DR engine went bang, I'm looking forward to see how this build turns out.

[NordieBoy]

Originally Posted by DRjoe

Overall I'm happy with how it turned out but the angle of the pipe as it comes from the exhaust port is a bit to steep and the bend round the down tube is quite tight but there no way else to do it that i could think of.

That's a nice finished pipe there.

You going to ruin it by putting a muffler on it?

[tileman]

+1

inspired............!!!!!!!!!!!!!!

[Travmoto]

Thanks DRJoe! My Gf is cranky as at me, I've just spent the last few hours just sitting here reading this from start to finish, and now I'm sad its finished for the time being. Now I know how those devotees to Avartar (the movie) felt when it finished and the had to go back to reality lol.

And those headers are the horn mate! Nothing shouts hardcore more than a tiged up header

[DRjoe]

Wow you guys are easily impressed. Its them kind of comments that keep me persisting with this old heap of crap.

So how long do you think it will take before i'm kicked out of thumpers?


thanks for all the great comments.

Joe

[Mezo]

How long before the cops count your cylinders

Originally Posted by DRjoe

Wow you guys are easily impressed. Its them kind of comments that keep me persisting with this old heap of crap.

So how long do you think it will take before i'm kicked out of thumpers?


thanks for all the great comments.

Joe

[MoBill]

Originally Posted by DRjoe

Wow you guys are easily impressed. Its them kind of comments that keep me persisting with this old heap of crap.

So how long do you think it will take before i'm kicked out of thumpers?


thanks for all the great comments.

Joe

Seriously, I come back every day.

[DRjoe]

Originally Posted by Mezo

How long before the cops count your cylinders

well the engine says suzuki on the side so i dont think they'll notice but just in case i will get a compliance plate and tell them about the engine number change.