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Old 02-27-2010, 07:42 PM   #466
Travmoto
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Joe just leave one spark plug out during the build...... does that technically make it a thumper?
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Old 02-27-2010, 08:30 PM   #467
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I wouldn't think any of the mods check in here very often so if we all keep quite about the extra cylinder they'll never find out and i can carry on playing in the thumper sandpit.
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Old 02-28-2010, 12:03 AM   #468
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Quote:
Originally Posted by Gustavo.Ramos
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!
A bit late now, but to make the welds smooth on the inside while you use the Tig. You must 'purge' the inside of the pipe with Argon.

Method: Tape both ends of the pipe. Insert gas line on one end (place a 'Tee' in you gas hose) the other end, prick the tape. This will let the air escape, and fill the space with Argon.
After a few practise runs, you'll work it out.
If you go chasing performance, this is important.

Before you hot up this motor, buy 'Four-Stroke Performance Tuning' by A. Graham Bell. I found this book more releavent that 'Tuning for Speed' by Phil Irving (but still a bloody good read).

While reading this, many weird 'why is it so' things will become apparent!
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Old 02-28-2010, 01:28 AM   #469
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Thanks for the purging tip i'll do that next time.
The guy at the exhaust shop mentioned it once but i didn't have a clue what he was going on about but it all make sense now you've mentioned it

Hey Mezo I tried your dads exhaust program and it turns out my header are the correct length and diameter for 7000rpm but the exhaust ports are way to small and would be more suited to about 4000rpm
also the inlet tracks are the perfect length to match my headers but are about 100mm to short for the the exhaust port diameter.

I was surprised at the difference of the length that the inlet tracks should be when you change the chosen rpm by just a few thousand.
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Old 02-28-2010, 02:48 AM   #470
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Quote:
Originally Posted by DRjoe
Thanks for the purging tip i'll do that next time.
The guy at the exhaust shop mentioned it once but i didn't have a clue what he was going on about but it all make sense now you've mentioned it
No worries

Quote:
Originally Posted by DRjoe
the exhaust ports are way to small and would be more suited to about 4000rpm.
See tip B before you attack the ports with the die grinder.
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Old 02-28-2010, 04:47 AM   #471
Gustavo.Ramos
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Quote:
Originally Posted by dirt_bloke

Before you hot up this motor, buy 'Four-Stroke Performance Tuning' by A. Graham Bell. I found this book more releavent that 'Tuning for Speed' by Phil Irving (but still a bloody good read).

While reading this, many weird 'why is it so' things will become apparent!
I like this kind of reading!

One more for the weird book list noone would ever find to offer me unless i specifically indicate all the details! Tkz
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Old 02-28-2010, 04:59 PM   #472
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That is some excellent work Joe! Good to see you sticking to it. :) Can't wait to see it finished.
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Old 02-28-2010, 07:56 PM   #473
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Quote:
Originally Posted by dirt_bloke
No worries



See tip B before you attack the ports with the die grinder.
I wont be taking a grinder to the ports for awhile yet so i'll have plenty of time to read that book.

thanks again for the tip
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Old 03-01-2010, 05:16 AM   #474
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nice pipe man!
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Old 03-01-2010, 02:28 PM   #475
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Wow! I{m impressed! Nice job Joe! Looking foreward to the first ride.
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Old 03-01-2010, 04:15 PM   #476
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look what arrived today


there quite heavy so i started a bit of weight saving by cutting out the cat.


pretty aren't they


weight with the cat


without the cat


and the cat itself


with my highly accurate scales i reckon once I've drilled a few holes in the baffles for weight saving purposes and then welded them back up they'll come in at just over 3kg each
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Old 03-01-2010, 04:22 PM   #477
Travmoto
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lol I'm picturing now the puzzled looks on peoples faces when you ride past, KTM bits, Suzuki bits and god knows what else... this things going to be a hoot when its finished.

Keep up the good work mate, and don't let the rain slow you down, we all need these updates
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Old 03-01-2010, 04:45 PM   #478
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Quote:
Originally Posted by Travmoto
lol I'm picturing now the puzzled looks on peoples faces when you ride past, KTM bits, Suzuki bits and god knows what else... this things going to be a hoot when its finished.

Keep up the good work mate, and don't let the rain slow you down, we all need these updates
It'll definitely going to be a laugh when i first get pulled over by a cop.

I'm hoping it will go something like this.

Pc plod: "alow alow alow whats all this then"

Me: "it's a bike officer"

Pc plod: "and what kind of bike would it be sonny"

Me: "well officer I started with a dr650 which then blew up so i put a gs500 motor in it which meant i had to change a few bits so i suppose its a dr500t"

Pc plod: "ah maybe you should just go"

Me: "ok" barp baarp baaaarp baaaaaaaaaarp baaaaaaaaaaaaaaaaaaaaaaaaarp baaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa



The rain is speeding things up. I took a week of work to finish the bike and i keep getting calls from people wanting work done on there boats and now its raining i can say no without loosing out.
So it's full steam ahead with the bike now well that's if i can get off the dam computer.
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Old 03-01-2010, 05:28 PM   #479
Travmoto
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Quote:
Originally Posted by DRjoe
It'll definitely going to be a laugh when i first get pulled over by a cop.

I'm hoping it will go something like this.

Pc plod: "alow alow alow whats all this then"

Me: "it's a bike officer"

Pc plod: "and what kind of bike would it be sonny"

Me: "well officer I started with a dr650 which then blew up so i put a gs500 motor in it which meant i had to change a few bits so i suppose its a dr500t"

Pc plod: "ah maybe you should just go"

Me: "ok" barp baarp baaaarp baaaaaaaaaarp baaaaaaaaaaaaaaaaaaaaaaaaarp baaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
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Old 03-02-2010, 05:29 AM   #480
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got a bit more done today.

first off i finished the mufflers after cutting the cats out i sat stared at the baffles for a while.

I Have grow to prefer quieter pipes but for some reason i just couldn't stop myself from doing this.


oops a might have drilled strieght through the baffle


I cut the end off the cat and welded it back on


Since i bought my tig welder last year i've only really done alloy with it so the exhaust headers and the mufflers are the only stainless work i have done. It turns out stainless is a crap load easier to weld than alloy.
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