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Discussion in 'Some Assembly Required' started by Tommy_J, Feb 2, 2011.
Stainless dog dish from pet store or Dollar General
It turns out there was no need to have cut this clearance hole in the bodywork. Tonight I'll try to make the best of things and make a panel to fill it in. I may use the panel to mount a tiny boost controller valve.
Sorry to see your preemptive strike has hit an empty bunker! Will the panel repair be in steel and have nice rivets around the perimeter? It could turn into one of the "telltale" trim pieces with the little boost knob hanging off it. The controller could be readily accessible and yet recessed enough not to hang up on your gear as you slide from the gas cap to the tail rack, when the boost hits.
edit to add:
If my side panels were shiny, I'd offer to trade. Mine has grown a raspberry or two whilst sliding a bit too sideways on the cinder roads...
I'd hoped the cheap little ebay boost controller was little enough but on second thought it would stick up a bit too much to mount there.
Sooo, I'll put in a screen for ventilation. I can't say if this ventilation will be good or bad but at least the panel doesn't look like a mistake anymore.
Card board pattern and 0.1" aluminum screen
Trimming in progress
Nice grill!! I hope you don't end up roasting any weenies on it...
So, that is such a cool piece of trim, I, the no bling king, need one!
(scratches are my idea of bling for the Orange beast)
This means I have to get my ass out into the shop and get to work. Should take only a week or so to get the bench cleaned off. I have been neglecting too many projects, of late, and there is a huge pile of shi* where my bench should be.
A box of J bends from ebay. 303 stainless with 1.5 inch diameter. This diameter looks small compared to the stock 1.75" but is probably the best size for a turbo. One of these bends was special. It has a tight radius 90 bend that will be used at the connection to the turbo.
$120 delivered and is enough for the next project too.
I hope that is is a misprint and the material you have chosen is NOT 303. Let's hope it's 304. The problem with 303 is that it is a free machining stainless steel. It has sulpher in it's composition and that is not good when it comes to welding
I have done it before but it is not recomended. It can be done by using low heat and adding filler rod right away to prevent cracking. Use 308L filler rod. Again it's probably a misprint.
Looks like a fun project so far.
I assumed it was 303 based on the price. The ebay auction actually didn't specify the alloy. It seems to weld very well with a TIG machine.
A bit more stitching on the muffler. Baffle assembly is in. Then the end plate that attaches to the turbo can get tacked on. At that point I can bolt it up to the turbo and mount it to the bike. Then, finally, header construction can begin.
About the headers -
It would be so easy to make a 12 inch pipe to connect the factory header outlet to the turbo, but that's not what I plan to do.
In the very first post I said an objective was to improve off road ability. One way to make this happen is to loose the exhaust pipes under the engine. I bashed mine in when the bike was a week old. To solve the lack of ground clearance a whole new exhaust will be made from scratch.
Here's my well bashed header. KTM was moronic when they gave this bike more suspension travel than ground clearance. Any jump at all could ground the stock header.
A snap decision was made not to use the the stainless tubing bought just for this project. The original plan was to make new 1.5" fittings and flanges for the cylinder head junction. To do that means no real progress over the weekend.
Instead I'm going to scrounge 1.75" stainless from the stock header and 4 Ducati mufflers that were laying around. Hopefully this is enough tubing. I better not screw up.
This is the tubing available to build a new header out of. Should be just enough. It feels kinda scary to cut up my stock header. No going back now!
The EX-KTM header.
Assembly of the new header begins by installing a piece of the stock header to the head. Bits of the old header are trimmed to follow the desired path.
Chunks of the old pipe were cut to appropriate length and the joints mocked up by taping together. This routing is similar to the SuperEnduro's.
Once I'm sure the layout is what I wanted I took the pipe off. A bit of the tape is pealed back so a tiny tack weld cane be made.
Just two tacks per joint will be used at first. As things progress more tacks will be added.
Pipe back on for a test fit.
What do you do for a living Tommy?
Now, Now, don't go blowing Tommy's cover like that! He is just a regular joe with a motorcycle in his garage and some curiosity about taping a whistle on the back of said moto. Let the man work, the rest of us are drooling for the next pics/post... dreaming that this build-along produces a dyno chart and black streaks coming out the driveway!
Lots of experienced technique and knowledge on display, no doubt!
This is a good one.
Might I suggest that a mod sticky this thread???
Tommy. Once you get the header back to the turbo, I think you should take it to an exhaust manufacturer and have it jigged up. I think many people would buy them, who are riding SM, SMR, and possibly even SE, who would like to do a single muffler for weight savings and leaving room for Ned's auxillary fuel tank, would be all over a header like this.....even without the power snail hanging back there. Besides it takes the exhaust out of harm's way, and leaves mucho room for a skidplate/bashplate.
I need more!
The ADV or SE headers bolt right up to an SM or SMR(same exhaust). The standard ADV 2-into-1 conversion process can then be done for a single muffler. The fringe benefit to ADV pipes are the added ground clearance!!
This is FangFactor's bike, he is in Australia:
A stock SM header is an easy single side conversion, it is already a single pipe at the end...
I took my 2-onto-1 to a well known exhaust mfg and they said that there isn't enough of an SM market to even recover their tooling costs. The name brands do business in the thousands of pieces and not dozens.