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Re:bobber project
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TOPIC: Re:bobber project
#960926
BubbaKahuna (User)
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Re:bobber project 1 Year, 10 Months ago  
Damn that's gonna be a calendar bike when you're done!

I'd hold off on the exhaust until you get the intake sorted out.
The pipes will have to clear that and you want to avoid pre-heating your intake air if you can.

Love the quality of your work!
 
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This fits in here, right? I mean, I can make this fit in here ... right?

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#960933
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Re:bobber project 1 Year, 10 Months ago  
BubbaKahuna wrote:
Damn that's gonna be a calendar bike when you're done!

I'd hold off on the exhaust until you get the intake sorted out.
The pipes will have to clear that and you want to avoid pre-heating your intake air if you can.

Love the quality of your work!


cheers for that.... i hope it all comes together in the end

did you miss the post on the air intake.

this is my air box.... i plan to add a layer of heat insulation to the under side of the tank and to the under side of the heat shield i made that sits ontop of the carb.



the grill is were the air will flow in... should be as cool as it can be, all the way up there...? no hot pipes or engine just the handle bars.



this is inside my air box.... which is under the petrol tank. i also added cooling finns to the risers i made to lift the filter.

nothing but fresh air infront of it....

 
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#960948
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Re:bobber project 1 Year, 10 Months ago  
 
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It\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\'s been lots of fun guys... Thank you Gram and catch you all on the other site.
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#961613
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Re:bobber project 1 Year, 10 Months ago  
exhaust pipes.... so before i really got started i decided to do a little light reading on the topic.... which turned into more reading.... which turned into a heap of gobbly gook.
dont get me wrong, it was very interesting and it all made perfect sense and although all the articals i read pointed to the same conclusions.....? there were no real formulas....? at best all you could get was a good starting point and then after making your pipes..... you, with the use of some high tech measuring equipment could test and then modify, adjust evry thing that can be and then test some more.

so i want to make my own..... just because.... and really all i want is for the bike to run.....? im not making a race bike so what does it matter...?

all the reading has helped, i have changed my initial design, gaining inspiration from the many articles i read.
im going to stick closely to the stock dimensions and make small adjustments for the extra air/fuel i will be adding.
while still doing what i want.... suck it and see..... fix the problems as they come.

so yeah..... im almost finished designing....?

mean while i thought i would do a little work on the electrics.

started with fitting the fuse box.... placing it under the front of the seat, just at the rear of the tank. lift the seat to change a fuse....



need a small bracket that locks into the fuse box and screws to the frame.
here i have marked out some 1.6mm s/s, used my bench shears.




then i finished cutting it with an angle grinder, files, linisher, bending jig, drill and emery cloth.... and ended up with this.





the snail horns came, so i fitted them.



earth cable, fitting it to one of the rises i made to lift the tank..... 10mm x 20mm steel. made a shorter cable out of the stock one. drilled and tapped M6 in the frame.



here it is running to the neg terminal of the bat.



starting to sort out the spagetti.




when the tank is on... the shape of the cavity should act like an amplifier..... hopefully making the horns even louder.

 
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Last Edit: 2016/04/26 10:23 By masterhermit.
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#961615
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Re:bobber project 1 Year, 10 Months ago  
Man. The way your mind works to see both the current part and how it needs to fit. And then be able to take whatever you have and simply make what you need to make it work astounds me. It's amazing and just beautiful handiwork. Everything you finish is not just functional but also art.

Keep up with these pics I look forward to them and the end result.

SD
 
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#961618
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Re:bobber project 1 Year, 10 Months ago  
TheSheepdog wrote:
Man. The way your mind works to see both the current part and how it needs to fit. And then be able to take whatever you have and simply make what you need to make it work astounds me. It's amazing and just beautiful handiwork. Everything you finish is not just functional but also art.

Keep up with these pics I look forward to them and the end result.

SD


thats really nice of you to say so..... all i can say is im having a ball doing it....
cheers for that sheepdog
 
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#961643
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Re:bobber project 1 Year, 10 Months ago  
Yeah, what Sheepdog said! Mucho admiration for your skill set!
 
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#963001
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Re:bobber project 1 Year, 10 Months ago  
exhaust pipes...... easy.....? if you have the technology...... i dont (at the moment)

so..... i have been trying to work out how to make what i want with what i have..? not so easy. i have thought about making some formers..... (lots of work) thought about buying one of these beauties... http://jd2.com.au/benders/model-32-bender.html (lots of money)

instead i decided to free form, almost...? then when i have wasted some time and made some scrap....? then may be i would buy one of those benders.

found some and bought some s/s..... which should turn into my exhaust system.



first off i need a clamp, specific for the 38.1mm tube.... found a piece of al



centred it in the four jaw in the lathe



centre drilled, then 8mm pilot, 13mm and last a 30mm



now i could feed the boring tool in to open it out to 38.1mm



onto the band saw to cut it in half



remove sharp edges



tube clamp



ok.... so some of us have probably used sand to bend copper tube...? i have and even better was when i tried the ice method.
not sure how it will go here....? worried that if i dont get the sand packed in well it wont behave.... that is if it will at all....? but you never know if you dont try.

welded shut one end of a test piece..... only tacked so there would be some where for hot gas to vent.



made the other cap with a way to allow me to pack the sand in.... using the bolt i made to ram a rod into the sand.... just to make sure it was packed.





now for the fun part..... heating up the tube and trying to make it bend.

but... its late and im hungry
 
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Last Edit: 2016/04/26 10:31 By masterhermit.
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#963034
LuckyDon (User)
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Re:bobber project 1 Year, 10 Months ago  
That $875 tube bender would not make what you want.
To make bends in that size of tubing you will need a tube bender that costs a LOT MORE than $875.

The tube bender has to have a mandrel inside of the tube to keep the tube from getting wrinkles.
That is WHY motorcycle exhausts cost so much money . They know the muffler shop cannot do this for you and they know you cannot afford a real mandrel bender.

So they can keep charging $500-$1000 for a motorcycle exhaust.

You can buy stainless tubing and elbows on E bay and cut and weld them.
Even that is not easy to make look that good, and of course it will have to be wrapped to hide the welds.
 
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#963461
masterhermit (User)
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Re:bobber project 1 Year, 10 Months ago  
looks like your right Don..... i was on the Aust site for JD and they didnt have all the details, but i checked out the US site and yes it wont do what i want.
would have to increase the wall thickness and the diameter of the clr.....

looking into bismuth or a mixture of low melt alloys and trying it instead of sand..... i did try a sample bend with the sand packed tube. had some issues as the sand was still a little wet and heating it created steam which ended up blowing sand out as it vented.... i think what was packed sand was no longer and i did start to get a small kink as i tightened the bend. but i was free forming.... so i am going to make a die to form it around.
 
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