OZ ATV :: The Australian ATV Forum

[Mart 300r]

As i chopped up my pipe off my airey for the laydown engine.Ive decided to try my hands at fabbing one up.Not sure on how shell perform as i didnt mapp the cylinder or nothing like that.If it doesnt run ill keep changing things untill it performs how i want it.Doin it more for just the love of fabricating stuff lol,better make the most of my time before the baby comes lol.
Im making the entire pipe out of paper first which are exact cone templates of the ones ill be rolling up,So ill mock it all up ive recorded each cone dimension then ill pull it all apart and roll the steel cones and tig it all up.If the pipe performs well ill b making a jig as i have everything recorded and will make some for people if they wanted one.I just hate how dg is about the only pipe that can be bought for the aireys annoys me,and wasnt impressed at all how the dg's perform.






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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[ylwgtr]

ahhhhh the joys of it....ive done it many many times there are some pretty good pipe design programs out there to do this sort of thing...The one ive got prints out the templates....i will post up the name of it when i go up in the office as its on the main PC. Have you thought about the old cutting two halves in side profile/welding them together and pumping them up with a porta power mart?Good work mate....will be watching this

[Mart 300r]

Yeh ive messed around with a few pipe programs.Ive also been doing lots of reading up on ways to measure port timing etc but really at the end of the day the way i look at it im riding on the sand dunes not a motogp circuit and i really do think its best to (i know it sounds stupid) learn the hard way, I will definately learn from doing this. Do you mean how the mass produced pipes are made??how do you go about porta powering them some type of die or something??

When i first built the laydown r engine the pipe i had on it was absolute garbage then ive built a few then the one ive built performs really well.All im chasing is something that performs well(doesnt have to be a horsepower monster) an looks good I really dont think ya can beat the look of a full sectional pipe.
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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[ylwgtr]

hang on mate....i post some pics for you

[ylwgtr]

they call it hydro forming.....cut the shape out x 2 weld together...then pump away!!!You can use a High pressure cleaner and just pump it up with water instead.....i once used a power steering pump off a car with an electric motor from a washing machine and a series of hydraulic pipes and valves

[Mart 300r]

Yeh now i know what ya mean.Ive used the water process once back in the day to fix a couple dings in a pipe.There is less disturbance of the pressure waves using that procdeure ay??
Is there anything you havent had a go at lol i might just go out in the shed and burn my paper pipe now hahahah.
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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[ForeverThreeWheels]

Looking great mate, I knew it was only a matter of time before you attacked pipes. Im keen to start chopping up some swingarms and modding lengths/designs. Have you considered doing an Out Of Frame drag pipe for an airy.
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[slightlydodgy]

that's good work both of you I'm only just getting to muster the courage to modify frames properly
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Tremble with fear - I've had an idea

[Mart 300r]

ForeverThreeWheels wrote:

Looking great mate, I knew it was only a matter of time before you attacked pipes. Im keen to start chopping up some swingarms and modding lengths/designs. Have you considered doing an Out Of Frame drag pipe for an airy.

Yeh would love to do one mate.Although fabricating and welding is the easy part gettin the pipe right is the hard part im more than happy to cut an chop an change mine a million times.I would hate to make one for someone and have it go like a dog then them hate me for it lol.But i think the ol usa boys would love to have some drag pipes hangin off
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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[Mart 300r]

slightlydodgy wrote:

that's good work both of you I'm only just getting to muster the courage to modify frames properly

Thanks mate
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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[richie_supercharged]

Good stuff mate
I have a sectional pipe on my 84 not sure what it is
Don't think it's a bills
You can borrow it if you need something to reference off
It's just sitting there in the shed cause the bike is pulled apart
Or I could measure some bits



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If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[Mart 300r]

Richie one of the fellas i used to ride with had that exact pipe it ran really well. I might get you to take a few measure ments when i get on my other comp ill draw where i would like ya to measure only if its not to much hassle mate.cheers
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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[Mart 300r]

Ylwgtr
Mate what pressure were you getting up to to pump them out (kpa)i might look at going that way for the header sections.an maybe some info on the program u have for the templates?
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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[richie_supercharged]

Mart 300r wrote:

Richie one of the fellas i used to ride with had that exact pipe it ran really well. I might get you to take a few measure ments when i get on my other comp ill draw where i would like ya to measure only if its not to much hassle mate.cheers

No worries mate il dig the pipe out
_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[ylwgtr]

depends on the thickness of the material your using and the shape ofcourse,a broad area will pump up quite easy where as the tighter areas require more pressure (you will see when you try it the broader areas pump up first) you can dolly it up with a whackometer in areas to massage it while your going.....i cant remember the pressures.....but 1000 sphincter pulses per second rings a bell

[ylwgtr]

i forgot to have a look on the pc upstairs.....i will check in the morning

[Mart 300r]

Richie all i really need is the width of the belly section.Also the inside diameter of the stinger.Pretty sure they are 28mm but not sure that is pretty crucial.

ylwgtr material im using is just .9 mild steel.1000 sphincter pulses lol Thats what its like when im testing raaf tanker delivery hoses we take them to 1500 kpa but the scary part is they have to be tested on site with avtur (jetfuel)the ol sphicter runs at 2000 pulses a second lol.

Heres abit of an update few xxxx's later an im nearly done on the mock up wont be until sunday arvo i get to start rollin the actual pipe gotta go to bathurst fr family stuff lol oh well!!! here she is any way coming up not to bad i reckon.not sure if im lovin the amount of cones at the header stage but dunno if i wanna atempt the hydro form or just stick with wat i know i can do.






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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[ylwgtr]

my tension wrench has ft-lbs,nm and spps settings

[slightlydodgy]

firstly I know nothing about 2smokers so I if I seem like an idiot there is a reason. You have said you're not keen on he amount of cones in he header section. From the pics it looks to be the same size to the expansion chamber, could you use a mandrel (same as they use in auto exhaust shops) to bend this up even in segments it might be easier and potentially lest prone to leaking
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Tremble with fear - I've had an idea

[Mart 300r]

Mate you dnt sound like an idiot at all. The pipe starts to taper at about 1/4 away around the second bend .5mm at a time.i will build it like this for now then might look into the hydro forming if ppl are keen for them just to save wrk.thanks for your thoughts,prob with using tube etc is pretty limited on sizes etc
Cheers mate
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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[ForeverThreeWheels]

I think it looks trick mate. Hope it runs even better. Good work.
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[slightlydodgy]

After reading your post I had another thought (about to find out where my name comes from ) Would using my aforementioned method of shaping using the same size pipe as your straight? piece across the bottom and then cutting a slot or fine wedge out lengthwise out to gain your taper? I have used this method to make various exhausts (cars and bikes) fit when joining different sizes/ shapes Sorry to pick your brain For some reason this is interesting me and always keen to learn something new
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Tremble with fear - I've had an idea

[Mart 300r]

Cutting a wedge out will actually be the wrong size mate when they try to marry up, you would have to cut right through on the degrees you want well actually half the degrees then spin them around.Although in saying that i know exactly where you are coming from ive used the old cut abit out and pull it together trick heaps lol.Just not real good method for this one mate.

Heres a few more photos,got some cones rolled up, Welded the seam on one of the cones and then ran outta gas on my tig!!





The "huge" set of rolls i own lol

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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[richie_supercharged]

Sorry mate did you still want those measurements il have em Saturday
_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[slightlydodgy]

Really nice work I doubt I would have the patience. I'm following these sorts of posts with interest as I'm putting a Chinese 250 four stroke (identical to the Honda XR) into a early 90's Yamaha YZ and have just been handed a Kawi KDX 80 complete apart from motor and boss has said grab one of the retired Mudbugs to power it
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Tremble with fear - I've had an idea