#5 lives... almost

Günter was away for an extended vacation touring the UK, so progress had stalled a bit. In the meantime, I had ordered brakes lines and 3D printed a couple of odds and sods for more of a tidy "professional" appearance.

We dived into it again yesterday and finished the day with working brakes and throttle, nicely centred brake calipers, a revised, wider chain slipper for the swing arm, fuel lines and overhauled fuel taps, overhauled foot pegs and pedals, tacho mountings as well as commencing work on the exhaust bread box. The 3D printer was also busy, making cable guides and clips as well little rubber tie-downs for the fuel tank.

Oil cooler bracketry and engine breather catch can are up next.

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The ugly fucker... still not sure if it's going to work. :rolleyes:

piet
 
Is that an original Breganze/Zane 650 collector box and are you planning to use it as part of the exhaust system or is it just to protect the bottom of the engine when you jack it up? 🤷
 
Andy J said:
Is that an original Breganze/Zane 650 collector box and are you planning to use it as part of the exhaust system or is it just to protect the bottom of the engine when you jack it up? 🤷
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Yes Andy, we're thinking of using it as a preliminary silencer box. It is turning into a challenge due to space limitations though, good chance we'll axe the idea.

The bike made your ears bleed back in the day when BLOODY LOUD was considered normal. Not too concerned about sacrificing a few ponies.

piet
 
IMO you're better off attenuating the nastier (sharper) edge of exhaust noise by having decent length straight-through mufflers with plenty of damping 'wool' around a large surface area perf tube. They can be big bore and unrestrictive. Mine taper from 44mm at the inlet to 55mm at the outlet. Complication is they probably need to have the elbow shape like a triple can.

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Well aware of that Quentin, but we're trying to keep the optics at least close to original with a couple of cheeky meggas poking out each side. ;)

The original "system" has been blasted and painted, will probably go on for first set-up dyno runs. Gonna wake up the whole valley! Hopefully in the very near future...

piet
 
Grazie, but next time I'll come I hope I don't restrain you that much from working! It would be great pleasure for me to hear when the beast will burst into life. As you describe the pipes it could easily turn into a "the sun will become dark and the birds will go by their feets" event.
However, due to a conflict in my calendar I won't be able to come to the Nuerburgring event ...
 
Bit of an update...

Günter and I haven't been idle and a fair bit has been going on.

The exhaust breadbox idea has been ditched and Günter splashed out on a new pair of meggas. They are almost the same shape and size as the originals and have an internal sleeve with absorption matting.

DSCF3038 harris 600 auspuff.JPG Günter had them made locally, the bike was at the companys' workshop for a fortnight for fitting. The result is absolutely superb! It's a crying shame that they'll eventually require painting as they're made from mild steel. We'll leave them raw for the time being though, just too damn nice. Photo by Jo.

A pair of oil cooler brackets were designed and duely printed in ABS, should be both durable and heat-resistant enough to cope.

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A bit chunky maybe, but hardly visible when fitted. Lighter than billet alloy as well as being easier for me to make. Thirty minutes playing CAD designer and feeding the printer, sit down for breakfast and come back to a finished product. Sure beats carving them out by hand.

While I was at it, neat cable clips were also printed, actually no great fan of cable ties.IMG_2759.JPG

Wired the ignition coils and boxes. The starter button shorts the ignition, the on/off switch is used to switch between the 2 available ignition curves.
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More pics soon.

piet
 
motoddrob said:
Instead of paint for the exhaust how about ceramic coating Piet.
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Is a clear ceramic coating available Rob?

Depends a bit on how it survives next weeks event, weather forecast sounds a bit dodgy. Flat black would be period appropriate anyway.

piet
 
It's certainly beautiful work, Piet. A quick spray with Dulux clear and Roberto's ya zio!

Shame it's not Ti or that other exotic exhaust metal ... very expensive and would probably crack.
 
Clear ceramic, now that would be interesting. Got sick of painting the Toddy 3/1 on the Motodd so had them ceramic coated 20 years ago after having the headers remade as the original rusted out probably from lack of paint!!, and they still look good. The "silencer" is still the original now being 40 years old and I put that down to the ceramic coating.
 
My stainless system was Ceramic coated inside and out also probably 20 years ago, its there version of a shiny, chrome-like finish. It looked great for maybe 4 or 5 years, and then it needed a good Autosol once a year. Now it's a dull silver colour, okish but not shiny. BTW, the hype back then included that the coating held the temperature in the pipe, almost allowing you to touch it and not burn your skin; in reality burned, but nowhere near as bad as when not coated. They reckoned it upped performance as well, but they always say that.
 
On the switch, I would replace the R with an F... ;) (simply put some orange or red or what it is paint accordingly, so the R turns into an F f.e.).

Pretty sure you would have a grin any time you look at the switch then...
 
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