Topic: DIY titanium 4into1

[Sam Green Racing]

1400 euros, not bad, plus you have the satisfaction of saying "I made that" when someone asks "where did you buy that fabulous exhaust TUBE" Well done Mec.

Sam.

PS. Frank was close, was it half of a 5 or 7 day week? 

[mec]

was it half of a 5 or 7 day week? 

whats a 5 day week? i do have 7 day weeks only
?? believe me, it was a lot of work, much, much more than i expected.

all the work is nearly done. only welding of the loops has to be done. i will wait with the weldings, till i have done some polishing or brush work to the tubes. or when i do not see any success, a professional polisher will get his chance.

these days some 0.5mm titanium sheet metall will arrive. this will be material for a light weight megaphon.

to make fit the 50.8x0.89mm end tube, it took approx 3 hours. it turned out to be a 08/15 job, was easy to do.

mec

[mec]

best of all:

this Ti conversion saves 3kg! to the overall weight of the bike.

steel:
headers including collector and end pipe: 3930gr
megaphon: 1270gr
total: 5200gr

titanium:
headers, collector and end pipe: 1773gr
silencer: 920gr
total: 2693gr

mec

[MFHP]

love that ! Great work again. Loved the dry clutch as well!
Your a lucky guy having the time to do this stuff !

[Toxic]

I have become addicted to this thread.  It's the first thing I check in the morning.

What are you going to build next?

[mec]

hi to all and thx,

i do not have a future project so far.
i have to do some checks to my racing guzzi, oil and oil filter change, rod big end shells are to replace, can be done through the oilsump cover however.

bit there are some ideas i have:
how about a vacuum pump attched to the crankcase of our sohc? it does good to the motoGP bikes, should not be a disdvantage for our vintage racers. i am not sure, if it would be a great benefit, because our drysump system with the bigger returnpump creates some sort of negative pressure in the cases already. it seems that we have the same system as the brand new ducati panigale (http://www.motorcycle.com/gallery/gallery.php/d/312615-3/13.jpg), but we have it since 40 years!!

another idea: how about a completely redesigned cyl head? from outside exactly the same look, but inside preped for bigger valves. when i look at the bore (+71mm) of my stroker engine and the tiny diameter of the combustion chamber, it is clear why the hp output is on the weak side. the 1000ccm suzuki GS1000 does have huge 38mm (or similar) in-valves stock.

but i would like to see someone other do this job. i would prefere to watch and comment

mec

[Tews19]

Great work Mec, can we hear how it sounds?

[754]

 Mec that is a huge amount of work you did, I bet you enjoyed it.
 Am I seeing your pics properly, it looks like you lifted your motor up 5 degrees at the front? is that correct?
 Then your pipes are safe, they will not fit other 750s!!

 Do you still have the 101 Scout ?

[Retro Rocket]

another idea: how about a completely redesigned cyl head? from outside exactly the same look, but inside preped for bigger valves. when i look at the bore (+71mm) of my stroker engine and the tiny diameter of the combustion chamber, it is clear why the hp output is on the weak side. the 1000ccm suzuki GS1000 does have huge 38mm (or similar) in-valves stock.

Mec, would it be possible to re-manufacture an existing head, welding up the valve guide openings and putting them in a new position to allow for bigger valves.?

[mec]

Great work Mec, can we hear how it sounds?

yes, i think there will be videos. at the latest when we are on the racetrack again.

Mec that is a huge amount of work you did, I bet you enjoyed it.
 Am I seeing your pics properly, it looks like you lifted your motor up 5 degrees at the front? is that correct?
 Then your pipes are safe, they will not fit other 750s!!

 Do you still have the 101 Scout ?

yes, the engine is lifted by some degrees at the front. should give more ground clearence.
the pipes will fit other sohc750s, but one will have to adapt the end pipe.

i still have my 101 scout. it will go to a bike show the next weekend.

Mec, would it be possible to re-manufacture an existing head, welding up the valve guide openings and putting them in a new position to allow for bigger valves.?

i had similar thoughts, but i do not know, if it is doable. the deep hole is not easy to reach/weld, the material is a pain to weld. all has to be done 4, maybe 8 times (exhaust valve guide openings). maybe one has to weld all the openings for the valve seats too. as i mentioned, i would like to see one other do this job.

mec

[Retro Rocket]

Quote from: Retro Rocket on February 02, 2012, 05:16:29 pm

    Mec, would it be possible to re-manufacture an existing head, welding up the valve guide openings and putting them in a new position to allow for bigger valves.?


i had similar thoughts, but i do not know, if it is doable. the deep hole is not easy to reach/weld, the material is a pain to weld. all has to be done 4, maybe 8 times (exhaust valve guide openings). maybe one has to weld all the openings for the valve seats too. as i mentioned, i would like to see one other do this job.

mec

Me too.....

[mec]

here is the last step of my work:

building of the megaphon

first i made a dummy megaphon out of mild 0.8mm aluminium. this was easy to build so that i expected no problems for the titanium one.
but as i saw at a later stage, this was a great mistake.
the material i had, was 0.5mm titanium grade 1, but not large enough for the megaphon. further i had 0.5mm titanium grade 5 laying around, large enough for the conical pipe.

mec

[mec]

my very small sheet rolling machine had its difficulties to bend the metall. in addition to this i had no experience with rolling a cone. the result was a cone which was not bend correctly. it was no problem to make the long weld clamping the cone together with hose binders. but the cone turned out to stand under tension and was not perfectly round. the same with the small reverse cone. all this problems caused by the hard grade 5 titanium.

mec

[mec]

curious if the welds will withstand the vibrations.
at last i can say that the megaphon is not the most beautifull part of the exhaust system (maybe i will make a second one), but it is a really lightweight one: 181gr.
the complete weight savings are 3200gr compared to the steel exhaust system.

mec

[MRieck]

You're a madman Mec.

[tweakin]

Your work is ridiculous!  Well done...

[bwaller]

Yeah I agree with both replies above. Bloody cool work Mec. It will be over the top polished! 

[mec]

hi to all,

yesterday the exhaust system came back from the polisher. i payed 85€ and was happy not to have done this job by myself.
after some thoroughly cleaning I welded all the loops to the pipes, attached the springs and.........mission completed.

have a nice time, friends

mec

[cben750f0]

bloody amazing mec, love your work, now all you need to do is take a video of that bad boy in action, i wanna hear what that sounds like
!!! also are you going to put it on a dyno, for some comparison figures?


again excellent work M8

peace

[EDU]

What do you mean 'have a nice time'?? We want a video of this thing running!!!! Preferably in HD... hahaha 

[mec]

@ cben750f0

i would like to have a dyno run for comparison, but that costs me a complete day. i am dreaming to have a dyno at my home one day, however.


@ EDU

a short video? no, i prefere to make a 2h movie, my egli bike as the leading actor, angelina jolie and me in a supporting role

mec

[bikebitzofvt]

Now that's a movie I'd pay to see!!!!!

Fantastic work, as always!!!

[cben750f0]

sorry mec...but angi and the bike yeah....mec.....er....

lol sweet just make sure you let all of us know when the production of the full length feature is done.... COS I WANNA SEE IT!!!!.

peace

[Free Booter]

That collector on the exhaust really is a work of art. nice job.

[lucky]

If you get the bike light enough the riders weight will make it top heavy. LOL

Once I had a motorcycle and every last bolt and nut was titanium.