Author Topic: 1981 XV1000 TR1-project  (Read 35054 times)

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Offline grcamna2

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Re: 1981 XV1000 TR1-project
« Reply #150 on: June 07, 2024, 02:00:21 PM »
Looks absolutely wonderful.
I especially enjoy seeing that 2 into 1 exhaust header and look forward to your showing of the complete exhaust. A very nice creation.  :) 8) 8)
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #151 on: June 08, 2024, 03:52:38 AM »
Looks absolutely wonderful.
I especially enjoy seeing that 2 into 1 exhaust header and look forward to your showing of the complete exhaust. A very nice creation.  :) 8) 8)

Thank you very much, and here it is:



Offline grcamna2

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Re: 1981 XV1000 TR1-project
« Reply #152 on: June 08, 2024, 05:55:45 AM »
Wow !!
I'm surprised you found the company that makes the high exhaust and it's a great looking part:complete.  :)  Very nice quality  ;)
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #153 on: June 08, 2024, 08:46:37 AM »
Well... the "company" that made the exhast is myself.
Started out with the bends in the picture below and the rest is fabricated by my own two hands  :)


Offline grcamna2

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Re: 1981 XV1000 TR1-project
« Reply #154 on: June 08, 2024, 12:40:36 PM »
I See !   :)
You did a very nice job.  ;)

Edit:What type of fasteners/bolts & hardware do you use to hold everything together ?
« Last Edit: June 08, 2024, 06:49:45 PM by grcamna2 »
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline RAFster122s

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Re: 1981 XV1000 TR1-project
« Reply #155 on: June 08, 2024, 06:08:16 PM »
Mad skills
David- back in the desert SW!

Offline BenelliSEI

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Re: 1981 XV1000 TR1-project
« Reply #156 on: June 08, 2024, 08:32:50 PM »
Wonderful!

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #157 on: June 08, 2024, 10:46:03 PM »

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #158 on: June 08, 2024, 10:46:48 PM »
Wonderful!

Thank you, glad you like it  :)

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #159 on: June 08, 2024, 11:55:14 PM »
I See !   :)
You did a very nice job.  ;)

Edit:What type of fasteners/bolts & hardware do you use to hold everything together ?

Here's the complete story:

The bends are made from AISI304 stainless which is the best material for a stainless exhaust.
Lots of time and thought went into figuring out the way I wanted the pipes to sit and fit, both looks as well as weight and fitment had to be considered.... also nobody want to burn their thighs when riding the thing.

Turned two stainless bungs that go into the heads, and they are held on by the stock brackets.
I then welded the pipes into the bungs and started routing the pipes, tackwelding them together.

Turned a press tool and pressed good fitting slip joints that does not leak, and does not need fasteners.

When the routing was done I fully welded the pipes, and because the fitting of the joints were done with no gaps the pipes did not move at all during the process.

I needed a heat shield where the pipe passes my leg, and I milled that out of a bigger pipe of stainless.
The heat shield is bolted to the collector and the mid pipe and thus also keeps the two parts together.

So... the pipes are held to the heads by the stock brackets.
The front pipe is just slipped into the collector with no fastener.
The mid pipe is just slipped on after the collector, and the heat shield hold them together even further.
The silencer is then held to the midpipe by springs and to the subframe by the stainless band.

And thats it  :)

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #160 on: June 08, 2024, 11:57:57 PM »
...and...

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #161 on: June 09, 2024, 12:00:34 AM »
...and...

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #162 on: June 09, 2024, 12:05:48 AM »
The pipes were then vapor blasted to give them the satin shine I wanted and to remove the blueing from the welds.
And they have since yellowed by the heat which I find very nice  :)
« Last Edit: June 09, 2024, 11:09:49 AM by DME »

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #163 on: June 19, 2024, 12:16:29 PM »
Electrical system, front brake and handlebars back on, getting closer to firing it up but there are still a few more things to fix...


Offline grcamna2

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Re: 1981 XV1000 TR1-project
« Reply #164 on: June 19, 2024, 01:42:43 PM »
The electrical  :)  That's complete.
I like the left side view:my favorite to see.
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline MauiK3

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Re: 1981 XV1000 TR1-project
« Reply #165 on: June 19, 2024, 02:18:42 PM »
Very nice looking
1973 CB 750 K3
10/72 build Z1 Kawasaki

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #166 on: June 21, 2024, 11:57:38 AM »
Got the bike all assembled today and decided to check the dry weight.
Started by weighing the slings and they weighed 0.3 kilos.
Then hung the bike and found the dry weight to land at 181 kilos.
Very happy with that number as my stock TR1 lands at 231 kilos dry, so pretty much 50 kilos has now been shed from the project  :)

Offline grcamna2

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Re: 1981 XV1000 TR1-project
« Reply #167 on: June 21, 2024, 05:52:07 PM »
Excellent  :)

I'm enjoying the journey of your custom Yamaha XV1000 TR-1 build very much and the explanation of your exhaust being built from reply #159 - #161 !  8)
I like the design of the "press tool" so that the exhaust pipes fit very tight during the build process.
« Last Edit: July 21, 2024, 08:25:04 PM by grcamna2 »
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline BenelliSEI

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Re: 1981 XV1000 TR1-project
« Reply #168 on: June 23, 2024, 05:59:54 PM »
Beautiful project!

Offline RAFster122s

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Re: 1981 XV1000 TR1-project
« Reply #169 on: June 23, 2024, 09:55:25 PM »
It certainly is looking trim and your efforts certainly have paid off on trimming weight, amazing amount of weight loss on the bike.
David- back in the desert SW!

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #170 on: June 24, 2024, 02:05:29 AM »
Yeah, I wouldnt have guessed that so much could be shed  :D
The weightloss has also made a dramatic change to the handling of the bike, and for the better that is  ;D
I´m now at the point where i can't find any more obvious things to do to lighten the bike even further, except start switching stuff to more "exotic" materials like aluminium rims, titanium axels and bolts, alloy tank, etc... and that is not going to happen.
Excessive hole drilling would be another way to go, but this project has been as much about looks as of weight and function and to "perforate" to bike to save a gram or two more is not going to happen either.
Lookwise (and weightwise...) it's pretty much where I want it right now, only thing remaining is the paint on the tank and seat  :)

« Last Edit: June 25, 2024, 01:31:39 AM by DME »

Offline grcamna2

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Re: 1981 XV1000 TR1-project
« Reply #171 on: June 24, 2024, 09:53:46 AM »
I know that the OEM exhaust is Very heavy and the seat.
I hope your presently installed seat will give you enough comfort.
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline BenelliSEI

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Re: 1981 XV1000 TR1-project
« Reply #172 on: June 24, 2024, 01:40:36 PM »
Paint it and enjoy the outcome!

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #173 on: July 21, 2024, 04:45:21 PM »
Sanded down the stock decals on the tank and laid down a coat of epoxy primer on the tank and seat today.
Once harded the primer will be sanded level, and once thats done its a matter of getting the paint scheme laid out irl  :)

Offline DME

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Re: 1981 XV1000 TR1-project
« Reply #174 on: July 26, 2024, 01:09:09 PM »
The epoxyprimer has now been leveled with 320-grit paper and that got rid of all imperfections.
I did however sand through the primer on a few small spots so another coat will be necessary.
The plan is to go over everthing with 600-grit paper as a finish to paint over... but if someone over here has more experience of surface prep for paint I'd be tankful for advice  :)