cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Dec 8, 2009 18:42:23 GMT 10
The last few days have been interesting. Fitted GSXR Calipers up front. Even just the colour makes a huge difference. Forgot how much of a pain in the ar$3 bleeing brakes are. Oh and I had 5 or 6 bottles of Brake Fluid when we moved 3 months ago, and could I find any when I needed it? No - had to go to the servo. :-( Then come Monday I went and got me a Pipe Bender - love Birthday $$$$. Turned out to not be as helpful as I had expected . . . . so had to do it the hard way, which involved a total of 9 pieces for the upper part of the exhaust. Here are a couple of pics. Initially I was trying to make it look neat, but then I remembered that it will be wrapped in Ceramic Tape anyway, so I just concentrated on getting it to fit and have some chance of flowing. All things going well, I will be able to seam up all the welds tomorrow.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Dec 11, 2009 18:28:40 GMT 10
Well, I got to start it this arvo. To test for leaks in the new system mainly - there are so many joins it ain't funny. Only found 4 . . . . pretty happy about that.
Sound? Deep, thumpy rumble. And loud. Properly obnoxiously loud.
Much louder than I remember my Staintunes being. Reckon I'm gonna need baffles for my own sanity let alone to avoid the plod.
Pics coming later.
Have a great weekend all.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Dec 16, 2009 12:58:07 GMT 10
Filled the holes and gave it a polish, then hit it with a couple coats of ceramic based exhaust paint. And also put the mounting tab on to have the Reg/Rec under the tail as mentioned before. With the number plate on it won't be able to be seen, and the hugger should prevent a lot of shite getting stuck on it. Now to the ever so time consuming task of surface prep, paint and so on. Oh and I'm doing the Top Cowl again too. Gonna do a proper jobbie using Fiberglass and so on. You know - because I like to do things the hard way!
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Post by binny on Dec 16, 2009 20:59:47 GMT 10
Nice work cheeky. Sounds like your getting there. Can't wait to see the finished product.
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shayne
Omnipresent
1998 Blueprint
Posts: 8,639
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Post by shayne on Dec 17, 2009 21:20:57 GMT 10
Looks a lot better with some paint on it mate. Came up pretty good I reckon.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Dec 25, 2009 9:20:05 GMT 10
Been thinking about the exhaust. It's going to need restrictors of some sort - mostly to keep the noise at a bearable level, but also to provide some back pressure as I don't want to sacrifice low end ride-ability. However, i happen to like the great gapping holes at the end of the cans, and reckon some of the impact of the design will be diminished by a pair of db killers hanging out the end. So I'm after some thoughts on how to get the best of both worlds. Can I 'bury' the restrictors half way down the cans and still get some noise reduction and keep low-end power? Or can i put a single restrictor in the second part of the new system - see pic . . . . What potential problems/challenges am I going to see with either of these routes? Will one provide better potential low-end power or easier tunability from the current state? Will having the restrictor further in the pipe rather than in the cans cause any issues? Anything I have missed? Anyway it's Christmas day, so I hope you all have a great one and look forward to 'chatting' in the New Year.
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shayne
Omnipresent
1998 Blueprint
Posts: 8,639
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Post by shayne on Dec 25, 2009 10:19:23 GMT 10
This is a tricky one I reckon.
First up I reckon that your design will most probably provide enough back pressure anyway, as it goes to a single pipe in the middle. Exhaust design is tricky, as the timing of the pulses needs to be precise. Pipe length and collector design and position are very important. So whether your design will work ok or not is impossible to predict. But I would think it would not need further restriction.
As for baffling, the best type is where the gas flow is not restricted, just like a normal race type muffler which most aftermarket bike mufflers are. I think adding a restricter is not such a good idea with your single pipe set-up as it may reduce gas flow too much.
I would try it out first and see how it is. If it is too loud then you could look at the muffler internals to perhaps improve the sound deadening.
Are you wrapping them in ceramic tape too? That will cut noise quite a lot, more than you may expect.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Dec 25, 2009 15:17:20 GMT 10
I will be wrapping the second part of the exhaust - from just before the arrow above right through to the clamps at the cans. Glad to hear that will cut some noise . . . . it might be enough.
I am hoping that by keeping the original header length to the single pipe I have been able to match the pulses pretty well, though that remains to be seen.
I think waiting to see how it sounds real world rather than in the garage is a good idea.
Will keep you all posted.
Thanks Shayne :-)
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Jan 3, 2010 15:00:53 GMT 10
Have been working my tail off on this project as have had a few days off. But both the Card Reader and the sync cable for my camera died at the same time so all my pics are stuck in the camera. Bastard!!
Anyway hope to have the paint finished this week and then final assembly by the weekend - if this friggin' rain would just bugger off and leave me alone :-)
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Post by Von Nudenut on Jan 3, 2010 16:04:32 GMT 10
Looking good cheeky, hope you get the paint on soon! I know what you mean about the rain. I was in the surf at Nth Gong yesdy when it started pelting down. I was making jokes with my young bloke about getting wet in the rain, not realising that we had left all the windows at home open! Laptop get drenched, but fired it up today and here I am, phew!!
Russ
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Jan 4, 2010 17:41:20 GMT 10
As promised here is the long over due update. Got the Card Reader to work this arvo. Whilst this is not the order things happened as I was working on all aspects at once so to speak, here is a run down on what I have achieved in the past week or so; Tidied up the exhaust. First I wrapped it (with some help from my brother); Then I Painted the wrap as the white was getting dirty just being looked at and I didn't like it that much; Then I cleaned up the cans and painted them with the same High Temp Paint; The little Stainless Bolts set it off nice I think. The Top cowl has been the most work of any single component I reckon. Not only was it my first real Fibreglassing job, but the weather played havoc with curing times. Started with a model to see what I thought I'd like; Then I carved up some Surfboard foam; The foam was supposed to be glassed straight over and then 'melted' out with some sort of thinners.. Buggered if I could find anything that would eat it, so I had to make it in pieces (5 all up) and then join them up. There's plenty of glass in it so it is a bit heavy. You will see bits of Aluminum Foil here and there. This was what I used to stop it sticking to the foam, but not all of it would peel off. Initially it was to be hinged and flip up, hence the large groove on the front edge to accommodate the back of the seat. This was ugly and presented itself as an unnecessary complication, so I ditched the idea and now it just wedges under the seat. Here is the original base that allows for hinge placement; Hinges were from kitchen cabinets as they had a motion that pulled the cowl up and away from the seat. Here is the top part as original design; Top of the completed cowl - note the steps to allow for fitment under the seat; Here is the base - note the block to locate it between the frame rails; Here is the completed item in spray putty - bugger of a job to get it smooth; Here is the catch for the latch; Here is the catch in place before glassing up; The hole allows for the Bolt that holds the latch in place and also is the mounting point for the little spring the makes the cowl 'pop' up when released. Everything has had a coat of Matt Black as a base coat, with the proper body colour going over that after a sand to smooth. This gives me a chance to see any imperfections in the surface before I use the good paint and also to mock up parts proper as needed. Like the rear hugger; And lastly the swingarm after 2 coats of Satin Black; All things going well, final assembly will happen this coming weekend. I think I've got everything sorted . . . . but we shall see :-P
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Jan 4, 2010 18:15:42 GMT 10
I also did some work on the subframe. Used some bog to smooth out the edges and so on. It's come up better than if I'd left it raw.
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buckets
Senior Member
2001 - Red
Posts: 376
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Post by buckets on Jan 4, 2010 19:55:32 GMT 10
All the effort seems to be paying off. Well done and very ballsy!!
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Post by vtrfighter on Jan 4, 2010 20:52:07 GMT 10
Very well done mate!!!
and don't forget to call me if you need a second pair of hands for the reassembly.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Jan 4, 2010 22:01:55 GMT 10
Very well done mate!!! and don't forget to call me if you need a second pair of hands for the reassembly. Definitely.
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Sammy
Honourable Member
Black S3
Posts: 739
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Post by Sammy on Jan 5, 2010 9:05:58 GMT 10
Awesome effort
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shayne
Omnipresent
1998 Blueprint
Posts: 8,639
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Post by shayne on Jan 6, 2010 9:07:45 GMT 10
Coming along pretty nicely now mate. Gotta love hand made parts.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Jan 7, 2010 17:33:40 GMT 10
Thanks guys.
Put the clear Top Coat on today. Must've been a big temp drop in between 2nd and 3rd coats as it is all cloudy. Pretty bummed about that.
If I am lucky 1200 grit Wet'n'Dry will cut it out and if I'm not lucky I'll have to respray colour and and clear. Respray is not necessarily a bad thing as the paint I had mixed up doesn't have the little mica/flec in it that the original paint has - dopey bugger at the paint shop 'couldn't see it'.
Oh well, assembly still goes ahead on Sat, as all the bits I am having to fix are not necessary for the build.
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Post by vtrfighter on Jan 7, 2010 18:09:47 GMT 10
2 more sleeps ;D
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Jan 9, 2010 19:03:54 GMT 10
Evening all. I stuffed - been a big day, spent 10 hours working on the bike, but it is pretty much done, including an oil and filter change. Just gotta cut and polish the paint I did to get it nice and shiny - be about 2 hours - and then for the photo shoot.
To be honest I am a bit disappointed in the paint, but the rest came up great, even the wiring seemed to work well (except a glitch with an earth cable not working) and there is more space in the back cavity than I had anticipated.
It sounds really good and I think the exhaust wrap has softened it a bit, but will give more in-depth feedback tomorrow when I take it for a long ride.
Heat doesn't seem to be an issue. I started it and left it idling (with the odd rev once warm to check out the noise :-) ) to bake the exhaust paint and see how good the warp really is. Could just hold onto it after the paint had stopped smoking, and there was no change in temp inside the cavity between the cans.
That is all for now - bigger update tomorrow.
My beer is going down very well at the moment . . .
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Post by vtrfighter on Jan 9, 2010 20:42:04 GMT 10
Evening all. I stuffed - been a big day, spent 10 hours working on the bike, but it is pretty much done, including an oil and filter change. Just gotta cut and polish the paint I did to get it nice and shiny - be about 2 hours - and then for the photo shoot. To be honest I am a bit disappointed in the paint, but the rest came up great, even the wiring seemed to work well (except a glitch with an earth cable not working) and there is more space in the back cavity than I had anticipated. It sounds really good and I think the exhaust wrap has softened it a bit, but will give more in-depth feedback tomorrow when I take it for a long ride. Heat doesn't seem to be an issue. I started it and left it idling (with the odd rev once warm to check out the noise :-) ) to bake the exhaust paint and see how good the warp really is. Could just hold onto it after the paint had stopped smoking, and there was no change in temp inside the cavity between the cans. That is all for now - bigger update tomorrow. My beer is going down very well at the moment . . . Really sorry Matt i didnt make it down to help, DAMN CARS! got about 40 mins into it and the temp hit red hot!!!!! pulled over, popped bonnet to see tank on radiator split on passenger side from top to bottom long story short $300ish and it was fixed. Just glad it happened close to home. Cant wait to see the pics mate...
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shayne
Omnipresent
1998 Blueprint
Posts: 8,639
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Post by shayne on Jan 10, 2010 10:50:42 GMT 10
Think on the positive side with the paint - just focus on all the other work you did yourself. If ultimately you need to pay a pro to do the job how you want you will still be a very long way in front.
I painted a lot of small parts on my bike, but when it came to the fairing I new my skill was not good enough, and that I would not be happy with it. So I had it done professionally.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Jan 10, 2010 14:22:23 GMT 10
Think on the positive side with the paint - just focus on all the other work you did yourself. If ultimately you need to pay a pro to do the job how you want you will still be a very long way in front. I painted a lot of small parts on my bike, but when it came to the fairing I new my skill was not good enough, and that I would not be happy with it. So I had it done professionally. Yep am considering getting it all tidied up professionally when I have it 'finished'. Either that or going to TAFE and doing a course. I have the gear (Air Compressor and a Gun), just no friggin' idea how to get it all set up properly. Either way I can get the prep done okay it's just the painting . . . Really sorry Matt i didnt make it down to help, DAMN CARS! got about 40 mins into it and the temp hit red hot!!!!! pulled over, popped bonnet to see tank on radiator split on passenger side from top to bottom long story short $300ish and it was fixed. Just glad it happened close to home. Cant wait to see the pics mate... No worries mate - was a bummer, but I wasn't stressed. The case of beer will keep me 'quenched' for a while anyway ;D I took some photo's this morning, but the bloody card reader is still buggered and I've not bought a new one. Ordered one on eBay for $3 inc delivery (save $40 etc) just gotta wait for it to come from Hong Kong. Beats me how that and the patch cable for the camera died at the same time. Anyway, it sounds great - has a nice bark, but is not too loud. Will still need ear plugs when doing long trips. No apparent issues with heat - inside of my leg notices the proximity of the pipes when stationary, but otherwise is fine. When I finally get pics up you will see that I have the Rego Label on the LHS side. it was originally closer to the pipe and got a bit 'soft' so I moved it. Has a 6mm shock spacer in it too and I reckon it handles heaps better. That and the changed seat position make the riding position much more aggressive. My wife asked me if I was happy, because that's the sort of question women ask. I replied 'About what?' to make sure it wasn't a trick question (oh and because I'm a smart ar$3). Truth is I am pretty happy over all, but there are some things that I will be 'fixing'. Oh and I fitted the HID this AM too. Not too difficult and it looks the goods - just need to test it out at night. A friend of mine is playing at the Excelsior (Glebe) on Friday 15th at 8:30pm so I might shoot up for that. Hopefully pics soon.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Jan 10, 2010 14:51:08 GMT 10
Guess who feels like a bit of a knob. We had a spare Card Reader in my wife's Laptop Bag. But the good news is that pics are now here . . . . Note the OZFirestorm sticker . . . . Hope you like . . . .
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Post by vtrfighter on Jan 10, 2010 15:56:01 GMT 10
Mate, that looks great well done! im still bummed i wasn't there to witness this miracle unfold...
Great work Matt!!!!!
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Jan 10, 2010 16:07:31 GMT 10
Mate, that looks great well done! im still bummed i wasn't there to witness this miracle unfold... You would have also seen all the 'warts' so to speak - this way there is a little mystery Besides there is always next time . . . . Yep, I have plans for another make over already. Just not right now - gotta get this one right first.
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Post by vtrfighter on Jan 10, 2010 16:14:04 GMT 10
Yep, I have plans for another make over already. Just not right now - gotta get this one right first. OOOOOOH DO TELL!!!!
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Jan 10, 2010 16:20:53 GMT 10
Yep, I have plans for another make over already. Just not right now - gotta get this one right first. OOOOOOH DO TELL!!!! Mmmmmm no. ;D Not yet . . . . . in time, need to get the design 100% sorted first.
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Post by vtrfighter on Jan 10, 2010 17:09:12 GMT 10
not even a little hint? at least tell us where its going to take place?
Engine? Swinger? Front end? Frame?
C'moooooooooooon...
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Jan 10, 2010 17:33:16 GMT 10
Lets just say the following will remain untouched (aside from paint);
Main Frame Swinger Engine Wheels Forks
Everything else gets 'fixed' . . . .
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