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welshlamb
Joined: 09 Mar 2011 Posts: 592 Location: South Wales , Nr. Abergavenny
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Posted: Fri Nov 24, 2023 6:29 pm Post subject: |
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of course it took ages to be delivered. The can diameter is not a standard size so the 'tubes' had to be hand bent and welded. Then of course the end caps (which are 'spun' an a former) had to be custom made and the guy doing that was moving premises.... you get the picture !! After many txts and messages the cans were finally ready to collect.
very nice and clearly lighter than original but not quite as much as you might expect, as the central perforated tube is still steel. The OE twin exhaust and 1-2 section (incl bracket) weighed 3.7kg. The new set up was 2.5kg. However its all part of a plan to shave 20kg off the weight of a standard(full faired) DB2. Also its weight away from the C of G and high up.
However a quick mate up to the bike showed a problem. Due to the different bend shape of OE and Ti exhaust 1-2 section, that bit was fouling on the main frame
You can see the difference here with the TI and OE exhaust overlaid on each other
So 1-2 section sent back and a new one made.
_________________ Not as many bikes as I would like and already too many to keep up with! |
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welshlamb
Joined: 09 Mar 2011 Posts: 592 Location: South Wales , Nr. Abergavenny
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Posted: Fri Nov 24, 2023 6:49 pm Post subject: |
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I wanted the exhaust can mounting to be via conventional exhaust clamps and have a factory finish. Of course with the non standard standard can diameter theen standard clamps dont fit either! Quickly solved by sticking a strip of heat resistant silicone rubber inside each clamp.
I then needed something to attach the clamps to and quickly came up with several sketches and tried various cardboard templates, each time trial fitting the seat/tank unit to check fit.
When I thought I had got it right I cut out a metal template (not pretty but all critical dims correct and tried it in place for a final check
[url=https://postimg.cc/bsmV2SVD]
[/url]
satisfied with that I made a final dwg and sent this off to a company that would make it with waterjet cutter EVEN AS A ONE OFF ! at a very reasonable price also doing the bending and hole cutting. (themachine bending meant I could dispense with the 'slots' on my cardboard designs which were only there to ease home bending. Finished product wight is almost the same and now a lot stronger.
I picked up the final pieces in person as I didn't want at this stage anything getting lost in couriers/post! Here it is alongside my metal template.
_________________ Not as many bikes as I would like and already too many to keep up with!
Last edited by welshlamb on Mon Dec 18, 2023 6:17 pm; edited 1 time in total |
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welshlamb
Joined: 09 Mar 2011 Posts: 592 Location: South Wales , Nr. Abergavenny
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Posted: Fri Nov 24, 2023 6:58 pm Post subject: |
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All that remained was to mount on the bike and check no cock ups made ! (Had to go for the Ti fasteners, vanity got the better off me!)
Looking good I think.
Apologies if the preceding posts are a bit long winded but I think its a good example of all the twists and turns involved in making custom parts to fit. _________________ Not as many bikes as I would like and already too many to keep up with! |
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TVRRICH
Joined: 05 Feb 2016 Posts: 211 Location: Coventry UK
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Posted: Mon Nov 27, 2023 8:53 pm Post subject: |
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Looking great Ralph, i bet it will sound better than great |
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hindsight
Joined: 13 Feb 2010 Posts: 126 Location: Central Scotland
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Posted: Tue Nov 28, 2023 10:49 am Post subject: |
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Well done - loving it! |
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brian
Joined: 22 Aug 2011 Posts: 3769 Location: Australia
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Posted: Thu Dec 14, 2023 2:23 am Post subject: |
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Looking fantastic Ralph! The cardboard templates are a good idea… easy to make and modify as you go.
I must say… your 50kg weight loss target is significant. The Ti exhaust, Ti bolts and ally brackets will certainly help with it. I guess there will be a good weight saving in the half fairing as well.
A few years ago I slashed 50kgs off a ZXR750, but it was quite easy as I was building a race bike. A road bike is a lot more difficult to shave that kind of weight as you still need to keep all the heavy electrics etc. materials like carbon fibre and titanium get expensive, especially for custom or one off parts. _________________ '99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851 |
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rib333
Joined: 14 Aug 2022 Posts: 1 Location: New York USA
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Posted: Thu Dec 14, 2023 4:52 am Post subject: |
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Any chance the maker of the exhaust would be willing to make another one, identical to your final version? |
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welshlamb
Joined: 09 Mar 2011 Posts: 592 Location: South Wales , Nr. Abergavenny
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Posted: Mon Dec 18, 2023 6:01 pm Post subject: |
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brian wrote: |
I must say… your 50kg weight loss target is significant. The Ti exhaust, Ti bolts and ally brackets will certainly help with it. I guess there will be a good weight saving in the half fairing as well. |
Shite! where did I say 50kg loss? If I did it's a typo! My ideal was 'sub150kg' These were the project objectives at the start
Targets 150, 90, 0.600 (kg- RWHP, hp/kg)
Standard 169, 73, 0.432
I keep a spreadsheet of all items taken off/replaced and their weights and as it stands Im looking at about 21kg saving . I didn't get a chance to measure the standard bike's weight or indeed HP ('Hindsight' can you verify the Owners Handbook weight of 169kg? (wet?, semi-wet? dry?)) Based on these weights and 90 RWHP after tuning then outcome should be
148kg, 90RWHP, 0.607 hp/kg
Power to weight improvement 39%
Engine spec is lightened flywheel and clutch, JE high comp pistons, significantly reworked head ports and SSie cams (almost same as ST2 which are rocking horse pooh!) all finished off with Keihin FCR39s and that much more free flowing exhaust. I will be disappointed if I can't get the 90RWHP when its dyno'd.
I can't believe how I've let this one slip over the last year so planning to get back out in the garage over Christmas/New Year and get serious with this .
I'm getting too old to waste time !!! _________________ Not as many bikes as I would like and already too many to keep up with! |
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welshlamb
Joined: 09 Mar 2011 Posts: 592 Location: South Wales , Nr. Abergavenny
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Posted: Mon Dec 18, 2023 6:14 pm Post subject: |
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rib333 wrote: |
Any chance the maker of the exhaust would be willing to make another one, identical to your final version? |
I can't answer for him but I know he had to get special parts made and he is usually flat out on British and European race superbikes and the like.
He didn't make a jig for these as not worth it for a one off. He would need another set of exhausts to use as a master
In short I would say 'very unlikely' Are there no suitable fabricators your side of the pond? _________________ Not as many bikes as I would like and already too many to keep up with! |
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brian
Joined: 22 Aug 2011 Posts: 3769 Location: Australia
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Posted: Wed Dec 20, 2023 11:57 pm Post subject: |
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welshlamb wrote: |
brian wrote: |
I must say… your 50kg weight loss target is significant. The Ti exhaust, Ti bolts and ally brackets will certainly help with it. I guess there will be a good weight saving in the half fairing as well. |
Shite! where did I say 50kg loss? If I did it's a typo! My ideal was 'sub150kg' These were the project objectives at the start
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HaHa, oops, that was a typo on my part. I meant to type 20kg as you said in an earlier post. 20kg is a significant weight saving on a 160kg bike! _________________ '99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851 |
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brian
Joined: 22 Aug 2011 Posts: 3769 Location: Australia
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Posted: Thu Dec 21, 2023 12:02 am Post subject: |
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welshlamb wrote: |
Targets 150, 90, 0.600 (kg- RWHP, hp/kg)
Standard 169, 73, 0.432
I keep a spreadsheet of all items taken off/replaced and their weights and as it stands Im looking at about 21kg saving . I didn't get a chance to measure the standard bike's weight or indeed HP ('Hindsight' can you verify the Owners Handbook weight of 169kg? (wet?, semi-wet? dry?)) Based on these weights and 90 RWHP after tuning then outcome should be
148kg, 90RWHP, 0.607 hp/kg
Power to weight improvement 39%
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A really good real world improvement to the bike. Good numbers. _________________ '99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851 |
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brian
Joined: 22 Aug 2011 Posts: 3769 Location: Australia
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Posted: Thu Dec 21, 2023 12:04 am Post subject: |
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welshlamb wrote: |
I didn't get a chance to measure the standard bike's weight or indeed HP ('Hindsight' can you verify the Owners Handbook weight of 169kg? (wet?, semi-wet? dry?)) |
Information that I've seen for the DB2 is a DRY weight of 168 kgs. From memory the DB2 Junior was a few kgs lighter. _________________ '99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851 |
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welshlamb
Joined: 09 Mar 2011 Posts: 592 Location: South Wales , Nr. Abergavenny
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Posted: Thu Dec 21, 2023 6:21 pm Post subject: |
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Yay, don’t need trip to the doctors just yet re typo!
Would also help if i could loose 5kg. After I stopped work i dropped 10 kg in 2 years... no working away, hotel meals or entertaining customers. Pretty much stayed the same since + or - a kilo or two. I like my food (and drink too much). Only problem with loosing wight is a load of clothes don’t noir anymore! _________________ Not as many bikes as I would like and already too many to keep up with! |
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brian
Joined: 22 Aug 2011 Posts: 3769 Location: Australia
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Posted: Fri Dec 22, 2023 4:40 am Post subject: |
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Yeah I'm hearing you. The older one get, the harder it is to stay fit! _________________ '99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851 |
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