OzVMX Forum

Marque Remarks => Suzuki => Topic started by: oldfart on October 15, 2009, 08:35:53 pm

Title: Expansion chamber repairs
Post by: oldfart on October 15, 2009, 08:35:53 pm

Rm 250  1980   chamber that required a new header pipe , white mark on pipe indicates reference point
                    (http://i72.photobucket.com/albums/i180/mutchoo/expansionchamberrepairs001.jpg)
           

Title: Re: Expansion chamber repairs
Post by: oldfart on October 15, 2009, 08:41:48 pm

This image indicates materials reqiured    Musket header pipe ( bought off flea bay for $20-00)
2 inch mandrel 180 u bend   $26-00
First cut is to allow new header to slide up over chamber and show true cut line -
(http://i72.photobucket.com/albums/i180/mutchoo/expansionchamberrepairs002.jpg)

Title: Re: Expansion chamber repairs
Post by: oldfart on October 15, 2009, 08:47:46 pm

Cut new header at  dodgey weld ( 90 degree bend that enters head )    clean up new header with die-grinder ( piece in vice ) internal bore - cut 2 " mandrel bend in half  and shorten long leg, cut off piece near my grubby thumb as you will require this at head manifold
(http://i72.photobucket.com/albums/i180/mutchoo/expansionchamberrepairs003.jpg)

Title: Re: Expansion chamber repairs
Post by: oldfart on October 15, 2009, 08:59:29 pm

trim your mandrel bend and shape it to suit entry at head , and add manifold section  which is welded to 90 degree bend
Tack it all together and remove from bike making sure it can be re-installed with ease
 (http://i72.photobucket.com/albums/i180/mutchoo/expansionchamberrepairs005.jpg)

Title: Re: Expansion chamber repairs
Post by: oldfart on October 15, 2009, 09:05:35 pm

End result .....spring lugs are fence wire ( # 8 wire ) bent into shape
I have made the pipe fit closer to down tube , as front guards tend to bend and burn on pipe

materials just under $50-00      labour   4 hours over 3 nights
Time to post this thread   1 hour  ;D
(http://i72.photobucket.com/albums/i180/mutchoo/expansionchamberrepairs004.jpg)

Title: Re: Expansion chamber repairs
Post by: Lozza on October 15, 2009, 09:14:34 pm

That turned out pretty good Stew  ;D

Title: Re: Expansion chamber repairs
Post by: Rossvickicampbell on October 15, 2009, 09:27:58 pm

actually very good indeed!

Rossco

Title: Re: Expansion chamber repairs
Post by: pmc57 on October 15, 2009, 09:55:22 pm

Stew
I thought I recognised that Musket header pipe and the barrel and head finish, then I saw who was the author of the thread and put tow and two together.
Great job Stew, I know where to come for any pipe repair work from now on.

pmc57

Title: Re: Expansion chamber repairs
Post by: oldfart on October 15, 2009, 10:05:55 pm

product replacement range .... they do sell to public    ( MS  143   used ) as donour
http://www.musket.co.nz/product.asp?brand_id=1&cate_id=2&Submit2=Search&make_id=11&parttype_id=&model=&partNo=&offset=10

Title: Re: Expansion chamber repairs
Post by: DR on October 15, 2009, 11:07:21 pm

Well.. Well.. Well.. and what do we have here eh Stew :P you saw Roger's TS185 with the Plankman header repair and you just had to go 1 better didn't ya! ;) problem is, your's still looks like the stock pipe ::)

Title: Re: Expansion chamber repairs
Post by: bazza on October 17, 2009, 03:09:06 pm

Stu you old duck shooter,nice job.You cant take the Kiwi out of the boy,only a kiwi would use #8 fencing wire

Title: Re: Expansion chamber repairs
Post by: BJJ on October 17, 2009, 03:11:09 pm

Excellent addition to this forum.  Thanks for posting!