New project: XS1100 endurance racer

[DiverRay]

Just called the shop. On a car, the engine will turn 6K RPM, and the Alternator is geared for 2 or 3 times engine speed. That says 12K or 18K RPM with no problem! Should work!

[Mathh]

Just called the shop. On a car, the engine will turn 6K RPM, and the Alternator is geared for 2 or 3 times engine speed. That says 12K or 18K RPM with no problem! Should work!

Wow! that is good news. Thanks a lot!

[kta]

This build is AWESOME!

more more more!!!!

[Mathh]

I have been busy adapting the downpipes. That is a pain in the neck because there is no room to play with and the stainless is only 0.8mm thick. Will be very hard to weld and keep it clean....
Okay first thing is to hack up the Supertrapp collector,before:



after:



Shortened the downpipes on the cylinder side:



Exhaust side now with separate flanges:



test fitting, frame and engine upside down, oilfilter cover must be removable, even with the collector in place:



made the outer downpipe radius as tight as possible, but they still touch the framerails... :

So I am now thinking of modifying the frame after all or figure out if i can turn the outer 2 downpipes inwards without losing height (only one finger room between engine and collector box left) and without having to rebend the downpipes (that will be near impossible I guess).

Thanks to the owner of Sparks Trading here in holland I am now the happy owner of a Dymag magnesium cushdrive, 41 alu sprocket in 520....and yesterday I received my matching front wheel from France (brand new and boxed since 2003):



No weight problem there, less than 3 kilos:

[Mathh]

And another update:
I have some more grey hair now after last week... I shortened all downpipes 1.5 inch so the radius starts immediately after the flange. Because of that I had to widen the
exhaustrings and mounting holes. This Supertrapp collector was a piece of art and extremely accurately built, now a bit less accurate ... jeezz..



I tilted all four downpipes inwards, the outer ones a bit more than the inner ones..





It was a pain in the neck to get the pipes a bit symmetrical viewing from the front, have them run around and over the oil filter cover (must be removable with the exhaust on) ánd let them come together at the bottom (top in the pics).
That coming together did not work that well with pipe #1, that one needs another bend in order to use the old collector again...



Both my welding bottles are empty now, going to do that first now...

[daveyg]

Would you consider fabricating a 4-2-1 design? That would very much simplify your plight (as the right pair of pipes are aligned and touching, and the left pair of pipes are aligned and touching) if you cut another inch and a half or so from the ends (eliminate the outward bends) It appears that it should line up better, and then you could use some 2-1 Y-pipes, starting with inlets that are equal to your pipe's diameter, and an outlet slightly larger, then use a small length of pipe to connect the two sides together, with a slightly larger yet Y-pipe. I had thought of building a design like that for my XJ650, until I realized it would be too long. (My outlet going to my muffler would be farther back than the rear footpeg) But perhaps it would work for your application. Speaking of which, what are you planning on using for a muffler? Or do you plan on using any muffler at all?
See this stock CBR1000RR pipe here That is what I got, and cut up to make my pipes that I abandoned. (still have all the pieces though...)

[Mathh]

Would you consider fabricating a 4-2-1 design? That would very much simplify your plight (as the right pair of pipes are aligned and touching, and the left pair of pipes are aligned and touching) if you cut another inch and a half or so from the ends (eliminate the outward bends) It appears that it should line up better, and then you could use some 2-1 Y-pipes, starting with inlets that are equal to your pipe's diameter, and an outlet slightly larger, then use a small length of pipe to connect the two sides together, with a slightly larger yet Y-pipe. I had thought of building a design like that for my XJ650, until I realized it would be too long. (My outlet going to my muffler would be farther back than the rear footpeg) But perhaps it would work for your application. Speaking of which, what are you planning on using for a muffler? Or do you plan on using any muffler at all?
See this stock CBR1000RR pipe here That is what I got, and cut up to make my pipes that I abandoned. (still have all the pieces though...)

Yeah, I'm considering that as i have a stainless 2009 Blade exhaust at home and some more primary and secondary extractors. Problem is exhaust fabrication is a science in itself. That same science says that with a good 4 -2-1 cylinders #4 and #1 and #2 and #3 should be combined for bikes with a 180 degree design (as our yam). In my case I am combining #1 and #2 and #3 and #4. However the Blade exhaust proves this science different.? This is a nice read : click.
I have to do some more research befor i make a decision. Great thinking Daveyg!

[81xsproject]

The first exhaust we put on my buddies '77 KZ1000 was some one-off, 4-2-1 that we found on eBay. It combined #4-#1 and #3-#2 at the 4 to 2 y's. My buddy didn't like the looks of a black header with chrome muffler, so he dropped the change for a V&H 4-1. There was a noticeable drop in performance. I would LOVE to build a setup like that for my 11.

[petejw]

Im currently running a 4-2-1, (cylinders 1 & 2 are paired as are cylinders 3 & 4) there is a noticable difference with mid range power
compared to a 4 -1, but will lose a cpl of hp at the top end.

[Mathh]

hi pete, looks good. Is it possible to give me some section length measurements? What brand is this?

[Mathh]

Of course, Tranzac Australia

[petejw]

Hey Mathh,
The exhaust is a Tranzac system, i believe they are
situated in Queensland in aus.

The system is currently on the bike and the measurements
are a little rough,
the headers are equal length at 63cm, 3cm are fitted into the Y collector,
from this Y collector to the end Y connector (secondary pipes) is 52cm from cylinders 1 & 2,
and 47cm from cylinders 3 & 4.
then theres a chrome extension fitted prior to the muffler.


sometime down the track id like to cut the end Y pipe and fit a X pipe
and fit 2 mufflers.

Mathh, u going to use a single or dual muffler system?

[Mathh]

Thanks Pete, did you measure the pipes from the inside (radius) or the outside? And what is the diameter of the primary, secondary and final pipe?
I will be building a single muffler system exciting on the right...

[petejw]

Hey Mathh, with the exhaust fitted to the bike,
i took a tape measure from the top of the header pipe
down (outside) hope that makes sense.

header pipes are 38.5mm
secondary pipe 43.3mm
final pipe 51mm
these measurements were done with vernier callipers.

[Mathh]

Thanks Tomorrow I will check what i have lying around..