it's cold outside the blade came off that's what it is i'm i'm blaming everything on the cold today
hi i'm paul brodie we're back in my shop mitch me camera manufacturing fabrication
thank you all for the coffees we appreciate it very much we are back working on the tiger cub
the last time we worked on this cub we did a thread inside the port some people said well
why don't you use the milling machine well the obvious reason why is because i can't
cut a thread in the milling machine this is oversized thread so i want you to see here
this is the standard insert that goes into a tiger cub head can you see how much larger this
one is it's definitely bigger and what i've done is on the stock one it has holes there
well i think the holes make it weaker it definitely interrupts the flow of the exhaust gas
i know small point but so i didn't put any holes in here what i'm going to do is
i left it long we're going to use my favorite strong loctite retaining compound 620 you see
here here the width of the shoulder it's not that big look how big the shoulder is here
so once this goes in with some good loctite it should really hold that's what i'm counting on so
this is installation time our last videos were assembly we did three consecutive videos
on assembling all or building motorcycles so i like doing that but it's great to be back
fabricating making something so what we're doing is
we're going to install the insert and then we're going to make a header pipe out of bits of tubing
and then after it's installed you see i've got a groove there that's where the hacksaw cut goes
sort of like when we did the the shark mounts on the aramaki same kind of principle
you should feel at bottom
see there's a little edge there that's helping me to determine if my filing is flat
because that little mark of machining goes all the way around
if you're wondering why i only have two exhaust studs it's because i only have two exhaust studs
they come in shorter and these are the long ones and i ordered them from england and they have
not showed up yet imagine that but if you have two studs you can hold down a motor a cylinder head so
i got the gasket on this there's the head gasket because you got to maintain the right heights
okay these are the engine bolts that go in and this
made out of stainless steel what i wanted you to see is see how i've mocked the bolts
one two three so that i know where they go because they are three different lengths
so i went one two three that's how i figured out
which bolts go where so this was the mock-up pipe and this went will it still go in there
all right we'll go in there okay so that was the mock-up pipe like that and it used to go in a
little bit farther so it used to go into this mark right there that was where the exhaust spigot was
so that's
basically where this line is drawn so if we
cut it right there then we'll see how this fits okay we'll go to the bandsaw
can you see when they bend a tube that it even though they have a
i think they use the mandrel but it does not stay round at all so what i'm going to
do is i'm going to start to watch where the handle ends up in terms of a clock
so
i'm at 7 30 now okay 7 30. i used to teach this in frame building 101 when we had to
do some ovalization or something like that so there we moved it 10 000
and we still have to go 39 38. so that's where i was last time 7 30. so we're going to go to
i'm calling that 8 30. it's it's not quite at nine o'clock yet
we're out one and a half thousand that's good enough right mitch mitch is nodding
and smiling i know you can't see him but he's nodding and smiling right now
okay and we want this to come down at the same angle as the as the down
tube we're going to call this the down tube and i think it looks pretty good
i just did tiny little tack welds that's all see how the slot is at the bottom
oh yeah so all depending on the angle here that's that's a good match
and when i look down here that also matches as well so i think we're off to a good start
i have my mock-up header pipe and you can see here this is is the straight section and then
there's a curved tube here so i'm gonna i'm gonna hack saw off the tack welds here and
then i'm gonna put this into the cylinder head then i'm going to mark on the frame
are you with me i'm going to mark on the frame where the tube ends and then i'm going
to use the other header pipe that i just welded on put it onto the exhaust manifold
and then if it's too long i'll cut it to the same length as this because i'm trying to replicate
this i know someone else that uses a hacksaw a lot you know that guy
okay so let's see what happens oh there we go
so i put that in there like that
this is very technical can you see how i'm making it level
like that so that's the height of the straight section
line it up that's where i want to cut it right there
what i'm going to do now is i'm going to unhack so this and then i can try this on here
to see how it fits and then when i get the right length and shape i transferred onto here
so that looks pretty good like that handy having a mock-up pipe because otherwise
i don't know how you do it how's this for being scientific
on top of plywood so if i go to three different spots
this will be close enough
that's where that ends but we have to put in a curved piece as well
so we'll figure out how long that curved piece has to be it's not going to be very long at all
see what's important now is to get this at the right angle and if i if i butt that up
against that tube can you see how this is a little higher than that i need to open up this angle here
so that it comes down a bit like that's that's what i want right there
so i put two lines there that's my orientation what the masking tape does it it holds the tubes
are concentric with each other that's the plan and it means that i can
use both hands on my tic tacs so that is the plan
so i've got the masking tape on it now and if i run my fingers around
i can feel if the tubes are out or in line with each other
i like how it flows down it's it's got a good shape to it
and then all we need to do now is to join up this and this and we're going to use i don't know if
i use this it's going to be all out around so i might use the piece from here i'm not sure
we'll figure it out first we'll weld this up and that's that's the last bit to do
okay we are welded so let's go figure out this little bit
okay so we want that to be right about there that looks good
yeah we got lots of room there that looks good what's happening is that it's the pipe here this
header pipe is at a slight angle to this oh this is at a slight angle to this so the largest part
won't be right on the bottom it's going to be back here a little bit i got my vernier this is a real
vernier because it's got the vernier scale on it and i'm going to just see what the space is here
600 thou that's the smallest part
and if i go to the back and measure it i think that's about the widest part
8.75
and then the other side is 600 about something like that i'm pretty sure
the first one is experimental just to see how it fits i doubt that it's going
to fit properly the very first time i just don't think so but you don't know so you try
okay so there's the red mark we're going to cut on this side of the of the blue line tape
so here we go look at that see what happens i can i can rock it back and forth so i need to
take some more off i need to take more off here and then this needs to slide down incrementally
that looks pretty good like that i think what i'm going to do
is i'm going to tack this part of the header pipe onto that
and then make my final adjustments on that last piece there so that goes like that
let's try that
that looks pretty good
okay
there's not a whole lot of space but there's just enough space so it doesn't hit nice i'm
doing a little bit of folly now just to show you this process and then we're going to install
the muffler and i'll do all the final filing later because you don't want to watch all that
so that's basically how the process works you you file down until it all becomes smooth and then
once it's all done and you take some i don't know 180 grit go over the whole pipe scotch brite
looks like a one-piece header muffler what we're gonna do now i had an idea we're gonna
install this it's one piece and i'm gonna see how fast i can put it on the bike because i
used to do things like that and when wins and prizes at trade shows whole other story but
let's see how long it takes to put this on the bike okay
good
one
it is 55 seconds
i don't know i get a lot of joy out of doing stupid stuff like that but anyway well you have
been in my shop watching heather how to so that's great i'm glad you came along for the ride mitch
and i like coffee if you buy us coffees that's much appreciated see you next week take care