3XV Big Off rebuild

[yanw]

OK, so I may have some time to do some bits and pieces (famous last words).

A few questions:
1) Does anyone know if the SPR cast iron flanges will fit R/RS barrels?
2) If #1 is "they won't" has anyone got any advice on making some stubs up? Should I try local engineers?  I need pipe that is 33.5mm ID 45mm OD, ideally so I can turn some O-ring grooves in one end and weld (?) some flat plate to the other.

Dan Gecko has some cast iron stubs or I could get some made up. Does anyone else have any for sale or just to borrow to measure up? I'm more than happy to pay postage to/from.

I've had no joy selling those lovely SPR pipes so I'm having to look at making them fit my RS 

[ybk]

I doubt the cast iron flanges will fit the RS cylinder, especially the exhaust shape on the cylinder side. An engineering place may be able to help remake them in alloy if you give them the cast iron one and a cylinder to match? That's similar to what I did to get R flanges made to fit SP pipes..

Are you firm on your price for them? I'm casually looking for SPR pipes but around the price these SPR jackals sold for on yahoo..

http://page18.auctions.yahoo.co.jp/jp/auction/w112784027

[yanw]

Are you firm on your price for them? I'm casually looking for SPR pipes but around the price these SPR jackals sold for on yahoo.

I'll PM you, save talking dirty in public....

[yanw]

OK, so I think the SPR cast iron headers are a no-no due to the stud spacing exhaust shape.

I've got a mate who has a mate with a plasma cutter. The guy I know has a lathe, vertical and horizontal milling machines and can braze as well so after some discussions we think we can fabricate some headers for the Jackal pipes I have.

Over the Christmas break I've been doing some more measurements and made up a "first trial" mock header to check fit:
.

My measurements make the two 8mm stud holes 78mm between the centres with the centre line of the exhaust port 37mm one side and 41mm the other. The centre of the exhaust port is 7mm from the line between the stud centres. The R/RS exhaust port has a 33.5mm internal diameter.

I think I will have to angle the pipe out of the header flat plate (probably 5mm sheet steel (??)) to clear the barrel and match to the expansion chambers a bit better.

Has anyone else made up R/RS exhaust headers and got any measurements to hand? Any suggestions for the design/methodology would be gratefully received.

[Paul]

Shame Yan. A lot of faffing about but you're getting there.

[Yuri]

Is it not easier to buy this ?
http://www.geckomotorcycles.co.uk/magento/parts-yamaha/yamaha-tzr250-3xv-dfr-exhaust-collars.html

[yanw]

Is it not easier to buy this ?
http://www.geckomotorcycles.co.uk/magento/parts-yamaha/yamaha-tzr250-3xv-dfr-exhaust-collars.html

Unfortunately not Yuri. The pipes are for the later SPR and are too short for the R/RS. Also the stud spacing is different. My headers need to be about 90mm long off the face of the barrel. Hence the poly-pipe in the picture 

[Neal]

Sorry for the late response , I have a spr flange that you can borrow for measurements if needed or I can try measure them for you , pic to follow in a short while ..

[Yuri]

I have a set of sugo's for the SPR with flanges for the 93/94 SP if you like measurements

[yanw]

Thanks for the offers of the SP/SPR flanges. It might be good for me to understand what sort of angles the internal "tubes" have so I can mimic them however I think the SP/SPR stud spacings are different to the R/RS.

I have measured off the R/RS barrels and the R/RS exhausts both with a set of vernier calipers and using the "gasket paper and hammer" method.

In short (if you forgive the pun) I am trying to mate R/RS barrels to the "short" late SPR pipes I have. I need a flange that matches the R/RS "off center (times two)" stud spacing with a length of exhaust pipe to meet up with the shorter late SPR expansion chambers.

Ideally I should sell these pipes and get some R/RS ones however that would leave me £400+ out of pocket. I'm hoping that this will be a cheaper option....

[Neal]

In my humble opinion , if I was hotting up my bike I would get custom pipes designed for my motor instead of sugo pipes . Guys like Kenny for example have proved their designs a few times . Of cos there are many pipe builders but their names skip me ATM .
Where I am I can't find anyone in my state that wants my money for custom work I want done I have to try elsewhere 

[Yuri]

I got the corect sugo pipes for my SP so Edd are going to buy the SPR sugo pipes from me . Edd will install the pipes on a R model mybe you can ask him to make you sum ?

[yanw]

Dan Maccas has very kindly given me some Martin77 R/RS flanges to use on my "header project". I've managed to MIG some washers on them as Dan had slotted them to go on an SP. I've been looking at tube and offsets to connect them to the pipes but I need to do more measuring at the weekend.

I've given up on GRP bodywork, bitten the bullet and got some Chinese ABS ones. I say "got" but this is me. Paid 16/02 (eBay), chased why they still hadn't shipped 24/02, got this reply 25/02:

Hi,
Thank you for your purchase fairing from our shop.

Normally the fairing needs about 10 working days to finish, but because the Chinese New Year is coming, during the New Year holiday, factory workers did not work a long time.

So the fairing needs to wait till Mar-5 that it can be start to do. Can you wait for it?
Sorry about this matter bring to you, hope you understand. As your request, we will back to work as soon as possible. Please at ease !!!

Happy New Year

Looks like they paint to order, and the painters have all gone home. Is it me or is it taking the p155 just a little to take an order and then say it's going to take 17 days (plus 14 to do the work??) to get them painted before we ship them?

[jools]

Just read this Yanw

I have some stainless headers that were made up a while back for the R/RS cylinders, that will take a TZ pipe internally.

I came across them the other day, if they are any use ?

[yanw]

Thanks Jools, i will get back to you after the weekend.