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Guzzi 1100 custom build

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    Posted: 24 Jan 2023 at 10:05
Apart from a polish the exhaust is welded up and finished. I didn’t want to have distortion and burn through when attaching the baffles, so for these I used TIG braze which worked quite well.

The slip joints are held together with springs and to hold these I needed to make some spring hoops. These are actual quite difficult to make to get the bend just right and to a consistent shape. I made a little jig to make these.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 22 Jan 2023 at 16:33
Originally posted by Samz101 Samz101 wrote:

 I’m another in agreement about your engineering skills, but the thing that makes me most envious is I presume you have some kinda heating in your garage/workshop/shed?  I darn’t enter mine for fear of  frostbite at this time of year! 
  Enjoying the thread, keep it going.  Thanks.

yes, the garage is centrally heated, so its quite warm, although of late its been turned down  to a level to just keep the chill off.  dam energy prices!   the workshop at the side has no heating but is warmed to a degree by the garage...
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Samz101 Quote  Post ReplyReply Direct Link To This Post Posted: 22 Jan 2023 at 14:39
 I’m another in agreement about your engineering skills, but the thing that makes me most envious is I presume you have some kinda heating in your garage/workshop/shed?  I darn’t enter mine for fear of  frostbite at this time of year! 
  Enjoying the thread, keep it going.  Thanks.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 21 Jan 2023 at 10:01
Originally posted by krglorioso krglorioso wrote:

Full agreement with what Andy said; your skill set is incredible. Also incredible is the automated machinery available today to make things.

I began as a Velocette dealership mechanic in 1961 outside of New York City.
We made special things then by CAD (cardboard assisted design), where a template for a part was made of shirt cardboard or a cereal box and once that appeared satisfactory the item was made in metal, using a hack saw, a grinding wheel, a belt-driven drill press and a hand file. Small wonder I'm fascinated by the mods for this Guzzi 1100.

Ralph

thanks for the complements guys...  As you will see I have graduated from Cardboard to FAD....  Foam Assisted Design TongueTongue

When i bought the bike it had a QD system on it… while I liked the concept, it was too big and heavy so I sold it on and decided to make an underslung exhaust of my own design. I wanted smaller and much lighter. I started with a mock-up of builders foam to get the shape and angles, and then moddled this in 3D. I did do a basic model on my iPad, but then found I had to pay to output it to a file! really frustrating! so I got my mate to do it and then had all the individual parts laser cut.

The baffle plates have staggered holes, which should quieten it down somewhat, but if not, I have a backup plan! Who knows if this will kill any performance? if I lose a few BHP so be it… but you never know!

here is a 1 min video of the process 







Edited by Buzzer - 21 Jan 2023 at 10:21
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jan 2023 at 22:27
Originally posted by krglorioso krglorioso wrote:


We made special things then by CAD (cardboard assisted design), where a template for a part was made of shirt cardboard or a cereal box and once that appeared satisfactory the item was made in metal, using a hack saw, a grinding wheel, a belt-driven drill press and a hand file.

Yes, I've done a bit of that in my time, but only using hand tools. Results were "interesting". LOL
Brian.

Better 5 minutes late in this world than years early in the next.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote krglorioso Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jan 2023 at 18:59
Full agreement with what Andy said; your skill set is incredible. Also incredible is the automated machinery available today to make things.

I began as a Velocette dealership mechanic in 1961 outside of New York City.
We made special things then by CAD (cardboard assisted design), where a template for a part was made of shirt cardboard or a cereal box and once that appeared satisfactory the item was made in metal, using a hack saw, a grinding wheel, a belt-driven drill press and a hand file. Small wonder I'm fascinated by the mods for this Guzzi 1100.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Andyb Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jan 2023 at 18:48
Those brackets look great - as with others here, I am amazed by your skill set and what you can get made.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jan 2023 at 18:38
I picked up the headlight and fuel filter brackets today...  What a fantastic process waterjet cutting is!  They were profile cutting a 150mm thick block of alloy while I was there!  The jury is out on the brackets at the moment, but I am struggling to think of a better design

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Post Options Post Options   Thanks (1) Thanks(1)   Quote johnno Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jan 2023 at 15:47
Wow your goodThumbs Up
1100 sport corsa , Yam R1, guzzi 650tt rider
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jan 2023 at 10:48
To get the tank low, and get rid of the large pump mounting hole I had to cut the bottom out of the tank. easy enough with one of those 1mm cutting disks which I seem to use a lot of these days! I needed to make the infill patch and contour this to fit the hole. to make this easier I profiled it to the right shape by cutting some wood and pressing it to shape in the vice, then a bit of planishing to get it to the final shape. 

The aim is to get the gap as small as possible to facilitate a nice weld. I used some 1mm mild steel plate which matches the thickness of the tank, so TIG welding is no problem on a low amp setting. I used a couple of magnets to position it before adding a few tacks all round. At this point I ran out of Argon...  The last refill I bought was £65..  now its £104!

The outlet is made, but I need the filter fitting on the bike first so I can position it to get the pipe runs neat. Once this is welded on I can leak test.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 12 Jan 2023 at 10:32
I tried for a while to make a seat out of alloy sheet, and failed.  the shape is just to complicated!  in the end I decided on an alloy and glass fibre approach.  I lifted the tank slightly so the finished seat will have some clearance, and then covered it with duct tape, followed by some tin foil to act a a release.  This actually worked quite well!  Cutting the foam to shape took a while and is a dusty job, but with the fan blowing on me and out the door it wasn't too bad.  The key to using resin is the mix ratio...  I used 2.5% as it was a cold day, in the summer that would have gone off in 5 mins!  I will send it to the trimmer to do his magic...  this is one of the few jobs I send out.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 09 Jan 2023 at 08:44
Making the exhaust retaining flange out of 15mm alloy plate was quick and easy… 

As an aside, that tin of marking blue is 50 years old, given to me by my Dad, along with one of my treasured possessions, a 0 – 1″ micrometre when I was 15 years old. Not much left in the tin now, but its still usable. 

The stainless steel collar however took an absolute age to make! I should have really used some stainless pipe, but its an odd size and I couldn’t get any that would fit, so I ended up machining it out of a solid piece of bar stock. I hate working with stainless… everything you do with it makes your life hard, just like the material!

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 07 Jan 2023 at 17:48
Time to start the fabrication of the back end. I decided to use some rose joints as I like the look they bring to a build. Experience has taught me to tack everything up first before welding fully! its going to be a very stubby back end, I have also used three 10mm LED as a stop and tail light. they are amazingly bright




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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 05 Jan 2023 at 09:38
While I love the look of a nice velocity stack they are not really practical for the road, hence while I make them for the photos I take, I like to use foam filters on the road. this of course means I need some suitable adaptors, which although you can buy them are REALLY expensive. these took a while to machine out of billet! I sometimes get asked where I get my material from for the lathe and miller. I am really lucky that there is a scrap yard locally that lets me hunt through the bins! They take scrap in from some of the aerospace companies so there are sometimes some nice bar ends in the skips. What is great about that is the bar ends are often etched with the material specification!

I don’t usually pay as I take my scrap in there and he writes the value in the back of his desk diary, and then as I take stuff, he takes the value off! he has done this for me for over 30 years! A few years ago I went in early in the year… he was no longer there as he had retired and I learned that his grandson had taken the company over. We chatted and I mentioned about the diary as I had a few pounds credit… The lad said he knew all about it and it was in the back of the book!



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Post Options Post Options   Thanks (0) Thanks(0)   Quote BondEquipe Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan 2023 at 15:41
You found an old fashioned breakers with sheds, how quaint!  I didn't think they existed any more.
Stephen
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