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Author Topic: XS750 to XS896 big bore  (Read 44813 times)

Offline Bootsey

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Re: XS750 to XS896 big bore
« Reply #290 on: Nov 26, 2017, 18:18:57 »
The bike looks ace, nice work!

Offline der_nanno

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Re: XS750 to XS896 big bore
« Reply #291 on: Nov 29, 2017, 05:08:54 »
Some nice work there! I am toying around with (roughly) the same idea, mainly because the VM36s need better filters than El-Cheapo (Emgo) on the back as they are restricting airflow notably. (Which is good if you're running CV-carbs as the slides don't flutter as much, but I am running classic smoothbore carbs... and just running stacks is not an option as the sidecar is parked outside nearly all the time.)

Cheers,
Greg
Real freedom starts with the freedom of thought.

My Blog:
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My Mule TR1.1 build here on DTT:
http://www.dotheton.com/forum/index.php?topic=75458.0

My Turbo TR1.1 (XV1000) build here on DTT:
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Offline XS750AU

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Re: XS750 to XS896 big bore
« Reply #292 on: Dec 03, 2017, 04:27:33 »
Plan B
Found some 60mm OD ally tube in my material stack. I had a 60mm OD hole saw, that does cut a little over size. The plan being to make up the filter tray out of 1.8mm sheet formed around MDF forming plates with a fare amount of hammer time. Needed to anneal the corners once.
The tubes were cut to length and then bored out to 55.5mm ID and the a small groove cut into the OD to engage with the filter tray. To assemble. I modified my swage tool to expand the ally tube and rivet them into the tray. No welding required and tubes are rock solid.
Now have to make up the foam filter.
Hope that all makes sense.  ;D
« Last Edit: Dec 03, 2017, 04:30:07 by XS750AU »
“Engineering is the art of being approximately right rather than exactly wrong.”

Yamaha XS750-2D
Yamaha XS896
Husaberg FE550
Yamaha TT250
Yamaha IT200N

Offline der_nanno

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Re: XS750 to XS896 big bore
« Reply #293 on: Dec 03, 2017, 04:50:08 »
Let us know how you fared as that looks mighty interestin and please also let us know about the air-filter you're using, I've had a similiar idea, with regards to the airbox, but haven't got round to doing anything about it until now.
« Last Edit: Dec 03, 2017, 04:51:43 by der_nanno »
Real freedom starts with the freedom of thought.

My Blog:
http://greasygreg.blogspot.co.at

My Mule TR1.1 build here on DTT:
http://www.dotheton.com/forum/index.php?topic=75458.0

My Turbo TR1.1 (XV1000) build here on DTT:
http://www.dotheton.com/forum/index.php?topic=72571

My XS Triple Sidecar build here on DTT:
http://www.dotheton.com/forum/index.php?topic=74211

Offline teazer

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Re: XS750 to XS896 big bore
« Reply #294 on: Dec 03, 2017, 16:27:23 »
Nice work,.

Offline XS750AU

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Re: XS750 to XS896 big bore
« Reply #295 on: Dec 04, 2017, 04:57:10 »
Quote
please also let us know about the air-filter you're using
I am using open cell polyurethane as my filter element. Unfortunately the foam I have is bright yellow, which does not look that good. Think I need to get some grey foam. I also have a light expanded metal mesh which I am going to try as a cover/retainer over the filter.
“Engineering is the art of being approximately right rather than exactly wrong.”

Yamaha XS750-2D
Yamaha XS896
Husaberg FE550
Yamaha TT250
Yamaha IT200N

Offline XS750AU

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Re: XS750 to XS896 big bore
« Reply #296 on: Dec 10, 2017, 03:05:51 »
Completely stripped the bike down today. Took me 3 hours. This time I lay the the engine and frame on its side and took the frame off the engine. Don't know why I have not used that method before - hell of a lot easier and no scraping/scratching the frame.
Now I am completing all welds and cleaning it up ready for painting.
“Engineering is the art of being approximately right rather than exactly wrong.”

Yamaha XS750-2D
Yamaha XS896
Husaberg FE550
Yamaha TT250
Yamaha IT200N

Offline stroker crazy

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Re: XS750 to XS896 big bore
« Reply #297 on: Dec 10, 2017, 04:36:31 »
Looking forward to seeing the finished bike!

Crazy
“Ride like the Wind” W.H.

Offline Ryan Stecken

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Re: XS750 to XS896 big bore
« Reply #298 on: Dec 11, 2017, 06:30:56 »
Can´t wait to see it finished!
May I ask you how you made the "tray" with the three holes for the air filter element?
Looks really nice,like a dye press or something,no welds...

Thanks!
« Last Edit: Dec 11, 2017, 06:41:41 by Ryan Stecken »

Offline XS750AU

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Re: XS750 to XS896 big bore
« Reply #299 on: Dec 12, 2017, 23:43:38 »
Quote
May I ask you how you made the "tray" with the three holes for the air filter element
Yes - guess the photos don't show the actual process. Doh!!!
In the photos you can see that I cut the blank out of aluminium sheet with a 20mm perimeter, and clamped it between 2 medium density fibre (19mm MDF) board former patterns. Probably should have annealed the corners first to make the forming easier, but you live and learn!!
Then I clamped the formers and sheet in my 8" vice and used a nylon hammer to start beating the perimeter over onto the former. Moving the part in the vice as needed. The straight sides form easily and can be done without annealing. In the corners there is an excess of material that needs to thicken up and grow out if the corners are going to be smooth. The MDF is a bit too soft to really bash out the corner. So I removed the ally tray from the formers - annealed the corners with a propane torch - and then used some solid 63mm steal round as a former in the vice and a steal hammer to finish the corners.
When the flange is fully formed the flange edge is far from flat due to the corners growing, so I clamped it onto the mill table and cleaned it up to a flat surface.
Final process was to cut the 60mm holes for the carbi inlets. The 3 holes used to clamp the MDF formers together, were at the correct spacing so those holes were used to guide the hole saw in the mill.
All in, including making the former patterns there was about 2hrs work in making the tray and probably 5 hrs for the whole air cleaner as you see it.
The MDF former pattern is pretty much stuffed now, with a steal former pattern it would be much easier and quicker to form the aluminium, but much more work to make the patterns.

Definitely no welds.
Cheers
Tim
« Last Edit: Dec 12, 2017, 23:45:47 by XS750AU »
“Engineering is the art of being approximately right rather than exactly wrong.”

Yamaha XS750-2D
Yamaha XS896
Husaberg FE550
Yamaha TT250
Yamaha IT200N