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PostPosted: Mon Oct 21, 2013 2:06 am 
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Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca
Ok heres the pipe before


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PostPosted: Mon Oct 21, 2013 2:07 am 
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Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca
Heres a good look of where its cut


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PostPosted: Mon Oct 21, 2013 2:16 am 
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Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca
I cut the one section after the u turn and turned it 180 degrees and hammer shaped both side to make sure it was perfect before I tacked it together then at the y-pipe connector I cut a 3/8 inch pie shape piece out then welded it back together to get the pipe to angle down more from the y-pipe. I then cut two 1/4 inch pie shapes up by the silencer mount side to get the pipe to level out after the clutch. Now since I changed the volume of the pipe by removing 7/8 of an inch of material from the main pipe I needed to add it somewhere to keep the correct tune. So since the y-pipe is going straight out of the head I added a 7/8 pie shape piece to the y-pipe. I cut the y-pipe and the flange only 3/4s of the wat and bent it down to make sure it cleared the starter and it was perfect I went and got some tubing and made to pieces and shaped them to fit and welded it all up. Then I bolted it all it and hung the pipe with the silencer and made the mount to mount the pipe to the frame like a power pros pipe. Basically the same mount style


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PostPosted: Mon Oct 21, 2013 9:54 am 
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Joined: Tue Aug 07, 2012 11:34 pm
Posts: 219
Thank you very much sir! Going to start tearing the sled apart soon. Just did the top end and all seals on the rotax: 183psi compression on both holes seems like a good start !


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PostPosted: Mon Oct 21, 2013 11:12 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Brittabrat wrote:
Thank you very much sir! Going to start tearing the sled apart soon. Just did the top end and all seals on the rotax: 183psi compression on both holes seems like a good start !


You checked the compression with the intake carbs exhaust installed?

183 psi sounds high you should check with the sled guys on that you might have high altitude domes or head installed the former owner might have used that Engine above 6000' if its 183 psi ready to run you will need to run race gas in it.


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PostPosted: Mon Oct 21, 2013 11:32 am 
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Joined: Tue Aug 07, 2012 11:34 pm
Posts: 219
Yeah it's 183psi in each cylinder with everything installed. I'll check back on the skidoo forums. Nobody said anything about race gas?


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PostPosted: Mon Oct 21, 2013 11:38 am 
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Joined: Sun Dec 24, 2006 5:58 pm
Posts: 2319
Location: near NJ rider
That's cool Russ, that'll make the header much easier to fab.

I would love to help on the CNC parts but my machine is not very accessible right now due to my garage falling down around it! Parts are very easy to make, you shouldn't have any problem.

No more phazer talk until you start a new thread.


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PostPosted: Mon Oct 21, 2013 12:47 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
shoubadaba wrote:
I cut the one section after the u turn and turned it 180 degrees and hammer shaped both side to make sure it was perfect before I tacked it together then at the y-pipe connector I cut a 3/8 inch pie shape piece out then welded it back together to get the pipe to angle down more from the y-pipe. I then cut two 1/4 inch pie shapes up by the silencer mount side to get the pipe to level out after the clutch. Now since I changed the volume of the pipe by removing 7/8 of an inch of material from the main pipe I needed to add it somewhere to keep the correct tune. So since the y-pipe is going straight out of the head I added a 7/8 pie shape piece to the y-pipe. I cut the y-pipe and the flange only 3/4s of the wat and bent it down to make sure it cleared the starter and it was perfect I went and got some tubing and made to pieces and shaped them to fit and welded it all up. Then I bolted it all it and hung the pipe with the silencer and made the mount to mount the pipe to the frame like a power pros pipe. Basically the same mount style


Pipe looks great, gas tank looks like a good fit also bet you guys cant wait to test drive :-)

What are the plans for the air box filter setup?

That is a after market civic radiator?


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PostPosted: Mon Oct 21, 2013 2:11 pm 
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Joined: Mon Jan 16, 2012 8:56 pm
Posts: 550
Real nice job Rusty, it was great hanging out the other day


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PostPosted: Mon Oct 21, 2013 2:57 pm 
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Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca
The radiator is an aftermarket civic radiator that is a 2 row it should cool it well. As for the airbox setup jordan is gonna go get a uni filter with an outerware for now that will be the prefilter. Im gonna make a filter inside the stock watercraft box that will go inplace of the flame arrestor with the stock housing with uni foam sandwiched between.


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PostPosted: Mon Oct 21, 2013 3:16 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
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Location: Chicago
shoubadaba wrote:
The radiator is an aftermarket civic radiator that is a 2 row it should cool it well. As for the airbox setup jordan is gonna go get a uni filter with an outerware for now that will be the prefilter. Im gonna make a filter inside the stock watercraft box that will go inplace of the flame arrestor with the stock housing with uni foam sandwiched between.


Looks good that's the route I was going to take if I went dual carbs, put a oiled foam filter inside the box thing then hook a over sized prefilter on the outside of the box or run a tube to a prefilter but I am still using the single carb and my old modified Pilot air box.


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PostPosted: Mon Oct 21, 2013 4:00 pm 
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Joined: Thu Apr 29, 2010 12:53 am
Posts: 1430
Location: Norco, CA
Rusty,
don't you need a stinger section between the chamber and silencer or does it have a reverse stinger?


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PostPosted: Mon Oct 21, 2013 8:15 pm 
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Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca
A stinger section? I don't know what you mean


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PostPosted: Mon Oct 21, 2013 8:50 pm 
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Joined: Thu Apr 29, 2010 12:53 am
Posts: 1430
Location: Norco, CA
you have the head pipe, divergent cone which expands the gasses, straight section, Don't recall the terminology, and the convergent cone which reflects the wave back to the piston, the stinger is at the end of the divergent cone and on a modern machine, well probably '80s on, is not taking into account the length of the silencer, don't know why that is either?
the 2 formulas I have seen for the stinger length in 12 times the convergent outlet, the other is the same length as the convergent cone. it is part of the tuned length of the pipe and a lot of it is for getting the pressure correct in the pipe, I have heard if too short you won't get enough heat in the pipe to work right, it has to do with the speed of sound and how that changes with temperature, I think pressure also plays a part of that, if the temperature is not correct then the tuned length will be off. You have to be a rocket scientist which I'm not!
I have read in two stroke tuners handbook and also talked to Don at power pros briefly that the stinger does not have to go out the back, as it is just acting to bleed out the exhaust gas it can actually be reversed and go inside the convergence pipe.
That is what I did on my 500 hybrid quad, I have not had enough time on it to say how well it works and don't have anything to compare it with.
I believe some go karts use the reverse use the reverse stinger


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PostPosted: Tue Oct 22, 2013 1:29 am 
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Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca
Ok so the stinger part your refering to is the the tube between the pipe and the silencer. Now on a pilot or odyssey its onlu 6 inches long but on a birt bike or quad its more like 12 inches long and on a sled i don't believe they even have an inch between the pipe and silencer. On this one there is 3 inches between the pipe and silencer hope it works lol. I think it will be fine as I have had 2 buggies with exhaust close to this and they worked very well. Guess we will find out in 3 days


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PostPosted: Tue Dec 10, 2013 2:41 am 
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Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca
An update on this car. After 2 weekends of Jordan running the 583 he felt it was too slow for his liking and asked me to take it off his hands I much obliged him and am the new owner of this car. Over the past month the 583 Engine and conversion kit has all been sold as a kit and the 500 is back in her. She is now sporting newer plastics and all the foot controls have been removed because I couldnt fit in the car with them in there. All the panels are powdercoated red like the frame and Im wainting on a few items to arrive so I can finally put fire in this 500. Pics will soon follow of her ;)


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PostPosted: Tue Dec 10, 2013 11:43 am 
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Joined: Sun Dec 24, 2006 5:58 pm
Posts: 2319
Location: near NJ rider
Looking forward to seeing it.


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PostPosted: Tue Dec 10, 2013 7:29 pm 
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Joined: Sat Nov 02, 2013 11:17 pm
Posts: 121
Location: temperance mi
Second that. Looks like one badass ride


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PostPosted: Wed Dec 11, 2013 12:22 am 
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Joined: Thu Oct 30, 2008 8:22 pm
Posts: 2641
Location: Rancho Cucamonga, Ca
bullnerd wrote:
Looking forward to seeing it.


Me too. Seeing it in my REAR VIEW MIRROR that is!!!!! LOL!!!


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