500 Two-Stroke Tech

Gary Papesh

Check out a program called "Cone Layout". It was designed for pipe building and is pretty easy to use. You can input the diameters ,length and degrees of angle of either end of the cone. Then you can save the file or save as an dxf. file (drawing exchange format). Then you can send the files to your local sheet metal shop for use on their cnc plasma cutter( Vulcan,Cybermation). Or you can print the profile on paper and cut it with snips. and The program only costs about $40.00 U.S. You can even download a free trial( that's what I did.) Now learning welding seems easy does'nt it! Sincerely, Gary Papesh.
www.pulserate software.com
Very Happy

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The man who dies with the biggest carbon footprint WINS !!!

Blackshaheen · Posted: Mon Nov 12, 2007 1:50 am Post subject:

Nice one Gary.
I hadn't thought to measure up my pipe before I cut it because I'm a Muppet! I still have one uncut upper and I haven't touched the lowers yet so I will measure them up and save the information.
Shaftoflame...you are dead right about cutting the cones. I have started one of the upper pipes and cutting the headers has been no problem due to their small diameter but the fat mid sections have been a bitch like this just to get a clean cut regardless of the angle. I have already stuffed up one cut and have simply butted the pipe back together in the same position Sad

One more weld I didn't need!
I have to come up with a better plan.
Froth, there are no instructions with the pipes and no rules really. They come as a straight pipe (if you just welded them as is) of a particular tuned length. You can cut them to run as you please as long as you take care not to alter the tuned length of the pipe too much (by cutting bits out and then throwing them instead of adding them back into the puzzle) and also that you make sure there are no angles in the pipe that will affect gas flow. I had one angle in my header which put it in the direction I wanted but it was too sharp so I re-cut it and softened the bend as a result for better flow later. I spoke to Dave Swarbrick about the tuned length of the pipe and he said that it isn't an overly 'pipey' or 'short' pipe and that I need not worry about losing a centimeter or so in the over all length. I estimate that this is how much material I will lose as filings when I cut. Obviously the more cuts I make the more material I lose.
I'm struggling a bit right now with cutting and learning as I go but I haven't destroyed them yet...yet.
Pics to follow when I get a bit further.
D.
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I will not tighten bolts after drinking beer, I will not tighten bolts after drinking beer,I will not tighten bolts after drinking beer,I will not...

rd84 · - - - - - Joined: 17 Nov 2005 Posts: 300 Location: UK

Hi,

I've yet to try the technique but I was told that using a large diameter jubilee clip as a cutting guide helps. - I'm going to work on a old set of mild steel pipes for practice later this year - so if you gain any insight into doing your pipes it would be nice to hear about what works well and what doesn't.

Cheers
Paul

Lynton · Joined: 23 Aug 2006 Posts: 43 Location: Bathurst Australia

If you get the Australian "MOTA" 2 stroke software it has pipe development and building sections. With the buildong you put in the bends you want, the thickness of the metal, the number of sections and it then prints out the templates full size. its great, no cutting up a straight pipe. There is a demo version on their site.

lynton

http://www.iwt.com.au/MOTA.HTM

vma500 · - - - - - Joined: 26 Jan 2006 Posts: 376

try this ''cone calculator 1.3'' .......for free Very Happy

http://www.rd350.nl/archief

goto software

rgds
M.

Andrew · Joined: 17 Nov 2005 Posts: 551 Location: Leicestershire. UK

Forming and cutting the sheet metal ok, you also need a set of rollers that have the conicle attachments which allow you to roll the cones. Not everybody has these.
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Andy (UK)
RZV500R
FRC
Faster Faster !!!

Blackshaheen · Posted: Sun Nov 18, 2007 7:02 am Post subject:

OK Folks,
HUUUUUGE change of plan. I can be such a Muppet!
I have no bodywork for my project as yet. I started cutting the pipes in Jolly Moto style, ie exiting before the oil tank and returning under the bike at the sub-frame. I have no oil tank either as I will be running pre-mix (some time before I die of old age I hope!). And then it happened...a Triumph T595 tail section fell into my lap. Offered it up to the bike and with some 'cut and paste' I think it's going to look good and work out fine. The Jolly Moto pipe arrangement wont fit under it though (IDIOT!). I am now going to run the pipes straight out from the barrels and through my non-existent oil tank. Bottom line is that I've wasted some time but everything will still be good. I am putting any pipe-work on hold until I have the tail fitted correctly and only then will I be able to see how best to arrange the pipes.
Idiot? Yes I am.
Thankyou and good night.
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I will not tighten bolts after drinking beer, I will not tighten bolts after drinking beer,I will not tighten bolts after drinking beer,I will not...

simon#51 · Joined: 11 Nov 2007 Posts: 82 Location: south wales, uk

Hi guys,
just joined this site, so hello to everyone, im building a track 500 at the moment, been doing it for 3 years. changed front and rear ends 3 times but finaly went with yamaha r6 2006 front and rear ends yzr500 1996 bodykit got jollymotos on it at the moment but need to recut and route the top pipes, they work really well with the terry shepperd tune allthough its still running standard carbs, im going for 32mm mikunis and zeeltronic cdi and pv control. there awsome!!.
Went out for a ride on my mates 500 yesterday (what a tool) 115 bhp at the back wheel, 4th gear wheelies no problem, tons of mid range pulls all the way up to 11,000 revs. felt much quicker than a gsxr1000 k5.
he's got swabricks massive tune 32mm mikuni and zeeltronic boxes.

check them out @ www.zeeltronic.com
will post some pics of my bike soon.
cheers simon.
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sharris

rztom · Posted: Mon Nov 19, 2007 10:24 am Post subject:

Hi Simon - welcome to the group! Cool

Shaftoflame · Joined: 24 Nov 2005 Posts: 323 Location: South Wales - UK

Mr Blackshe - and then my memory fails - never look on somethign like you are doing as a mistake - it is always a chance to learn, and your postings suggest that you are learning all the time - you have ideas and then they change, but you are making them happen - just post the pics.

R

Simon Where in SOuth Wales are you - I am over Port Talbot way

R
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Dreaming is not a failing, it is what makes us climb bigger mountains, make better bikes and love. However it can take up an inordinate amount of time...

Jeff B · Joined: 18 Nov 2005 Posts: 289 Location: Wisconsin

Shaftoflame · Joined: 24 Nov 2005 Posts: 323 Location: South Wales - UK

simon#51 · Joined: 11 Nov 2007 Posts: 82 Location: south wales, uk

I live in barry, did steve willis paint your 500 not so long ago. coz he doe's a lot of work for me, i own gp motorcycles in pontypridd,

cheers jeff, i'll try that routing coz it will be a crime to chop those pipes as they work really well, iv' tried lomas pipes and there's no mid range atall.
yes a pic of your pipes would be nice, and if anyone is interested in jollymoto pipes im' an agent for them and can offer discount for club members!!!!!.
ill' post some pics of my bike soon, iv' decided to go with norick abe rep as iv got the geniune marlboro bodykit from 1995, its even got the morlboro team roberts and norick stickers on it no9.i was going to keep them as memrabilia but sinse his death i thought it would be nice to build a replica of this.
what do you guts think!!!!.
cheers simon
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sharris

simon#51 · Joined: 11 Nov 2007 Posts: 82 Location: south wales, uk

SORRY I MENT GUYS,
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sharris

rztom · Posted: Tue Nov 20, 2007 10:23 pm Post subject:

Simon - well, this "guy" who speaks from his "gut" thinks that's a GREAT idea... DO IT..!! Cool

Oh, and make sure you post pics - we all luv pics....