Nev's V-star

Machining, welding project planning

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Matt McLeod
Posts: 10
Joined: Thu Nov 22, 2012 8:42 am
Location: Albion, Victoria
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Nev's V-star

Post by Matt McLeod » Wed Dec 19, 2012 9:43 am

CUSTOM EXHAUST

Nev wanted to bob out his new stock V-star 250, and started with the exhaust. We used a Biltwell Builder's Kit for this.

BEFORE
Image
V-star 250 stock exhaust by KrankEngineering, on Flickr

AFTER
Image
V-star 250 custom exhaust by KrankEngineering, on Flickr

I chopped up the stock rear cylinder pipe to get some bits I needed for the rear pot. There is very little room there, I guess that's why Yamaha take the standard exhaust back and down to the mufflers, rather than out to the side. I wanted to do "out to the side", for no good reason other than I thought it would look better.
Image
Chopped stock exhaust by KrankEngineering, on Flickr

So I ended up cutting out some new flanges from 6mm plate, and using the chopped exhaust, made up a little 90" hook to get the rear cylinder fumes to go to the right side of the bike.
Image
Rear cylinder pipe section by KrankEngineering, on Flickr

With a second flange on the right hook section, we can now bolt up on the right side of the bike. I had to chop the stock exhaust hanger that is welded to the frame to get it in there.
Image
Rear cylinder adaptor flange by KrankEngineering, on Flickr

Can't remember where I stole this idea from, but it works great. Ron Covell suggests using hose clamps for this job, but for long straight sections I get better results doing this:
Image
Pipe welding clamp by KrankEngineering, on Flickr

Needed some way to hang the pipe near the rear of the bike, so I made up a couple of hangers from 1.6mm, roughly formed into the diameter of the 1-3/4" pipe, with some M6 studs (ie M6 bolts with the heads cut off) plug welded from the back. Then I welded these on the back of the exhaust (see next pic)
Image
Exhaust hangers by KrankEngineering, on Flickr

With a bit of 5x20mm flat bar from the rack, oxy to heat it, bend it, make up a small tab to pick up the pipe studs, weld 'em together, dress, paint, done.
Image
Exhaust hanger bracker by KrankEngineering, on Flickr

This came out better than I hoped, makes the bike look heaps bigger, is plenty loud, and makes you laugh when you ride it. Job done.
Image
Custom V-star 250 exhaust by KrankEngineering, on Flickr
Matt McLeod
Krank Engineering
http://www.krankengineering.com

FTWMC01
Posts: 33
Joined: Wed Mar 03, 2010 2:05 pm
Location: Brisbane south

Re: Nev's V-star

Post by FTWMC01 » Wed Dec 19, 2012 9:14 pm

Looking good

xsive
Posts: 628
Joined: Wed Oct 24, 2007 12:58 am
Location: Rutherford,NSW

Re: Nev's V-star

Post by xsive » Wed Dec 19, 2012 10:07 pm

yep looks good the virago isnt the easiest to work with as i know with mrs xsives pipes took a different approach dropped it all down the centre of the frame and did a few turns to tune length the front and back cylinder equal got pretty close and the only reduction was at the port area they tend to be quite loud with out any baffles but do sound good . but whilst tuning found that her bike needed some back pressure so small baffles were made and rejetting of the carb to suit the pod fillter and pipes the performance difference was terrific. just a shame she didnt want to ride it when the project was finished .so i sold it today :evil:
IM NOT CRAZY ITS JUST OTHER PEOPLES PERCEPTION OF MY NORMALITY THAT DIFFERS

Matt McLeod
Posts: 10
Joined: Thu Nov 22, 2012 8:42 am
Location: Albion, Victoria
Contact:

Re: Nev's V-star

Post by Matt McLeod » Fri Dec 21, 2012 10:36 am

Thanks for those comments XSIVE, if we have any dramas you've given me a couple of places to check. So far so good...........!!
Matt McLeod
Krank Engineering
http://www.krankengineering.com

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