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Posted by JagLite
- March 13, 2016, 21:50:42 PMFinally the shop heater parts arrived and the repairman installed them Friday.
Three weeks with no heat in the shop...
This weekend was mostly spent painting but I did get to work on the flex tube exhaust a bit.
Cutting and tack welding along with some thinking.
The thinking is the tough part.
The inner pipe is a slip fit inside the pipe flange:
Both pipes tacked to the flange pipes:
The outer flex tube will slip over the inner tube after I seal weld the inner tube to the pipe flange stub.
Then the inner pipe will get welded to the collector and the outer flex will slip cover the joint.
That's the plan so far anyway, subject to change if I figure out a better way.
The outer tube will get a 3/4" wide band clamp around it at the flange for appearance.
Or possibly just a section of tube the size of the clamp welded over the end.
I haven't found anything to use as a dressing and since it is all getting painted flat black anyway... 
Here is a comparison of the sizes of flex tube:
The 1.5" I am using for the inner (actual) exhaust pipe, the 1.75" that I am using as the outer pipe for appearance, and the way too big 2.25" flex I thought I was going to use.
I tried to get 2.0" for the outer but can not get it without paying far too much for shipping.
I won't get to work on the pipe for two weeks as I am going out of state but I was glad to finally get to do something.
I hope to shoot the color coat on the tank, fenders, and side covers before I leave so they can dry while I am gone.
Posted by greenbarn
- March 02, 2016, 21:29:59 PMAnxiously awaiting.... Do you have anything in mind to cover the ends of the flex??
Posted by JagLite
- March 02, 2016, 21:18:09 PMMy outer flex pipe arrived.
But it won't work.
I don't know what I was thinking to order 2.25" flex tubing to go over the 1.5" inner flex.
It is HUGE. 
It is 2.25" I.D. and way too big.
It looks like a cartoon bike.
Goofy!!! 
So today I ordered a piece of 1.75" flex.
I also made some real progress on painting.
I called the pro's and had them come fix my shop heater.
Now I can actually do some painting this weekend.
I hope...
Posted by JagLite
- February 22, 2016, 10:41:55 AMBig plans for painting the tank, fenders, and side covers this weekend were frozen. 
The heater in the shop died. Or is on life support. I think the fan motor is overheating and tripping an internal relay.
I could only get the shop up to 52 degrees so I worked on other projects.
I will spray the high build primer asap...
The other tank and seat are for my street tracker that is also getting a change of color.
Other good news is that the 2.25" flex tubing for the new exhaust is finally on its way north to Alaska.
When it arrives I will be able to work on putting all the pieces together.
I'm not keen on the looks of the big fat Borla muffler so if it doesn't sound really good I will be replacing it with a smaller diameter glass pack probably. That would be more fitting with the period I think. That's the reason to make it myself, i can change it myself. 
One interesting thing when I was taking the tank off the bike I discovered that when it had been painted green, they did it on the bike! The electrical connectors and a few wires and hoses had green overspray on them. That was quite some masking job they had to do on the entire bike to be able to paint the tank while installed.
I guess the paint shop didn't want to try to find out how to remove the tank.
Or the previous owner probably. The fenders had been removed though.
Posted by JagLite
- February 09, 2016, 09:54:52 AMI will weld the flex to the pipe ends
I will make a bolt on connection to the muffler so that I can change the muffler if I don't like it.
I don't like how big it is so if it doesn't sound good to me, I will make my own muffler that is about 3" diameter.
Hopefully once it is together and painted flat black it will look smaller and mostly disappear.
Posted by greenbarn
- February 08, 2016, 21:51:28 PMLooking good so far.... One question: how will you fasten the flex tube to the hard pipe?
Posted by CDNRatMan
- February 07, 2016, 23:13:48 PM following and waiting to see how it works out......
Posted by JagLite
- February 07, 2016, 22:54:55 PMI finally had some time to play with the Drifter today...
First I cut up the headers from another bike for the flanges
Trial fit:
Yep, fit great.
If this was a custom show bike I would be done 
But this is a bike to ride so more is needed.
The flex tube won't bend as tight a radius as I want so some thinking time is required...
On to the rear pipe for now
Need a "T" to join front and rear pipes so this part of the headers I cut might be the ticket:
Hmmm, maybe another piece of the donor pipe on the T might help?
Yeah, that might work.
Don't know if it is needed but if so I have it.
Now to make the hanger mounts for the muffler that match the original:
This piece of scrap square tube should work:
Close enough for me
Drill some holes:
Time to wind up the welder
Two bolts and two nuts are welded inside the tabs.
I used the stock hanger to locate the tabs
Ready to bolt on for a trial.
End of the afternoon:
So far things are progressing as hoped. 
Keep in mind that if all goes according to plan all of this will be hidden by the 2" flex tube that goes over the inner pipe.
Still to do list:
Buy the pipe wrap that will go around the inner flex tube, inside the outer flex tube.
Buy the exterior 2" flex tube that will actually be seen.
Decide how I want to make the muffler end caps with the 1 1/2" tube size to match the inner flex tube.
Buy some 1 1/2" straight tube for the muffler outlet pipe.
So far so good
Posted by CDNRatMan
- January 31, 2016, 12:46:40 PM We are to.......
Posted by JagLite
- January 31, 2016, 09:36:18 AMI took a look at the old exhaust pipes I have and found two possible candidates for the head pipe flanges.
Both are new stock take-offs from bikes that the buyer had the dealer switch out for an aftermarket system.
I bought a few of these when a dealer was moving to a new building and had a garage sale.
I am glad to get back to work on the Drifter 
Posted by JagLite
- January 28, 2016, 10:21:44 AM1965 Rickman Metisse MkIII with Triumph TR6C 650 engine
Here is my build thread for the Rickman:
http://advrider.com/index.php?threads/1965-rickman-metisse-mk-iii-scrambler.818140/
Sunday I finished the new oil cooler installation on my DR650 Street Tracker
And the build thread for it:
http://advrider.com/index.php?threads/dr650-street-tracker-build.857154/
Posted by CDNRatMan
- January 28, 2016, 10:20:48 AMThe actual Roadhouse system does have the flex pipe going over solid pipe........they are just a slide over cover and in one set I saw it was cut out in the back to allow the heat out....
Posted by JagLite
- January 28, 2016, 09:26:54 AMHi Dan,
Here is the link to my ride report:
http://www.vulcandrifterriders.com/forum/index.php?topic=38628.0
I really like my shop you can tell.
It isn't fancy or well equipped compared to many, but it is the best I have ever had!
Interesting idea, putting the flex over the stock pipes as a heat shield.
Now that I have taken the stock system apart it does seem like that is possible.
I will try to remember to check that out.
Posted by deadeyedan
- January 27, 2016, 21:15:15 PMWOW WHERE I COME FROM THAT IS A HOUSE. HAPPY I AM ONLY 73 AND STILL HAVE TIME TO WORK ON ONE. WELL AT LEAST I FINALLY GOT THE BEER FRIDGE IN THE SHED WITH THE BIKE. APPRECIATE THE PICS. IS IT NOT PRACTICAL TO HAVE FLEX PIPE OVER EX.PIPES AS HEAT SHIELDS I HAVE THE SAME JACK AND I AM STEALING YOUR IDEA THANK YOU HOPE YOU HAVE PICS. OF YOUR TRIP TO SHARE DANNY
Posted by CDNRatMan
- January 26, 2016, 00:18:40 AM what no pictures of the Rickman...why what did we do to upset you that you talk about it and then do not post any pictures......now we have to just sit here and think about it....how mean you are.......