build your own expansion chamber!! plus adjustable header design - Printable Version +- Vintage Karting Forum (https://www.vintagekartforum.com) +-- Forum: Resource Archive (https://www.vintagekartforum.com/forumdisplay.php?fid=88) +--- Forum: Restoration Advise Section Basics to Complex (https://www.vintagekartforum.com/forumdisplay.php?fid=90) +---- Forum: expansion chambers (https://www.vintagekartforum.com/forumdisplay.php?fid=116) +---- Thread: build your own expansion chamber!! plus adjustable header design (/showthread.php?tid=1913) |
build your own expansion chamber!! plus adjustable header design - David Luciani - 11-07-2017 ok guys, a extremely good friend has forwarded these pix to me to post. he told me to also mention this Quote:You might mention in the album that this is an exact duplicate of the pipe as used on my Hornet Marauder back in 1967-68 he'd rather stay private so i'm not posting his name. those that know who this person is please leave his name out of your comments. i'll comment on each pix as best i can. Building the cone cut cone pattern from flat stock used dead blow or heavy rubber mallet shape on pipe this pix illustrated the holding angle that is best for hand forming a tapered pipe tube partially shaped cone.take you time and form it evenly getting closer you can see here how the angle you've been holding part at eventually lets the edges met smoothly nice even edge ready to tack weld tack pipe every inch or so starting on one end and working you way to the other.the originals (1967) were gas welded but these were welded with tig. short fat cone nearly done fat cone tacked up.note the body hammer.as you weld you can hammer the hot tacks flat if you're reasonably fast. cone finish welded RE: build your own expension chamber!! plus adjustable header design - David Luciani - 11-07-2017 part two building the pipe and adapters to eliminate flex pipe. finished expansion chamber a large washer still needs to be installed at the small end for safety purposes. otherwise in a collision the e-chamber becomes a fine example of a coring tool. conversely a "sweet potato" style cover may be installed over the stinger to lower noise emissions. a 1" hole needs to be added to silencer can for venting expansion chamber adjustable frame mount detail. expansion chamber header end detail.jpg comments from the builder will appear in quote boxes. Quote:Hi David, finished adjustable header this adjustable header eliminates the need for various length sections of flex pipe used to fine tune a kart to a specific track. the u shaped header section is made long on the e-chamber side deliberately so adjustments are possible. the slip section of this design is sized with the i.d. of the slip pipe being one size bigger than the o.d. of the header. a simple slot with two attached hose clamps completes the slip /tighten function of the header design. the connection between the header and e-chamber is accomplished by using the outer race of a standard 1" axle bearing - a pair of two hole axle flanges - two grade 5 bolts and a couple of compression springs. the e-chamber also has an adjustable mount on the far end to allow easy moves when adjusting the e-chamber track side. adjustable header detail blow up. adjustable header detail fully closed adjustable header detail fully open. header build details pix (a) 2 inch ball bearing and forming tool for flange side of header tool pix (b) bearing outer race being test fitted to expanded pipe below explains what else you need to start taper and hold ball bearing to expand pipe when pressing Quote:Hi David, building the slip section of adjustable header
here is a picture of the expansion chamber and header cleanly installed in kart side view of header and e-chsamber installed note spring in bolts for anti vib function installed header close in detail RE: build your own expension chamber!! plus adjustable header design - Jim Waltz - 11-07-2017 That is some nice work. RE: build your own expension chamber!! plus adjustable header design - David Luciani - 11-07-2017 it really is nice work. as you can see the guy building these knows a bit about welding!! and fabrication new ideas clean installs simple effective designs it's unfortunate that i can't credit him with the work but if you know him you know he's pretty private. Quote:Hi David, 12 2 inch ball bearing and wedge tool 13 bearing outer race being test fitted to expanded pipe 14 adjustable header detail blow up 15 adjustable header detail fully closed. 16 adjustable header detail fully open. 20 first jig 1 tapered to start flare in pipe. 21 first jig 1 tapered to start flare in pipe set up in press. 22 jig 2 on left used in bottom of pipe when pressing ball bearing. 23 jig 2 placed in adapter pipe ready for pressing. 24 jig 2 in press with 2 inch ball bearing on top to flare out opening. 25 ball bearing fits in flared pipe nicely now. 26 jig 1 is tapered bigger near top.push in further to make flare in pipe longer.pix is jig set up in press with blocking underneath. 27 pipe now properly flared still sitting on jig 2. Save RE: build your own expension chamber!! plus adjustable header design - Richard Stamile - 11-07-2017 I don't blame him one bit wanting to be private obvious a craftsman with excellent welding skills and the fact that he can produce a fine stinger doesn't mean he wants to do it for everyone but still offers a way to make them if you want to hone your of metal working skills and how to go about doing it thanks for this post RE: build your own expansion chamber!! plus adjustable header design - doug tenney - 11-08-2017 I think I met this gent at Avon this past summer. Is this him? RE: build your own expansion chamber!! plus adjustable header design - Gary Wlodarsky - 11-08-2017 ya know...love the workmanship...but...time and materials...wow...something like that has to take 15-20 hours and yeah,,i get it""I BUILT THAT""..... would prolly take me 20-30 hours at 90 bux and hour...great, I have 2700 dollar expansion chamber,,that may help performance,,,yeah, I know,,,""I MADE IT "" overrides all else... any body have RLVs number...LOL gw RE: build your own expansion chamber!! plus adjustable header design - steveohara - 11-09-2017 Two comments for other DIY fans.... for Mac engines with just about any shape expansion chamber you need to end up with the length of the header in the range of 9 to 10" from the face of the piston to the small end of the scavenge cone. The system shown here is a neat idea but at least two inches too long in the shortest configuration to perform well. It would be virtually impossible to build a slip joint system such as the one shown that can place the chamber in the correct relationship to the engine. Another consideration... Mac engines have fragile exhaust header mounting locations thus the use of flex between the header and pipe is highly recommended in order to provide compliance between the pipe and the header as the kart flexes and the motor shakes around. A rigid assembly such as the one shown here looks nice in the shows but it will end up tearing the inserts our of the two exhaust port screw locations if used on a runner, especially on bumpy tracks and on karts with swing mounts that are rubber mounted at the front end of the mount. In summary....very nice fabrication of a system that looks great but is not engineered to run fast or long on the track. Steve O'Hara RE: build your own expansion chamber!! plus adjustable header design - Richard Stamile - 11-09-2017 it looks like expansion chamber brackets are attached to the engine mounts and not the frame of the Kart so that would eliminate any need for flex pipe as far as i see from the photo's posted , can anyone on the forum comment on the type of clutch use with this type of exhaust set up i was told if your running the original 2 shoe Max Torque its not the best way to go because of the power range/rpm changes with clutch engagement RE: build your own expansion chamber!! plus adjustable header design - David Luciani - 11-10-2017 first i posted this article as a how to build an era correct pipe circa 1967 not a make your kart faster article. i may not have been super clear about this pipe in earlier posts. this pipe represents early pipe when they were still pretty new. in 1967 oil clutches were new on the scene so e-chamber development at first reflected dry clutch performance limitations. as with anything kart racing the evolution was very fast. within a couple of years oil clutches were common and e-chamber design became almost a science. so if you are looking for a fast or cheap design this isn't what you want. and building you own e-chamber is pretty silly in view of whats still commonly available. but if you are matching an existing pipe repairing a rare pipe or just like building things this may be for you. the article is more about how to hand build your own e-chamber pipe. something that without a cone roller will occupy at least four hours of your life if you are a skilled welder and metal former. rank amateurs can expect anywhere from 8-9 hours to never as a time result. i think building pipes is something the hobbiest should consider if they have the time skills and inclination to do it. or just swipe elements of the article to apply to your particular build so you install on a show kart is that much cleaner and era correct. anyway without starting a war about anything i am posting the builders reply. Quote:Hi David, Save |