4722 replies to this topic

[Nev]

do you have a clean air supply for breathing when you are welding?

 

Nope, I did open the garage door when I set fire to the carpet and some wood yesterday though.

 

I smell like a bonfire ATM.  

Edited by Nev, 08 December 2016 - 05:40 PM.

[hairy]

Prolonged exposure to welding fume may cause lung damage and various types of cancer, including lung, larynx and urinary tract. . Health effects from certain fumes may include metal fume fever, stomach ulcers, kidney damage and nervous system damage.

 

OSHA

[Ormes]

Wowzers, I'm tired, another full day of bashing, welding, cutting and struggling under the car.

 

But, it's finally finished, installed and tested at idle. It had a couple of whisper leaks in a couple of places, but nothing to worry about. Am gonna take for a gentle drive tomorrow to give it a few proper heat cycles.

 

At the last minute I was going to weld in a lambda bung for the dashboard AFR gauge, and then realised that I didn't have a 20mm drill bit, so this is something I will have to re-visit in a few days time, but it won't stop me being able to drive it in the meantime.

 

After the final assembly the noise seemed to have gone up a dB, but it overall way quieter than the old silencer. I could walk round the rear of the car and I my ears weren't ringing. Thankfully it didn't seem to rattle (yet).

 

I've learnt a lot from this mini project, as usual it has been humbling to actually struggle to build something rather than pay for someone else and not have a clue to the effort involved. My welding (key man skill !) is certainly better, particularly my tacking.

 

Will take some pics of the tailpipe (just a single 3.5" exit) tomorrow as it was dark when I finished 15 mins ago.

 

 

I've got the below if it helps?... Welcome to borrow as always...

 

https://www.machinem...drill-bit-set-/

[KurtVerbose]

 

I smell like a bonfire ATM.
 

 

I set fire to myself welding once.

 

 

 

 

Keep meaning to get a proper welding jacket, but I don't do too much welding these days.

[Nev]

Get a metal punch for your holes Nev. Makes short work of it. To keep distortion down weld an inch, stop, weld an inch elsewhere etc. Too much heat in one place is a pain. It's what killed my manifold project. Sent from my iPhone using Tapatalk

 

Would a 20mm punch get through stainless do you think? I do have some old imperial sizes that my dad gave me, I might try one to start the hole off and then open it up with a grinding bit.  

[Nev]

 

Wowzers, I'm tired, another full day of bashing, welding, cutting and struggling under the car.

 

But, it's finally finished, installed and tested at idle. It had a couple of whisper leaks in a couple of places, but nothing to worry about. Am gonna take for a gentle drive tomorrow to give it a few proper heat cycles.

 

At the last minute I was going to weld in a lambda bung for the dashboard AFR gauge, and then realised that I didn't have a 20mm drill bit, so this is something I will have to re-visit in a few days time, but it won't stop me being able to drive it in the meantime.

 

After the final assembly the noise seemed to have gone up a dB, but it overall way quieter than the old silencer. I could walk round the rear of the car and I my ears weren't ringing. Thankfully it didn't seem to rattle (yet).

 

I've learnt a lot from this mini project, as usual it has been humbling to actually struggle to build something rather than pay for someone else and not have a clue to the effort involved. My welding (key man skill !) is certainly better, particularly my tacking.

 

Will take some pics of the tailpipe (just a single 3.5" exit) tomorrow as it was dark when I finished 15 mins ago.

 

 

I've got the below if it helps?... Welcome to borrow as always...

 

https://www.machinem...drill-bit-set-/

 

 

Thanks Alex, the hole will be located on a tight bend, so it will be hard to drill accurately without the drill bit skating around on the curvature, so I think I will try FLD's idea of a hole punch first. Thanks anyway.

 

Can't wait for the commuter traffic to die down and then I'm off !

 

 

Edited by Nev, 09 December 2016 - 06:57 AM.

[Arno]

Would a 20mm punch get through stainless do you think? I do have some old imperial sizes that my dad gave me, I might try one to start the hole off and then open it up with a grinding bit.

 

 

 

Buy a Ti-coated stepped drill. Drill small 6-8mm pilot, then enlarge. (use cutting oil!)

 

 

Easy!

 

Bye, Arno.

[FLD]

I doubt a 20mm punch would be up to the job, as suggested above a step drill is good for holes that size.

[CocoPops]

For holes that need reaming?

[Nev]

Yea, I have step drills, but forgot I had them at the time!

 

Just been out for a 60 miles test drive. Sonic bliss, quite possible to drive without ear plugs now.

 

Nothing broke or snapped and it all behaved perfectly, though I could only take it up to about 5000 RPM due to slimey roads and traffic.

 

Drove over the Castle Combe for a sound check, but there was nobody there.

Edited by Nev, 09 December 2016 - 11:05 AM.

[Nev]

Cleared up the garage today, that alone took 30 mins; I had over a KG of metal dust in the dustpan at one point.

 

Some pics of the final setup and a pic of me yesterday evening when I got told to go and take a bath (not looking quite my best!).

 

It appears that my 60 mile test has turned the car filthy after being clean, if there is one thing that is futile with a car - it's cleaning it.

 

 

 

 

 

 

Edited by Nev, 09 December 2016 - 03:07 PM.

[Nev]

 

 

I smell like a bonfire ATM.  

 

I set fire to myself welding once.

 

Keep meaning to get a proper welding jacket, but I don't do too much welding these days.

 

 

Impressive pics!  

[mbes2]

Hats off Sir! Well done Nev!!

[Nev]

Thanks Mark.

 

The other main things I forgot to say is the new system has almost no drone. This is fab news and cruising will be a lot easier for it. I think my reflective wave design on one of the pipes might be the reason for this.

 

Lastly, I think I have lost some power, though it was hard to tell as I was having to be gentle on the accelerator due to the slime on the road. Once I get a dry day and get to really thrash it I will know better, though a dyno run at EFI Parts would be a lot more accurate than my guesswork.

Edited by Nev, 09 December 2016 - 03:47 PM.

[mbes2]

Dropping below 500bhp 

 

I feel your pain 

[CHILL Gone DUTCH]

get you name down for the pembrey track day nev 

 

 

[hairy]

You look seriously tired mate!

[The Batman]

Nev, worth putting additional heat sleeving on the gearbox cables?

 

i use this stuff

 

http://www.ebay.co.u...c8AAOSwwbdWINka

[Nev]

I did give the gear cables a quick look over, though they are distant from the pipe, maybe some heat wrap would be worth it as they are pigs to replace apparently.

 

It would probably be best to wrap the flexi pipe too with a load of exhaust wrap I have.

Edited by Nev, 09 December 2016 - 09:57 PM.

[Nev]

The next things to do is:

 

1/ install my new 275 Lb springs in the front to replace the 225 Lb ones

2/ put new discs and pads on the rear

3/ give a little nip/tweak to dial out a titchy bit of toe out on the front.

4/ take the silencer off and weld in the lambda bung for my AFR gauge and seam weld the micro leaks.

 

Today, I drove past Infinity Exhausts whom I previously drove to 2 times (and range 2 times) to get a quote out of them to build me a silencer that was quiet. Their advertising (all over Castle Coombe claims they can cater to any needs), yet they didn't want to take the job on as they couldn't be sure to make it quiet. I felt like popping in and showing them what a rank amateur like me in my shed can make first time, but I doubt they were the sort of people that would have felt any professional shame.

Edited by Nev, 09 December 2016 - 10:14 PM.