R100RT chop hack and slice without remorse. Looming 56K death

Gearbox oil change will mean pipes out of the way, but I guess you know that.
That'd be the time to change the oil filter too!

Wow, you're getting busy. Looking great. Nice work

You can not really tell from the photos I took that the merge collector is just to the rear of the trans drain plug. I can take pictures in the same way a chimp with a hammer can pound a nail; It gets done but it lacks finesse.

The whole exhaust system will be built with slip joints sealed with stainless band clamps. In all my years of wrenching I hated nothing more than having to cut apart something or completely build from scratch something someone did not have the foresight to see would be a problem or in the way of serviceability.

This is a great thread! Your sharing of the pics and build/modification process are much appreciated.

Keep up the good work.

Now it is time to make the exhaust come out from under the trans and up the other side under the seat. So I have to make a ( kinda sorta) mirror image of the merge clloector i just built.

I selected two 90s from the pile and spaced them apart just a little so i could expand them and slip a ban clamp between them.








The flat plate my ground clamp is on, is tacked to both pipes to prevent movement i will cut it out when i am done building the merge





Here is that same piece of stainless pipe I am using as a form to keep the inlet round





Once i finished this half i welded both halves together to make this monstrosity







And here it is in place the shift linkage clears it although I mish put a heat shield on the trans side and one on the leg side (something with lightening holes I think)








Right now this is where I am at with the project I will continue to update as I build stuff.

I had to mount the seat, I have been putting this off. It has just been sitting on the subframe and I want to build the rest of the exhaust.


so I added some pads to the rear with nutserts in the ends of the tubes and straps to bolt the seat to






I used the nutserts with bolts to use to locate the tail left to right, drilled holes in the straps and made floating hold-down that I will capture with tabs so the hold-down will "float " in order to allow adjustment front to rear and left to right.









Tail is solid as a porn star's behind

Did you try full rear shocks compression ? Seeing the pics, it looks like the shocks tanks should hit the bracket when rotating under compression. It might be just visual, but that seems a really really tight fit...

It looks that way in the photos but with the springs removed the shock have plenty of clearance in the mounts under full compression. Actually because of the angle of the shocks the arc of travel is very small.

Adjusting the free play in your clutch is going to be near impossible .. But I have to admit ... it's very cool.

That is one of the reasons I built that piece with slip joints, I wanted it to have a nice clean look that flanges do not provide and I wanted to be able to take it off easily in case I had to fix someting. I really am trying to put as much forethought into making the pieces that I do so that in the future they will either not get in the way, be easy to take off if they are in the way, and/or easy to replace.

The battery is the next trickey item that is ugly and needs to be hidden I am shooting for under the tank in the area the stock coils took up but we will see how that plays out

So I finally got some time to work on that outboard pipe that I did not like and do a little more of the exhaust system.


I cut the outboard pipe in order to add in a section of bend to bring it up higher



At least I got to see how my welding was looking on the inside





I added in the small section which put the pipe up quite a bit higher but it now does not match up X pipe I made




So I have to cut it again and add in yet another bend



Now that the piper was higher I had to modify the corresponding pipe on the X-pipe I ended up adding a small bend to it and using some heat to fine tune it


and now the finished product










Since I am finally done I can start to route the pipes up under the seat to finish this portion off










I only had 2 hours tonight to get this done so I was not able to finish the exhaust off completely however the next photo give an Idea of where it will exit and what it will look like when I am finished







I will spam this board with more photos as I take them

Crap I wish I could weld like that !! I have been out in my garage making little puddles of birdshit everywhere !!

Great stuff Mate !

Beautiful!

Loving this build thread! Great work!

I wouldn't sweat the equal pipe lengths too much. BMW even deviated from that (R1100GS/R).

And the aftermarket did it for Airheads. Luftmeister made unequal 2-into-1 systems:
http://4.bp.blogspot.com/_dRAIdZnfHvM/SE8aANS2pFI/AAAAAAAABKM/lJIaLp9Wqt4/s1600/DSC_0014.JPG

Mac seems to make symmetric ones:
http://macperformance.com/2-into-1-Exhaust-Systems_c83.htm

But if you aren't building a performance bike, why sweat it if it screws up the styling?

Here's a very elegant one that's gotten a lot of exposure:
http://www.bmwmoa.org/forum/showthread.php?14846-r90s-Exhaust

My original inspiration was the Team Incomplete racer (that bike makes my thighs all sweaty ) but after having to redo the outboad pipe I gave up on the equal length idea. They are still close but I stopped measuring, at some point I might bust out a tape just to satisfy my own curiosity though

I almost got the exhaust finished today all that is left are the mounting tabs








So here is where it exits






















So there you have it, plenty of room for the tire and shocks and it should not singe my butt either.Pipes dont store heat the way an underseat muffler does.

Update?

No chit,,, I hate to follow a thread like that and it just ends in the middle.
Hope the guy is ok...

Sorry I have not posted anything more but I have not done anything more . I lost my oomph and drive on this project for a little while, now while looking at my last post date it has been over 4 months . The only thing I have accomplished in those 4 months is building a sub MOA AR-15 (kinda hard to ride that)

I have to apologize for the delay I will get back to it as soon as I get home the week after next


Here to more photos