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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> How the Totally TTRs' shorty header pipes are made!
Post Info TOPIC: How the Totally TTRs' shorty header pipes are made!
TTRfan


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How the Totally TTRs' shorty header pipes are made!
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A customer reported a problem with the first of a batch of header pipes recently made up. It fouled the frame down tube and wouldn't tighten up against the gasket in the exhaust port.

I took the rest of the batch back to the fabricators this morning and they couldn't find a problem as they fitted their jig exactly. So I made another trip up the M5 with one from a previous batch that was on my own TTR and so fitted properly.

After a bit of faffing about, they realised that the radius on the first bend was too tight on the latest batch. So they have made up an addition to the jig and are going to make a new batch - but only after I have test fitted an altered pipe.

Whilst I was at the fabricators I as able to see the jig they used and now understand a little bit more about the manufacturing process.

I took the photo below of a pipe in the main jig and in the background is the jig they use to place the exhaust guard bolts exactly.

Shorty_jigs.jpg

 

Brian

 

 

 



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matador


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It was me, yep went to fit the pipe and it appeared to be aligned to fit outside the frame but I managed to tweek it back into line (done it before on other pipes), I reported it back as I didn't want anybody to have the same problem. Looking at the jig, it's easy to be a fraction out line, hopefully now sorted.

The new pipe really makes the bike look so much better, not just the shine but with the pipe now higher I could extend upwards an extension to the bash plate - will try it out soon. 



-- Edited by matador on Friday 6th of February 2015 07:06:53 PM

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TTRfan


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It took longer than I had hoped but we now have new stock of shorty pipes that fit very nicely biggrin

I had taken one of the original unpolished shorty pipes (that I had fitted to my "shopping" TTR project bike) for the fabricators to use as a pattern and, as an apology for the inconvenience and driving up and down the M5 dropping off and collecting them, I got my own pipe polished - looks OK I reckon wink

Shorty pipe on shopping TTR.JPG



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