WAWUZAT Northstar build thread (lots of pix) (Page 9/16)
WAWUZAT AUG 08, 06:41 PM

quote
Originally posted by Kento: What Model Harley is that in the Background????


2006 Sportster XL1200R ... and it's available ... http://your3forfree.oodle.com/view/576058216/
I want to get another bike, but this one has to leave the stable first.

EDITED 9/19/07 TO ADD: The Harley has been sold.

[This message has been edited by WAWUZAT (edited 09-19-2007).]

Kento AUG 08, 07:25 PM

quote
Originally posted by WAWUZAT:

2006 Sportster XL1200R ... and it's available ... http://your3forfree.oodle.com/view/576058216/
I want to get another bike, but this one has to leave the stable first.




love too but I just purchased a 06 XL 883
WAWUZAT AUG 19, 07:52 PM
A few updates ... I acquired a '97 throttle body via eBay, cleaned it thoroughly, and replaced the TPS and IAC valve. I haven't decided yet if I'll gut the MAF or fabricate my own connection for the air inlet tube. I still need to research my options on what to use for an inlet tube, but I'm holding off until after the engine is in the car. Convoluted dryer vent hose is NOT an option.

I've also installed the shroud over water pump belt and pulleys, and a few other minor items. And yes, the EGR valve and tubes are installed. In VA, when one swaps engines, it must be an equal year or newer year engine, and all of the emissions controls with the new engine must be transferred with the engine. Don't ask me how it will operate, and I'll tell you no lies.


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"For those who understand, no explanation is necessary. For those who do not, no explanation is possible."

Zac88GT AUG 19, 09:10 PM
I was thinking about gutting the MAF on mine too but decided to weld some 3 inch exhaust pipe to a flange and put a filter cone on the end inside the side scoop area.
WAWUZAT AUG 24, 04:44 PM
I started making my stainless steel exhaust manifolds this week. I'm going to follow the basic routing of the 2.8L V6 exhaust system ... crossover to the front ... transverse mounted 2-in/2-out catalytic converter ... then two rectangular pipes beneath the drivetrain to a 2-in/2-out muffler. The first steps were to determine perimeters for both large and small ends of the manifold tube, and make some cuts along the lengths of the two tubes.


The next step was to form the tubes into long cones using a few hose clamps.


Tackwelds along the seam between the hose clamps, and remove the clamps.


After welding the seam, I had to beat the tubes some with a large rubber mallet so I could get them round again ... they went a little egg shaped on me due to the "draw" of the welded seam. Once happy with their shape, I used a bench grinder to square each end with the centerline of the conical tubes. I tackwelded the first elbow to the small ends, and a scrap piece of angle-bar at the other end. The angle-bar will allow me to repeatedly position the manifold at the same height, and not be bothered with some loose spacers.


Laying out the curved cuts in the next three elbows was not much fun. I'll cut them this weekend using a friend's plasma-arc cutter ... and I'll cut the first three a little long. After I see how much fitting I must do, I may cut the three on the other manifold a tad shorter. I won't know for certain until I'm in it elbow deep (pun intended).

[This message has been edited by WAWUZAT (edited 08-24-2007).]

Zac88GT AUG 24, 04:59 PM
A single 2" cat seems pretty restrictive to me or were you planning on running 2? Even with 2, 2" seems pretty small. I went dual 2.5" into a single 3" muffler.
WAWUZAT AUG 24, 05:07 PM
Yes, I'm using two 2" lines, and the cat has two 2" inlets and two 2" outlets. The area of two 2" diameter circles is roughly 6.28 square inches, and the area of one 3" diameter circle is about 7.03 square inches. Based on circle diameters alone, the two 2" lines will flow about 90% of one 3" line. Not equal, but the 2" lines are a lot easier to fit into tight quarters.

[This message has been edited by WAWUZAT (edited 08-24-2007).]

Zac88GT AUG 24, 05:17 PM
Yeah when i did my exhaust i was trying to get away from tapering down into a 3" but couldn't avoid it. It's only 3" for about 4-5 inches though, the rest is dual 2.5". 2" pipes are definatly easier to route though and with that beefy automatic i don't imagine there is to much room.

[This message has been edited by Zac88GT (edited 08-24-2007).]

WAWUZAT AUG 24, 05:41 PM
FWIW, here's an advance photo (from the eBay auction) of the Flowmaster muffler I'll be using. The inlets come in through the side, and the outlets are located on the ends ... all 2-1/2" diameter. This muffler was made to fit a '68 Camaro or Firebird. This will sit where the original muffler was located, and that's another area where I'm tight on room because my GT40 body tucks in at the rear. Part of the body installation required whacking off the bottom four inches of the trunk, and now I'll remove more of the trunk bottom.
ryan.hess AUG 24, 05:51 PM
The stock exhaust is 2.25" (going by the stock crossover diameter). I think 2", even with our shorter exhaust, might be a bit on the restrictive side.