Part evolution from initial concept to final co-polyester print, shown at the front the traditional bulb clear lens, LED amber indicator and LED ring light.
The final part:
Test fit with traditional bulb holder style clear lens indicator:
New LED centres, these don’t have the big tail and rubber seal out the back so it’s vulnerable to stone impacts and dirt inside the rear arches.
To solve the first/damage issue I’ve modelled up a dust cap, on the right version 1 printed in one part. The rough surface comes from removing supports. Version 2 on the left, printed in two parts, up the other way. That leaves a clean finish on the ourside from the print bed and clean surface without any overhang for the inside.
Version 2 split print in more detail, these parts are glued together using CA / Superglue
Wire cap in place
The end is shaped so that shrink tube can easily be place over the cables to protect them
Built the other side of the exhaust today. Welding is ‘better’ than when I started but still pretty uneven. I can’t weld too far consistently around the curve yet. Did punch a few holes in the metal in places which results in having to ‘glob’ in filler rod to build it back up again. This part was back gassed as on the others before as it was a butt joint.
The 45º and straight pieces are sleeve fit, have welded these too so less clamps are needed. It also cuts down on potential exhaust leaks.
Once the two back boxes were hung I used some boxes and various peices of wood to hold the tips in place at the right height, this is with the car on the ground. Nothing on the Sportster is straight so this was done visually.
I used a piece of angle metal to line the tops and ends of the tips up. This helped make sure the tips were aligned straight with the ground, with each other and spaced from the back of the car.
Welding the tips on was a bit tricky, blew a few holes in the metal especially where the gaps were bigger. The left box alignment is slighly off, but it’s not visible once mounted and the tips are in the right place visually.
Both exhaust pipes mounted, the v-bands are visible in this shot. I used a tiny bit of exhaust paste on the mating surface, shouldn’t be needed with v-bands but I’d rather not have to take them off again! Also visible the zip tie exhaust hanger, nothing like attaching your exhaust to your suspension ;o) Kinds tempted to make some straight pipes that can be put in place of the back boxes, but that’s a whole new level of noise (did try running it with just the header and you need to wear ear protection…)
View from the otherside, wiring is hanging down. These cables need plumbing in properly and the metal shields putting back on the mufflers.
Car down on the ground from a low angle, the exahust tips are closer together than before (due to the input on the backbox being offset rather than in the middle).
The tips stick out a little further than the old ones, the wall thickness and slash cut work quite nicely.
Temporarily wired up the control box, and now for the noise test:
Closed it’s quieter than the jetex micro bullet muffers + the magnaflow boxes. Open it’s a bit of a beast, louder than before so that should be fun 😉 It’s pretty much were I wanted it to be, will see what it’s like on the road once the wiring is done.