Manky's Pop.

[Tony oily bike]

I'm curious to hear how it runs once both silencers are hooked up.
4 inches of ground clearance under the pipe.

4" ground clearance + Surrey's roads/potholes/speed bumps/suspension movement = be careful....

Looking gooooood... 

[Archie]

4" ground clearance is loads!

[Manky Monkey]

Yeah, off-roading across the Clandon Park estate where we live should be interesting!

[BikerGran]

We'll probably paint it black again, as there's nothing else in brass in the engine bay, then add a shiney retaining strap across the front.

Brass?  Better paint it quick before Doc ses it!

[spanners]

brass,,,,, leave it shiney,,and,,,, the ,,pikey,s,,, will have it away !!!!!!!

[terry t]

Hi Andy. pops coming along nicely there. have you had it running since putting the pipes on they look the part.when are you up the workshop next

[Manky Monkey]

Hi Terry.
Lots of running about picking up bits in the last week or so, so no real progress to show.
For example, the flanges that bolt the silencers to the headers came from "Pop Browns". They were 2 inch bore, but the silencers I'm using are 2" at one end & 1 1/2" at the other, so I needed a set of 1 1/2" flanges to connect the tail pipes to the back of the silencers. Chris at Pop Browns only had 2" on his stall at Wheelsday, but had some blank, undrilled ones at home. So I spent a day last week just driving to Essex & back to collect them, then had to arrange for forum member Saddlebags to bore them for me. Picked them up from his workshop yesterday.
The silencers are mild steel but the rest of the system will be stainless, so I've got a reel of stainless wire for my MIG welder -but PD's borrowed the MIG to weld up the hardtail he's building on my bike. So today, after commuting 40 miles to the workshop, I need to get all the stainless bits ready & take them to PD's place, weld them up & take them back to Loony's workshop to fit.
It's like that all the time -every job always needs 6 other things to be done first. So no, not had it running through the silencers yet & not got enough stainless tube to complete the system right out to the tailgate, but should have it muffled for the basingstoke show at the weekend. If I have enough time left, I'll also start modifying the bulkhead to take the radiator expansion tank, (we're going to reccess it in cos it's quite deep).
Should be at the workshop every day this week, but always best to check first.     

[terry t]

you going to be there this afternoon if so i will try and call in

[spanners]

andy which way round have you put the silencers ,,as regards  gas  ,,flow       2,inch in  to 1 1/2 out is the correct way.

there the same as i,ve used for different jobs over the years,  including f2 stock cars and v8 hot stox  where they were the only silencer you were allowed to use

[Manky Monkey]

Terry, Loony & I were there all afternoon -guess you couldn't make it. 
Yeah, large bore down to smaller bore Mike.

[Manky Monkey]

Left side finished as far as the back of the cab. The headers are stainless, as the rest of the pipes under the pick-up bed will be, but the silencers are mild steel so I've given them a quick coat of high temperature silver paint. The 1 1/2" pipes behind the silencers will follow the line of the chassis, back under the bed to the tailgate, but I only had 2 45 degree bends left over from the headers, so for now they end just behind the seats.

[Manky Monkey]

The silencers are tucked up as high as I can get them under the cab for maximum ground clearance -about 4 inches. With the passenger door wedged back in place, (both doors need some serious work to make them fit again after we've butchered the cab so much), you can barely see the pipes. There's still a repair panel to go in at the bottom of the A posts, just in front of the doors. With that fitted, you'll only see the stainless headers.

[poprodder]

looking good andy.
nice how the silencers are up out of view.

[Manky Monkey]

Hi Chris
Finally finished messing about, trying to smooth out the welds on the pipes today & bolted it all back together. So now we have both sides on, as far as the kick ups behind the cab. Still waiting for a friend of a friend to machine the 3" diameter blanking caps for the open header pipes, but we ran the engine this afternoon & clapped a couple of offcuts of ali plate over them to direct the exhaust gases back through the silencers. It's quieter, but not what you'd call quiet. Mind you, we've still got another 4 or 5 feet of pipe to add on either side, from the silencers to the back of the pick-up bed, which should make a difference. If it still proves too loud, I've got a back-up pair of Cherry Bomb silencers we could bung under the bed. We never expected it to be whisper quiet -if anyone has a decibel meter app' on their mobile phone we'll check it at the festival of transport this weekend. It's definitely running smoother though through the silencers, so a good result.

[Manky Monkey]

Time to start on the bodywork.
Remember these corner panels? They've been tacked on & removed several times, but today Mr L trimmed them down & properly tacked them in place. We needed a way of creating the double curviture of the rear corners of the cab -they don't just curve around from the doors to the cab back, they also curve from top to bottom. How do we do that then? Hmm...aha! a small brainwave from Mr L. He had an old British Leyland Mini in for some paintwork when we first reached this point & a quick eye up showed the Mini's front wings to be a perfect fit, (imagine them stood on end, with the headlight openings at the bottom). I bought a pair of repro wings from the local auto factors & today Loony trimmed & fitted them. We unbolted the pick-up bed & shifted it back a bit to give better access for welding.
Spot on. They finish the cab off nicely. Much more "original" looking than a single curved piece of sheet steel.