Aussie 1100's new life

[Troyskie]

I w&d the final two passes, and also fooled around with the direction of the final pass. Factory is vertical, but on the final 1500 gentle rub I went horizontal as it seemed to give a more uniform sheen. I gave them 4 thin coats of the clear.

[Troyskie]

The centre stand worked but was bent. This will be a problem for the new 4:2 system from Delkevic as the foot level rubs against the foot peg bracket.
I gave the replacement a general degrease (I think there was a couple of decades of chain lube on the LHS  ), and tidy up, then it got a couple of coats of the same black I used on the peg bracket inners. The old on is the dirty in this image, I tried to take another to show how bent it was..

[Troyskie]

Here's a pic of them end on. Shows the different angle a bit better...

[Urban_Legend]

Here is the donor.

Does the donor still have it's tank cap? Mine is pretty pitted through the chrome. Also, if I can replace the tank cap, I should be able to swap key barrels out right?

Sorry Troy no it doesn't The cap from that bike is now on mine.

Mark

[Troyskie]

Oh well, looks like the cap will get a had polish was well. Probably end up pulling it off and having it re-chromed one of these days...

[Troyskie]

Getting close to final assembly of these last parts.
A big thanks to Joe from Delkevic. The mufflers arrived on Friday with a cool little multitool, even has a torch and socket set in it!!
As the peg brackets are ready, headers, collector and mufflers ready, new (now it at least looks new) centre stand on, we can put it together!
The headers and collector were already installed once, so we know they fit.
As there seem to be no readily available mufflers for 1100s with 4:2 except the Delkevics I'm going to push the finish back by a week so I can take a day off and properly document the mods required to get them to line up with the collector.
My expected issues are, will the centre stand cause a need for re-routing? Will the pipes reduce the cornering? Will the connector pipes need to be totally re-built?

[Troyskie]

all booked and set for Monday!

[Troyskie]

Monday arrived and was used well!
Took her in to Glenn Henrys.
List to do today, replace footpeg brackets.
Clean up a little what was exposed.
Remove old headers & 4:1
Fit new headers, collector & slip-ons
work out what to do with the mid pipes between collector and mufflers

[Troyskie]

Removal of the footpeg brackets was straight forward, but a slightly tense operation. As the swingarm and rear frame attach onto these we used a couple of drifts to keep everything lined up.

[Troyskie]

After removing the brackets I tidied up as much as I could. Due to being in the workshop I didn't go too far with this as I'm paying by the hour.
In this next image I've tried to show the crack on the LHS bracket which is what prompted the replacement....
This was not a problem for general riding & with the 4:1 really no problem at all, but with the 4:2 going back on it was a risk. I did have to remove the gear sack though, as the crack did move with the rack attached.

[Troyskie]

New brackets on...this all seems so simple & quick now I'm posting, but with muchly dirty hands, spanner turning (amazingly I'm turning as much as Glenn is now  ), this was somewhat slow but, as before pretty straight forward.

[Troyskie]

Now for the old system removal....plus a couple of shots of the front engine with the old headers removed. She does need some love here and a repaint will be a fairly big job, which unfortunately will likely include pulling the exhaust system off in my shed. Functionally, everything seems fine however.

[Troyskie]

Here are the new headers and collector in place...

[Troyskie]

On to the mufflers. These were intended to go on to the original muffler attachment points...

[Troyskie]

The angles were all wrong and to get the muffler to line up with the collector and not have a sharp dogleg mid pipe we had to make a couple of brackets and attach from the rear footpeg... this extended the muffler way further back than I wanted, but it worked...