Aprilia SXRZ - Page 10
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Thread: Aprilia SXRZ

  1. #451
    Join Date
    Sep 2006
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    Wash. State
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    If your in SoCal, why not just contact FMF directly and ask them about a set of pipes........ They do make some killer stuff and should be amazed at the work already done. They could make em out of Ti as well to save you weight and make them look immaculate.

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  3. #452
    Join Date
    Apr 2009
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    Quote Originally Posted by Tfunk View Post
    If your in SoCal, why not just contact FMF directly and ask them about a set of pipes........ They do make some killer stuff and should be amazed at the work already done. They could make em out of Ti as well to save you weight and make them look immaculate.
    Well, I've never seen a one-off custom pipe from FMF. Never seen a hand-coned pipe from FMF, either.

    Where have you seen this? Post the info.

  4. #453
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    Sep 2006
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    Wash. State
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    I haven't, but that it is not the point. My point was to contact them, show them the progress already made and that you are serious in your build, and ASK them if they could do something for you. Was just and idea, I mean they are one of the largest aftermarket exhaust companies, they make tons of Ti stuff and I only use their products, they are top notch and work.

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  6. #454
    Join Date
    Apr 2009
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    I appreciate your input. I need all the help I can get.

    I was asking if you've seen hand-coned pipes, because The FMF pipes I've seen are made using stamped sections.

    Making hand-coned pipes isn't very difficult - but it's extremely difficult to get good performance and make beautiful pipes.

    I need to see examples of the workmanship before choosing someone. I'm hoping to end up with pipes that look like TSA, GPL, or Lomas custom pipes.

  7. #455
    Join Date
    Apr 2009
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    435

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    Battery box brackets welded in. Just need to jig it up and drill holes.






  8. #456
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    Apr 2009
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    435

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    Here's the latest.

    The engine is 378cc. There was some confusion (on my part) because I originally wanted a 421. When the engine builder told me that has last 378 dynoed at 77HP, that sounded about right to me - so I agreed.

    So, I've switched back to the PWK 28s (which need to look as good as the 33s). Soon, they'll be polished and looking trick.



    Also got rid of the red reed spacers. They looked awesome, but pushed the boost bottle 1/2 inch farther away from the head. So, there was a big space between the cut-out and the H20 outlet which looked wrong. I thought about using some thin spacers, but that would add 2 more gaskets and potential for air leaks.



    Looks like not enough room to build a proper airbox, so I might have to run open filters.

    Also need to design a new carb support rod. The rod I made for the 33s won't work.

  9. #457
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    Apr 2009
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    I was skeptical, but tried a pair of clear blue float bowls. Not sure if they will crack and/or leak - I didn't get that far.



    Supposed to fit PWK 28s, which they do - but they have an extra vent. That means 2 more tubes, and there are already 8 tubes on 2 carbs. Also, the brass overflow tubes are shorter than on the PWKs. Sending them back because of the overflow tubes.


  10. #458
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    Apr 2009
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    435

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    Found some air filters that fit. Still might make a custom filter.




    Sorting out the drain lines to the catch can.


  11. #459
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    Apr 2009
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    New carbs are polished. Still need titanium hardware.



    The 2 gold nitrided titanium screws are threaded into holes that I drilled and tapped for a carb support bracket.




  12. #460
    Join Date
    Apr 2009
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    435

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    Progress is slow, but I'm working on several projects at the same time.

    Working on rubber mounted brackets for the silencers.


  13. #461
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    Oct 2014
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    Still looking awesome as heck.

  14. #462
    Join Date
    Oct 2007
    Location
    Ohio
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    3

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    That's an awesome idea. I bought a RZ new in 1984 and put almost 40 k on and raced it, too. I think the Aprilia frame will work, since the v twin and RZ motors are probably close in width. Can't wait to see it!


    Sent from my iPad using Tapatalk

  15. #463
    Join Date
    Jun 2016
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    12

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    Craziness!

  16. #464
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    Nov 2013
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    27

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    "Wow" is all I have to say!

  17. #465
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    Apr 2009
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    435

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    Working on the silencer brackets.








  18. #466
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    Apr 2009
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    Need custom mandrel bent stainless tubing for the silencer in and out tubes.




  19. #467
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    Apr 2009
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    Cutting down the seat support rail for clearance.


  20. #468
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    Apr 2009
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    Working on the second mounting bracket for the carb support rod.


  21. #469
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    Sep 2014
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    10

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    ^supermoto p0rn. Seriously. i check for updates on this build almost every day

  22. #470
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    Apr 2009
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    435

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    Got titanium bolts and anodized aluminum washers for the carb caps and bowls.


  23. #471
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    Apr 2009
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    435

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    Getting on with the chop & weld. Cut sections of tubing to fill the cuts.






  24. #472
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    Apr 2009
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    Stainless exhaust flanges.



    Stainless silencer caps.


  25. #473
    Join Date
    Nov 2013
    Posts
    27

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    Such great work

  26. #474
    Join Date
    May 2015
    Posts
    57

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    This build inspired me to start a project. Outstanding work! I could only dream of building something like this. Don't have nearly enough patience to wait so many years before riding. Can't rush excellence, keep up the great work

    Sent from my SM-G900H using Tapatalk

  27. #475
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    Apr 2009
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    Drilled the two silencer blanks and inserted heli-coils. These new silencers have o-rings - the original Toomey silencers didn't.




    I took the stainless exhaust flanges back to the machine shop to reduce the flange thickness. One got bent and had to be remade. When I got the new one home it didn't look right. I asked for 0.062" but it was 0.052". Now it's too thin! Back to the machine shop and said I'll pay for another. Machinist said- "Just for 10 thousandths?" Fuck me- that's more than 15% off on the length. Both flanges are now done.


  28. #476
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    Apr 2009
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    If I copied the aluminum silencer end caps exactly, the stainless weight would be 240g.

    My design has them down to 116g. The aluminum caps are 83g.

    Still need to take off a little more. I asked for an O.D. of 2.250". The machinist cut them to 2.252 and they don't fit. I put a mic on the originals, and they're actually 2.248". Back to the shop again.


  29. #477
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    Apr 2009
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    435

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    Phase 1 of sprocket lightening is done. Hard to see, but there's a small radius on the corners.




  30. #478
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    Apr 2009
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    Quick preview shot. Better pics soon.

    The center hole is slightly out of alignment with the teeth. The center hole will be covered with a nut and lockwasher, that's why I centered the mods on the teeth.


  31. #479
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    May 2015
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    57

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    Have you decided what you're going to do with the headers? I'm guessing upswept?

    Sent from my SM-G900H using Tapatalk

  32. #480
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    Apr 2009
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    Quote Originally Posted by nico.allers View Post
    Have you decided what you're going to do with the headers? I'm guessing upswept?
    Yep.

    Will be working on the stinger sections before the pipe cones. Thinking about tig brazing the sections together and would like color anodizing between the beads. Sort of like this technique:




    We'll see....

  33. #481
    Join Date
    Nov 2013
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    27

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    Still brilliant. Glad you're keeping this up to date!

  34. #482
    Join Date
    Feb 2005
    Location
    Maine
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    521

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    Quote Originally Posted by Kodokan View Post
    The center hole is slightly out of alignment with the teeth.
    It's defective then, throw it out.

  35. #483
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    Apr 2009
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    435

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    Silencer brackets starting to take shape.

    Need to jig them up and get welding.


  36. #484
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    Oct 2014
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    1,891

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    Quote Originally Posted by Kodokan View Post
    Silencer brackets starting to take shape.

    Need to jig them up and get welding.

    I think you should post up pics of this work of art daily.

    Sent from my XT1254 using Tapatalk

  37. #485
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    Apr 2009
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    435

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    Welding the silencer bracket.



    Had to break it down to weld inside the bracket. Gotta clean up and jig it again to weld the silencers.








  38. #486
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    Oct 2014
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    Yay.

    Sent from my XT1254 using Tapatalk

  39. #487
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    Apr 2009
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    Silencers freshly welded to the silencer bracket.

    Need to clean up the welds, then figure a way to jig up the exhaust tips.

    Need the tips in position so I can measure for 2 machined spacers.




  40. #488
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    Apr 2009
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    Been working on connecting the exhaust tips to the silencers.

    More difficult than I thought to do it right. Making tight curves is more difficult with tubing vs. making rolled cones. With tubing, the angle cuts can only be slightly different - otherwise the edges won't match up well. It's even more difficult because I need a small, tight "S" shaped connection.

    I started cutting and shaping some small pieces, but I don't have the proper tools to make accurate cuts.




    Now trying something different.

    Designing a titanium bracket that will bolt onto the subframe exhaust tip holes. The bracket will have threaded bosses to relocate the exhaust tips. Maybe I can get a better angle to simplify the tip-to-silencer connection.

    First, I need to fabricate a bracket that is adjustable for height and width.


  41. #489
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    Apr 2009
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    435

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    Whipped up a quick bracket for a test.

    Looks like I'm on the right track.




    Starting to get a good fit, so I took measurements for the adapter mount.

    Will start with aluminum, instead of titanium, because it may take a couple of tries to get it right.


  42. #490
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    Apr 2009
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    435

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    There are 2 nuts on the tail that aren't easy to hold in position when installing - so, I made a couple of 10mm nut/flanged collar pieces out of grade 5 titanium.




  43. #491
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    Oct 2014
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    Custom made nuts, 😎, too cool.

    Sent from my XT1254 using Tapatalk

  44. #492
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    Nov 2013
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    27

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    Wow! That's attention to detail.

  45. #493
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    Oct 2014
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    I personally would've made them 12 pt. nuts, but thats just me.

  46. #494
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    Apr 2009
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    435

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    Quote Originally Posted by lloydstrans View Post
    I personally would've made them 12 pt. nuts, but thats just me.
    Are you saying you would mix 12 pt. nuts with 6 pt. nuts?

    Not me.

    Not all of the titanium hardware is custom made. I used lots of off-the-shelf titanium bolts that are not available in 12 pt.

    Hardware should match up, over the entire bike.

    I do appreciate your enthusiasm.

  47. #495
    Join Date
    Oct 2014
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    1,891

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    Absolutely not, just busting you cajones. I don't like getting stuff with non factory fasteners, so I wouldn't do it to myself.

  48. #496
    Join Date
    May 2016
    Posts
    147

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    This build is - simply put - AWESOME! Thanks for keeping us up to date! You have some real talent.

  49. #497
    Join Date
    Mar 2007
    Location
    Sunshine Coast. QLD. OZ
    Posts
    632

    Default Wow

    I'm so jealous of the skills on display.

    I'd love to fit an RZ350 engine in an Aprilia RS250 frame.
    (The engines are getting hard to source in Aussie.)
    "Illegitimi non carborundum "
    '17Husqvarna 701SM. KTMs-'06 450EXC '04 SX525 - Motard
    '96 Suzuki Bandit1200S - ATS (All The Sh*t)
    '08 YZ250F -MX raced so slowly, it's a sin
    '73 Honda Z50 minitrail - Road legal, Vintage, Cool

  50. #498
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    Apr 2009
    Posts
    435

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    First prototype adapter was a fail.

    Subframe holes were off. Only one bolt holding it on.


  51. #499
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    Apr 2009
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    435

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    Second prototype adapter.

    Bolts onto the subframe properly, but is too tall. Will shave 2mm off.


  52. #500
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    Apr 2009
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    435

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    Shaved down the adapter 2mm and fitted the exhaust tips.

    Left a one-finger gap between the plastic and the tips. Big mistake. Tips look too low.

    Decided to shave off another 5mm.


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