2-stroke Pipe Repair- HydraForce with custom bung

[@bmdbigfeet1031]

Made my own for about $300 cdn. Used a 4 ton porta power, made my own clamps. Most pipes have flanges on either end. Two plates per spigot, they gotta be strong. 3/8 or 10mm thick for the stinger ,only needed two bolts for clamping. I used pieces of Teflon and pieces of tire tube for sealing. Now the header spigot was a little more challenging. The 3/8 plate was ok but the bolts would bend because I had to tighten the outer plate so much. I could get 3 to 400 psi then the pressure would push water past the Teflon. I had to start over. Found 2 pieces of aluminum, 1in thick,6in long and 1 1/2 in wide. Drilled ,tapped threads and drilled 2in hole. The aluminum blocks sit flat together so no chance of it folding when under clamp pressure and bolted through for stability. Got lucky with the hole size , fit around the pipe perfectly and snug up against the flange. I threaded a Schrader valve into the plate for bleeding air.The outer plate was the 3/8 plate ,it won't bend. The porta-power doesn't know whether it has water or oil in it so I just put it together and tried it. Yup! Worked so damn good I had to weld a seam back together. 🤬 Oh well, Had to know how far to push it. Getting the kinks out is pretty tough but the dents come out super easy. 3 to 400psi does it. For the most part , the water treatment works better than heat. Using a torch doesn't get the pipe back to or close to it original shape, water puts even pressure throughout the whole unit. I can live with dents but a twisted pipe is horrible. Vibrating, leaking pipes suck. I haven't seen hydraforce for anything other that Euro bikes. Made it for yz250x. It was all built with a drill press,mig welder ,chop saw , 2in hole saw 3/4 hole saw. Basic shop tools. It was fun and it worked. The bung plug was beautiful, but I don't have a lathe.

[@CW-up7xv]

You can move the kickstart lever up one notch and it will sit perfectly between the tank and pipe. I have the same setup

[@TokyoOffroad]

Yes, I might do that. Even with the pipe perfect it's still quite close...

[@TokyoOffroad]

I just moved the kickstart lever one notch on the spline. Loads of clearance now. Much better in this position when using a Gnarly pipe. Thanks for the suggestion...

[@CW-up7xv]

@@TokyoOffroad yeah I forgot to mention that part about touching the footpeg. I've had no issues though.

[@BrendaEM]

Your custom bung is quite a bit like a split valve keeper. Good idea!

[@Drewski423]

You’re a freaking genius dude.

[@kfjfjfjewlsls]

the k in knipex is not silent, tought i'd point that out :P quality content as always

[@TokyoOffroad]

Yes, I know it's pronounced like that in Germany. But is that how English speakers pronounce it too? Being in Japan I'm kind of in the dark :-)

[@rods6405]

I know there are heaps of reasons NOT. But surely they can make a 2 stroke with the exhaust port facing towards the rear or side ?

[@clintcorbin3429]

See how that pipe comes out, goes to the left, then curves back over itself before going to the rear? 2-Stroke pipes have to be a certain length to function correctly. Putting the port on the rear would require you to run the pipe up to the front before turning it around to the rear anyway. And then there would be the question of where do you put the carb and air box?

[@grutzmac]

Thx for the video. For us who don't have a machine shop but we do have a Hydroforce kit - do you have any tricks for keeping the bun on the pipe and from blowing off?

[@TokyoOffroad]

Aaron Grutzmacher - The issue I had with the stock bung is that the o-ring would blow out, not that the bung would come off. It’s critical to try to keep the bung centered on the pipe while tightening. Sounds easy, but in practice is actually difficult (for me) to do while tightening securely enough.

[@nicolaevaleanu2953]

Can YOU Tell me the dimensions of the custom bung?

[@desmonchild]

Nice hammer work!!!

[@rodrigopoblete504]

Hi, is it compatible with the 2020 model of KTM?

[@TokyoOffroad]

No, I would not recommend trying to blow out the stock 2020 ktm pipes using this due to the corrugations. One option would be to take off the stock pipe (before damaged) and fit an aftermarket pipe which can be easily repaired. You could then fit the stock pipe back on if/when you sell the bike...

[@doublehelix109]

the only reason your 'o' ring blows out is when you tighten down the clamp it is not properly centered. use these all the time from throwing our bikes down silly shit, i have 2 spare pipes just for this reason we share a couple of these tools around in our riding group they work so well!!

[@TokyoOffroad]

Yes, I agree with you you. But I find it very difficult to keep the clamp centered when tighten. I also found that when hammering the o-ring would often blow out. This is the reason I got so frustrated the last time I used the stock clamp and decided to make my own. Other than this I think it's a great pipe repair method.

[@NirHason]

@@TokyoOffroad I found that releasing the pressure slowly keeps the shape you got after the fix. When I did it for the first time, I released the pressure fast and the pipe's shape lost about 40% of the "fix"...

[@palmpilote]

Will you sell this custom bung on your website?

[@TokyoOffroad]

No, I don’t think I’d be able to make it cheap enough to be attractive. I could make them to special order if there is interest.

[@PrimalEnduro]

@@TokyoOffroad I would be interested as I have a Beta 200 and the 250/300 bung does not fit because the shoulder/weld is deeper than the 250/300. Your bung is adjustable in that sense using the bolts.

[@TokyoOffroad]

That's interesting. I need some more information to confirm whether there are any other differences. You can contact me here: www.tokyooffroad.com/contact/

[@kw9799]

@@TokyoOffroadThere's interest. I'll buy a few of them as I have friends that own these as well as myself. Your fitting is obviously superior. Please make a few. Buying new pipes when you have a fixable one is annoying and wasteful. Your system looks awesome.

[@stone4858]

That Hydraforce is a great piece of tool, but it's just to expensive to buy 😔 If you had to buy one to make money buy fixing other peoples pipes it would be reasonable, but to buy for my self it's to much I guess

[@TokyoOffroad]

If you have some riding buddies why not buy one between you and share it. BTW I have no association with HydraForce and paid full price for mine.

[@stone4858]

@@TokyoOffroad It's a very good idea but I only have one friend that I ride with a he has a 4 stroke 😅

[@NirHason]

@@stone4858 So it's time for you to make sure he'll switch to 2 stroke (;

[@TokyoOffroad]

It's inevitable that he'll switch to a 2-stroke :-) Resistance is futile ;-)

[@NirHason]

@@TokyoOffroad LOL