EXPANSION CHAMBER BUILD PART 3: Cones & Pie Cuts

In the third video of our expansion chamber build series, we add on to the pipe by creating the expanding and contracting part of the exhaust. We did so by making a pie cut expansion chamber, using a band saw to cut each cone piece. After proper fit-up, we welded the whole thing together. Our next video will feature a silencer build in order to keep the noise down.
Please subscribe for more videos! Thank you and enjoy.

[@whatcanilearnhere9158]

i'm an old person with lots of experience fabricating, machining, restoring, etc, even some really "big dollar" stuff. somewhere i think there is still a VHS tape of me going 193mph down a local country road (had some police friends there to watch for other people, and radar gun my speed) anyways, really really enjoyed this vid!!! you are off to a better start than i was! now i'm motivated to use a little of my retirement time to build a rat bike outa some of the old stuff i have lying around from back in the day

[@jkoeberlein1]

I'm too impatient to make my own. So over the years I've bought 4 of them before I found one that works. Great job.

[@FormulaJake]

It took far longer than I'd like to admit! If you found one that works, run with it 🤘🏼

[@jkoeberlein1]

@@FormulaJake The sad thing is we have 2 or 3 ready made one but senior won't give them up. They were built for Scott and he can't let them go. I just need to copy them.

[@olivergough8550]

I think you did extremely well

[@rchydrozz751]

Remember in your shaping. The speed of sound changes with higher temperatures. That will effect the pressure wave back to the cylinder.

[@thailandmopedadventures611]

Very good Job - it is NOT easy.

[@billclark5943]

Great job for your first shot. Obviously we strive for a perfect fit but when your stuck with having to fill a gap lay the rod on its side in contact with the base metal and pulse the pedal. This will control heat and ensure the filler is always in position to fill when you apply the heat. As mentioned earlier the hammer an anvil would have allowed you to tap many of the gaps closed or reduce them

[@FormulaJake]

Thanks for the advice 👍🏼 I'm confident that if I tried again, it would come out much better. Just the practice alone makes it worth it!

[@AxelP33]

If you want to make perfect cones, you need to hammer them on cone anvils. Basically a solid cone made out of steel. Use a plastic mallet as not to stretch mallet. Tack the cones and "beat" the junctions. That will ensure a goot butt joint.

[@aleceshowe]

Very good for a first try

[@arttu8893]

Wayy yoo underrated

[@FormulaJake]

Thanks brother! Part 4 will be up in the next month :)

[@quartfeira]

Just keep practicing dude. You did an amazing job. ✌️

[@johnbrevard5966]

WOW, That's amazing the work and the finished product!..PS, where did you get the cone pupe

[@FormulaJake]

Thank you! It looks even better with the silencer and all mounted up as shown in part 4 and 5 😄 I bought the cones online from Cone Engineering!

[@magnatron7734]

Great vid

[@bMoth941]

It looks awesome. Looking for inspiration and tips as I’m planning to make a new exhaust for my DT175. Good videos 🙌

[@FormulaJake]

Thank you much! Best of luck on your project. I hope to get back to mine done day 🤙🏼

[@davidburke3378]

Ever try Acet/Oxy welding with a small tip and 1/16" rod? Might be easier to control and fill gaps. Also welds up dirty oily cracks in expansion chambers without getting porosity like TIG does.

[@FormulaJake]

Not a bad idea! I've never gas welded before, just TIG, MIG, and stick. I have the most experience with TIG though. With better fitment/prep, and a lot more practice, I could have these welds dialed 👍🏼

[@agushart1]

cakep ... keong nya

[@theeddies]

Looks good man. Did you do any calculations to find the sweet spot of the chamber or just educated guess?

[@FormulaJake]

Thanks brother. I did some calculations in part 1 to estimate it, and built it mostly according to those calculations. Of course, it isn't perfect, but should be close enough for my use!

[@theeddies]

@@FormulaJake That's right I forgot about that. Nice work!

[@larrywarner9314]

Free tip use mig wire it works good

[@MarttiSuomivuori]

It is amazing what you do with your do hands. I have two questions: On Dyno, what does it look like? could you find carbon fiber that could stand the temp?

[@FormulaJake]

Thank you sir! I have not had it on the dyno to test the power difference, but it certainly feels much better than the old pipe. I personally haven't heard of carbon fiber being used for the exhaust pipe itself, but it is commonly used on modern two strokes as a guard for expansion chambers.

[@Mattytube18]

Where did your cone come from?

[@joenels4356]

this stuff takes so long i hate prep lol no rush happy braaping soon

[@williamgreen2364]

U need alot smaller tig torch and thinner 1/16th wire. Good luck.

[@FormulaJake]

Yupp, midway through I ran out of 1/16 and had to use 3/32 because that's all I had. I've been trying out 0.035 MIG wire as filler for small welds, and so far it's worked out great.

[@guidosamson682]

The form is very nice. What i dint like is that you add too much wire. When i build an exhaust i dont use wire. Only when necessary to fill a gap. But thumbs up for your work. U cant get worse only betten. Lollll

[@FormulaJake]

Thanks for the advice! For my first major TIG project it went okay, and I've definitely seen some improvement over time 👍🏼

[@guidosamson682]

@@FormulaJake we weld with oxy acethyleen. Argon is too expensive. Only aluminum we weld tig. If we modify crank cases etc and reshape them. Please post video of rge bike starting and riding.

[@FormulaJake]

kzbin.info/www/bejne/eZOWkodppNZ9bsk My first time starting her up!

[@ALIVE8455]

Where did you get the cone piece to cut? Totally skipped over that.

[@FormulaJake]

www.coneeng.com

[@blkbird98ta]

I want one for my honda af16 polini corsa scooter build

[@wilson6x6]

Where did you get your cones? Did you make them yourself?

[@FormulaJake]

I bought them online from Cone Engineering. They have a bunch of different sizes! I bought them unwelded, so I had to run a bead down the length of each cone in order to fuse the seam.

[@13nutkiller]

No back purge?

[@FormulaJake]

Mild steel 🤘🏼

[@13nutkiller]

@@FormulaJake SO BACK PURGE IS ONLY NEEDED IN STAINLESS RIGHT? IS IOT MANDATORY

[@FormulaJake]

Only stainless, titanium, etc require a back purge. With mild steel and aluminum you might achieve better results, but it definitely is not necessary.

[@curtisburton4154]

Where did you get the cones?

[@FormulaJake]

Cone Engineering. Order them online

[@Steel-Team-6]

Did you make the cones or did you buy them

[@FormulaJake]

Bought them online from Cone Engineering because I don't have a slip roll. They arrived rolled but unwelded.

[@Steel-Team-6]

Airborne Productions thanks bro

[@joenels4356]

next time twist some .030 mig wire together with a drill and vice i used three pices for .065 wall eh?

[@FormulaJake]

What is the MIG wire used for? I'm not understanding what you're describing

[@joenels4356]

filler rod @@FormulaJake

[@FormulaJake]

@@joenels4356 gotcha. Great idea! Would have been perfect since i ran low on 1/16 filler, the 3/32 filler was absurd. The cones were .040 wall, 20 gauge.

[@joenels4356]

twist two for that thin i was using two for 065 wall @@FormulaJake

[@ugisievins6867]

where can get cones like that

[@FormulaJake]

I bought mine online at Cone Engineering

[@mr.king_3620]

Hi You make sailencer

[@FormulaJake]

Yes! Part 4 is here: kzbin.info/www/bejne/jn_PqZh5j8tmh7M

[@MK_Weldings]

Nice work !! I made exhaust too, look my last video

[@RFpipes410]

Nice work!! I made exhaust too, look my video

[@Liveforeever]

You are running too low of amps and too much filler material

[@joshuaharrison9331]

Everytime this guy cut the pipe he shortened it the thickness of the saw blade. This is a totally wrong method.

[@craigkoeberlein998]

Don’t they get sanded to fit?

[@joshuaharrison9331]

@@craigkoeberlein998 you mean sand off even more length?

[@craigkoeberlein998]

@@joshuaharrison9331 it they were cut a little long and sanded to fit? I would like to learn a better way. If there a video you recommend? Do you have one?

[@craigkoeberlein998]

@@joshuaharrison9331 I get what you’re saying I just don’t know what other method you would use to cut them.

[@joshuaharrison9331]

@@craigkoeberlein998 lol I do. Make cone template with the angles included. Cone layout for exsample

[@shawnomack3927]

That beard needs to go bro