Recently I came across your response to Teranantula Boy's comment in response to Andys Motorcycle Obsessions vid mocking his mental health, the comment you placed has since been removed. This surprised me as I believe your own wife suffered from depression due to the harassment from The workshop and his commenters. I don't agree with constant ridicule and thought by you ignoring it was the right path to go down but to make comments in response to your commenters who obviously watch vids from these channels is as bad. I have in the past defended your wife on Matts channel and makes your comment a disgrace not only to Andy but your wife and anyone else with mental health. It is constantly said on both channels you remove comments you don't like, I haven't been convinced of this so it should be interesting if my comment gets removed or you respond to it.
Nightster: Nightster, thank you for your message. For the record, the message you speak of was removed by the original poster himself, not us, and with that goes any responses to it, this is the way You Tube works for some reason. As you are aware, we have been on the receiving end of fixation from two particular channels, along with their audiences. We do not know these individuals. We have, however, had to endure over 3yrs of harassment at their hands. As a mature, professional woman I stepped back from publicly appearing in the videos due to the incessant, and completely unacceptable, vile and humiliating abuse from these individuals' fixation and their trolling audiences. These days, I take part only in the background work. It is their social media that has been the provocation, and it for that reason alone. I don't suffer from any mental health issues, I simply have been very upset and humiliated and as a woman, I do not have to tolerate this. However, that is not to say that we do not support, or understand, mental health issues and, in fact, we work privately helping people in this capacity. Having had to tolerate such abuse for so long, it would have been helpful had these individuals considered the impact of 'their' behaviours. All we have ever done is to seek to protect ourselves and to continue making the videos that people enjoy and support. It is deeply regrettable that a comment made about an individual, who had displayed abusive behaviour towards us yet again, caused him such offence, it was truly not intended. It was borne from having had to tolerate 3yrs of unending abuse, and admittedly, a careless and ill considered remark. We wish this individual well and hope that they can find harmony in their life. These individuals have sought to destroy everything we have worked on with our channel, and believe it or not, even our own private family business as well. They have manipulated, distorted and spun the truth. Perhaps you may not be aware, that one of their viewers has contacted every one of the companies we have had an association with, clearly in an attempt to further undermine and destroy all we have worked for. This is despicable and damaging. The creator, who's video comment stream it appears on, is fully aware of this, yet does nothing to attempt expiation. Thank you for your support, and the gift you sent us for the Harley project, your faith is much appreciated. With respect, Paula
Well said Paula , yourself and Derek have been really dignified over the last few year's and to my knowledge this is your first response ever , you know I have been incapacitated over the last few days which has given me time to scan over quite a few post , it has been heart warming to see how many people have stood by you especially on the Aussies post . Yes you have sponsors but just look at the professional videos it enables you to make , keep up the good work .....
@@Moonfleet41 it's a real shame as I used to love the banter and fun Mrs delboy brought to the videos..no more cake and questions with Mr Dyson now..loved that..a real family fun thing..but I gotta admit the hassle this channel gets from some pretty nasty,jealous and pathetic people is so sad to see..I really cant believe you still have the energy and spirit to put yourselves out there...I've always watched from very early on and genuinely think del is a modest..hold your hands up fella..never claimed to be anything he is not and glad he still got the will to keep sticking his head up despite the shit that is chucked at him
@@Moonfleet41 Hi Penny I only saw your reply as I did not get a notification and don't always get notifications to my comments for some reason. I accept your explanation and understand many of your points, I don't know where I picked up that you had mental health issues, i.e. depression over the comments made mainly by the commenters to these channels but can only have been from one of the channels or comments though I thought it was said by Del himself so I stand corrected. Regarding my initial comment to Tarantula Boy's comment, I believe what you say and I know you have helped people with issues. I'm not sure if the part of your comment where you state "It is deeply regrettable that a comment made about an individual, who had displayed abusive behaviour towards us yet again, caused him such offence, it was truly not intended" is an apology? If so no matter what he has said in the past it would have been better said to him though I don't know if it would be accepted or any returned and I think this correspondence would have been better if it had come from Del and not yourself. I too am tired of it all I think Andy is aware of hence my interest. Thanks for your reply.
I'm impressed... really impressed. I'm working on a B-King rebuilt-project since february and I can feel the satisfaction in every single little triumph you've reached with your own hands. Go on, boy! Greetings from germany!
The helical spring washer is not helping the dome nut(Which is good idea I haven't thought of)staying in place, it actually makes it easier to come off buy it self with all the vibration. A nut has better clamping force than a nut + helical spring washer. Just use normal 125/7089 washer and nut will have a better chance of staying put.
Hi Del, I must admit that I see no practical or aesthetic problem in plugging the air bleed holes but fabbin' bits is always satisfying. As regards the dome nuts, they always concern me in that without very careful measurement of all the nuts for each stud you cannot assume that they will not bottom out before achieving the clamping pressure. Also, spring washers have a terrible reputation for relieving the torque on the nut especially in exhaust applications where there are many heat/cooling cycles, which anneals the metal. I would have dispensed with the spring washers and relied on the silicone exhaust cement to lock the threads - it will prevent the nuts vibrating loose if you must use dome nuts. I prefer shouldered K nuts for this type of application.
I agree .Removing the old studs and threading the AI holes is the engineers solution and looks professional wherever it is possible and guaranteed not to leak , ever . On a scratch build engine I would weld the holes up as part of the eventual gas flowing process and polish of the exhaust ports . I totally agree but began my introduction into the world of mechanical engineering as a kid building racing bikes for my older brother . How many oil galleries , drysump pans etc., do you see with blanking plates closing up the galleries,etc. ? On my Triumph 675R race engines I have no choice but to machine solid dowels , remove reeds and use one cover as an additional breather in the cam cover and make a blanking plate for the other from 5 mm aluminium plate . Everywhere else where I've altered the block to remove the water pump and build the dry sump system the remains holes are threaded and blanking plugs fitted regardless of size and this operation leaves some pretty big holes to tap and plug throughout the lower crankcase . However this is not the racing world where K nuts are the only sensible fitment , its street fighter use so what looks like an after thought is the DBs in this application , where you see HT bolts replaced with A4 and even A2 Stainless socket cap scrws/ bolts along with their infererior strength and heat transference capability in , of all places , brake calipers , exhaust stub brackets etc . There are reasons why a stud and nut/washer is preferred , clamping force on cylinder heads , main bearing caps , etc., and used in every high performance engine design for a purpose , so deviation from this with a stainless socket head screw must not be ventured into on the basis of aesthetics .
A simple enough project, very nicely executed. I especially liked the approach of sandwiching the fabbed aluminum plates and then the gaskets between the steel ones you cut out earlier. Having seen your PAIR valve issues I took a closer look at my '99 Bandit 1200. I don't have 'em, though. Another job and video well done. Go team DBG!
Awesome job as always. I like the way you make your own parts. Del and Penny Have a great weekend and the wonderful week ahead ridesafely and God bless.
Thank you so much Paul, its been a really busy week, and a seriosuly challenging time on UA-cam lately, but onward and onward, staying focused on the bike project, and enjoying a bit of summer sun when we can... take care yourself, and have a Great weekend too.. D&Px
I am amazed by the things you do my friend, I wish I was half of the craftsman you are, well done, the good thing in every of your video I always learn something new. God bless you.
Thanks for another awesome video and an impressive job blocking off those holes, for sure (I've gone the route of tapping them and using a new bolt when doing similar jobs to remove an AIS, but I must admit I like your block-off plates better). Well done, and really enjoying your progress on this bike.
Thanks Donald, Always good to hear from you, yeah, the blot in the hole method is fine, and works really well, i guess i gust wanted to take the long road in this one, and im happy with the outcome.. have a good week mate, and take care.. Del.
It still amazes me how one little thought, can change the way you do things for the rest of your life. Even half a technique adopted, can make life easier....for the next time!
Another question for you, in regards to aftermarket headers, do you think there is any reason the header nuts would come loose? I did a full exhaust system on my MT-09 and didn't think of putting anything besides the stock nuts back onto it. For some reason I have a fear they will loosen over time? I tightened them to a pretty good amount (by feel).
Hi Dan, ok that's a understandably worry, but it'll be fine... remember the exhaust gasket rings you would have fitted with the new exhaust are crushable and as you tightened down the exhaust header, you crush in against the new gaskets to make a seal and generally the gasket pushes back against the header and it's very rare that those nuts will come loose by themselves, they certainly don't need to be lock nuts or have any form of thread locking compound on them (and with the heat in that area most locking compounds won't work anyway)... if you're worried, then it doesn't hurt to take a small quarter drive socket and ratchet and just give them a little gentle tweak to feel if they've come loose, it doesn't mean tighten them up more than they currently are, just some twisting pressure against them, and if they've come loose, then they'll move and do back up, but if they haven't you will just feel resistance and they won't move, so they are fine....
It was once said to me many years ago that if it doesn’t work it’s a bodge, if it does work then it’s a modification.... Excellent series, can’t wait for the next instalment.
Just a word of caution from somebody who has taken apart lots of boat engines and outdrives. Stainless and aluminum is often hopeless to get apart. The ally corrodes and sticks to the stainless like you can´t believe! It´s also worth investigating in if you really should use a copper based anti-seize combined with ally. Copper and ally don´t play well together and ally usually loses, badly. So there could be a good reason Suzuki chose to go with mild steel nuts and screws.
Thank you for yout insight, i have heard this before, and as a result i have ordered some AL1100 from Wurth, in the hope that it will keep things in order once the bike is on the road..
Fantastic outcome and finish. Looks so much neater now in that area Del. Another great vid and lesson in skills which aren’t taught anymore.... bring back the proper apprenticeship 👏👏👏
I’m about to do this, so you’re helping people all these years later. I don’t anticipate any problems, with it, but my secondhand exhaust has been a hit to put on, so I wish I’d done the PAURS mod first time around. Looking for your exhaust vid now. 🙂
Hi Del. How you been? I know you're busy but I was wondering if I could borrow your expertise for a moment. I've had issues with burning oil on my Hayabusa recently, and was wondering if this sounds familiar to you. A few years ago, I had the bike in to a local mechanic, to get stuck rotting exhaust removed (similar to yours). At some point during the process, they mentioned having to use some machine while remove the oil and 'the oil went everywhere' is what they said - I am forgetting exactly what they said, but they said they had some trouble removing the oil. They also mentioned they had the engine upside down, which I would assume was so they could machine the new threads in (like what you did). Anyways, since then, I have had issues with burning oil. I don't know if the previous work done is related, or if it is just a matter of time. I was experiencing 'bogging' and noticed I was a piston down. So I replaced the spark plugs and 2 of the coil packs (left the other 2). I have also replaced the oil twice since then. This worked at first, and it seemed to have fixed it, but I could notice some burning of oil coming out of the right exhaust (to the right as you sit on it, could smell it and see smoke). Eventually, the bogging started again, and I had noticed that there was oil on the right-most spark plug (as you sit on the bike), so I cleaned it off, put it back in. It seemed to work for a few months, until it happened again recently. I cleaned them off again, however, it only lasted about 15 minutes or riding, before one of the pistons went out again and it started bogging. So it is either getting worse, or somehow there is oil where there shouldn't be in the upper chamber. My question is, does that sound like piston ring failure to you? or is there something more mechanical or obvious that I am missing. Obviously, the only sensible thing to do would be to strip it down and have a look, but in your mind, what is the most typical cause of that? I am asking on the outside chance that I am missing something that might be immediately obvious to you. The bike is at 70k miles now for what its worth, a 02 plate. Anyway sorry for the war and peace. I know this probably isn't the right forum for this kind of lengthy question. I just though it be worth me reaching out to someone who I trust with Haybusa related stuff, before I resort to dropping it off at a mechanic. I guess the end goal here is if I should put any more money into fixing the bike, or will it be something cheap to fix. Thanks for your time anyway Del, yours videos have saved me a lot of money over the years. Maybe this message could help someone else as well.
Wow mate that is war and peace, but I get your question... if the bike rolled in to me, noting 70k miles, first thing I'd do is a leak down test, slightly better than a compression test, it pressurises the cylinders, testing their overall seal.. they will leak down, but the speed with which they do so is measurable data and there are guidelines... if number 4 is suddenly leaking down severely, then to test where it's coming from, check the crank case breather... if it's hissing out of there, then it's going down the bores past the rings... if it's hissing out of the rocker breather, it's going up past the valves... If you want to know which valves, listen to the exhaust, that will tell you it's exhaust valves, listen to the airbox and that'll tell you it's inlet valves..... once you know where your leak is, you can address it! I doubt it's bores, unless you have a broken ring as they are nickasil plated and hardly ever wear, but that's at least a direction to consider! Good luck with it mate, hope it's something not too expensive to fix...
@@Moonfleet41 Yeah my bad Del, I tried to cover the whole story in one go to paint a picture heh. I will check all those out so thanks a lot for your expertise there. Hopefully see your own Hayabusa pop up again in a vid in the future. Be a sad day when mine finally packs it but that's life I suppose. Cheers
Thanks Gary, it seems a long way off to even consider that at the moment, but its a great motivator to do my best with it though... Have a great weekend too, take care.. D&Px
Im curious about removing the pair valves. Will the ecu/and or injection system, now see the engine as running too rich and adjust/ thin down fuel/air mixture . And what electrical connections etc would you need to delete/tune?
Gen 1 has no Lambda sensor in the exhaust, so the ECU has no idea what's marching down the exhaust.. i have a hole to remove from the air box (and blank off) and maybe a power feed to disconnect.. not done one of these yet, done a few Triumphs, and the principles are all the same, just got to check out the anatomy and sort out the details..
Hi Del. I'm wonder if I'll try to remove the PAIR system on my Suzuki Intruder VZ 1500. The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase. So, is it advise to block the PAIR system? Can you give me your advise, please? Thanks and please take care,
Mate your videos, your delivery of content, your explanations and tricks of all trades are bloody awesome. Thanks very much. I was just going to say, I use a small pocket sized axe stone to clean off and face gasket surfaces. Don`t cut yourself... BTW.. I got a K1200r, a ZX9-C2 rat, and some trail bikes. Also a large collection of broken legs, collar bones, wrists and a knee. Keep up the good job my brother from another mother . All the Best from Perth Western Australia. And F##K the haters.
Hi! Delboy's first thank you for your videos , i really like the work you do on motorcycle , clean and precise , and with well explain details about what how you doing things or resolve problems , very good approach thank you againtake care Robert in Australia
@@Moonfleet41 Well you deserve the support. Just remember i be in the UK next year maybe if at the time time if you are not busy i'll visit you we be staying North of London in place call Luton we were there four months ago anyways but again if you plan some holiday to Australia late me know regards Robert
@@Moonfleet41 Onwards & upwards (even further)guys, I see all this negativity with various contributors, the whole idea is a common help to all , that's my 2 bobs worth 👍👍😎
Great video! Only concern is with aluminum for these and exhaust temps because they don't have the water cooling like the heads, I'm curious to see how they last! I first thought they would heat sink into the cyl head but with the silicone I'm not sure.. Thoughts?
Great video Del, I’ve learned a few things watching your projects to keep my CB750 in good nick. Just a thought that came into my head watching this video, I know it’s really whimsical and a bit of fun, but those blanking plates to me are begging for some individual engraving on them :) , maybe engrave the firing order on each one! Keep up the good work fella. Rob.
I now see what you mean by wait until this video....how cheeky with the brass and silver solder. Nevermind great work around with the little Ally plates - simple and great fun to make. Do your oil filter before sticking the exhaust manifold on, easier access. I was going to suggest bluing your new headers but bluing SS is quite literally not worth the time/effort/crazyiness required. I'd stick to wrapping them or getting them ceramic coated for some colour goodness plus long term protection.
Hi Marcus, I'm happy with the final outcome. Im just going to bolt the exhaust on loosely for now, it'll come off again in the future once ive decided.. maybe ill seek out a cool ceramic coating when i get to the final buildup, i have so much more to do still, its only in the early stages at the moment... ive cracked the seal on the filter already so its just hand loose ready fo when i change it and put the fresh oil in at the end.... like all projects, everything just gets temporarily hand tightened for now, it saves things like gaskets and seals getting trashed when you have to take things off again.. have a good weekend mate.. Del.
Thats a 36 grit metal sanding disc on a rubber backing pad... like this. www.ebay.co.uk/itm/Abracs-sanding-disc-fibre-discs-24-36-60-grit-or-backing-pad-4-4-5-5-7-inch/262453630629?hash=item3d1b7496a5:m:mB7R8aFgQDko8iJShziAYuA
Put some of that rtv on an engine case. Tried to use an amount in which it wouldnt ooz out the sides of the case and fall into the motor. Thought i i did pretty good plus the gasket as well and i tore it back down a while later and that stuff was everywhere
Speaking of Norton, I'll throw out a suggestion for your next project Del. How about a 1974 850 Roadster? Old school - not that I have a vested interest. :) - great work as always.
I saw a survey in the beginning of video ...the survey was to pick Cornetto,Pepsi, Coca-Cola,lays and exit so I picked Pepsi ...hope that it's what you wanted of posted that survey
Based on the original gaskets being card and them not flowing exhaust gases I might have just used Loctite 272 on the nuts, being that it's rated for 450F/232C, but I sure liked the job as I hate overpaying for bespoke parts I could make for a fraction of the price considering when you enjoy the fabrication it's all just cheap therapy.
I've just come by this . The reason why the gaskets are card as its an Air Injection System where cold air is mixed with outgoing exhaust gases to reignite unburnt fuel further down the exhaust system . The exhaust gas (after removing the AI system) in this region will now hit up to 900°C in hard use so anything rated under that is useless . Localised temperatures will be around a few hundred degrees less , so get rid of your A2 or even A4 stainless steel fixings etc around the exhaust . The engineers approach to this is removing old studs and tapping out the hole and fitting a hex , torx , delta etc., blanking screw . You can use your stainless steel here as you are never going to remove them and they are not a stressed item . Tap the hole with a second cut tap just enough for the thread length to bit and tighten down the plug until tight and flush , using no sealant as it will seal itself. Then forget it as it will never leak or give problems ever . Given the luxury of doing a head off strip and porting job I would weld these holes up solid before porting . I know because I'm an engineer have been building race bikes , cars and designing high performance parts solutions for 50 years . Think F1 /aerospace solutions not aesthetics , street fighter look for a solution .
Hey Del, I like how you put stainless steel bolts everywhere because they wont rust, but I have a question. Is it good idea to use stainless? From a guy who is really into all that mechanic stuffs and he is really good with details and knowledge just like you. He told me using stainless bolts is really bad because they tend to get stuck really hard. And by hard he mean the bolt can bring rust from the frame lets say and be really hard to unscrew. So hard that he had to break it somehow and than drill it out. So thats why im asking is it good idea for the long term? I know it will never rust regardless of anything but if it get stuck it will be just as bad as those bolts on the exhaust?
Another great vid mate, bet you`re glad to keep moving forwards instead of 3 steps forward and 12 backwards lol,, as for the angle grinder comment below,, i`ve put angle grinders and festool rotex sanders / polishers in my vice for years, never had one fly across the workshop yet, i sometimes wrap a ratchet clamp round mine just to make sure,, but i ain`t gonna tell you how to suck eggs mate as you know the crack already, keep up the good work, have fun and take care. Claypole.
Better watch out using a thin cutting disc like that on the side 😬. Really not what it is made for, use a good thick grinding disc next time. Can easily rupture the disc and take an eye or fly into your arm/leg and cut an artery. Dont believe me, google it! You will see some horrible photos.
Bram de Graaf check how much it is flexing?? Nae sure about you but i have never seen a grinding disc flex like that. I used to remove a lot of material with cutting discs like that, until i seen one in someones forearm with blood pouring out. Never again.
#1 Marine Sparky Its a grinding disc mate... mounted on a rubber baking pad..36 grit, designed for grinding metal..! One of these.. www.ebay.co.uk/itm/Abracs-sanding-disc-fibre-discs-24-36-60-grit-or-backing-pad-4-4-5-5-7-inch/262453630629?var=561257237946&hash=item3d1b7496a5:m:mB7R8aFgQDko8iJShziAYuA
I respect the fact that you show mistakes or things that didn’t work out as you first planned......a few UA-camrs out there who bitch n moan about what you do, just don’t get the fact that many of us just happen to enjoy what you do, it’s entertaining and we don’t expect you to be a bloody genius, anyways mini rant over. Good Job 👍
Recently I came across your response to Teranantula Boy's comment in response to Andys Motorcycle Obsessions vid mocking his mental health, the comment you placed has since been removed. This surprised me as I believe your own wife suffered from depression due to the harassment from The workshop and his commenters. I don't agree with constant ridicule and thought by you ignoring it was the right path to go down but to make comments in response to your commenters who obviously watch vids from these channels is as bad.
I have in the past defended your wife on Matts channel and makes your comment a disgrace not only to Andy but your wife and anyone else with mental health.
It is constantly said on both channels you remove comments you don't like, I haven't been convinced of this so it should be interesting if my comment gets removed or you respond to it.
Nightster: Nightster, thank you for your message. For the record, the message you speak of was removed by the original poster himself, not us, and with that goes any responses to it, this is the way You Tube works for some reason. As you are aware, we have been on the receiving end of fixation from two particular channels, along with their audiences. We do not know these individuals. We have, however, had to endure over 3yrs of harassment at their hands.
As a mature, professional woman I stepped back from publicly appearing in the videos due to the incessant, and completely unacceptable, vile and humiliating abuse from these individuals' fixation and their trolling audiences. These days, I take part only in the background work. It is their social media that has been the provocation, and it for that reason alone. I don't suffer from any mental health issues, I simply have been very upset and humiliated and as a woman, I do not have to tolerate this. However, that is not to say that we do not support, or understand, mental health issues and, in fact, we work privately helping people in this capacity.
Having had to tolerate such abuse for so long, it would have been helpful had these individuals considered the impact of 'their' behaviours. All we have ever done is to seek to protect ourselves and to continue making the videos that people enjoy and support. It is deeply regrettable that a comment made about an individual, who had displayed abusive behaviour towards us yet again, caused him such offence, it was truly not intended. It was borne from having had to tolerate 3yrs of unending abuse, and admittedly, a careless and ill considered remark. We wish this individual well and hope that they can find harmony in their life.
These individuals have sought to destroy everything we have worked on with our channel, and believe it or not, even our own private family business as well. They have manipulated, distorted and spun the truth. Perhaps you may not be aware, that one of their viewers has contacted every one of the companies we have had an association with, clearly in an attempt to further undermine and destroy all we have worked for. This is despicable and damaging. The creator, who's video comment stream it appears on, is fully aware of this, yet does nothing to attempt expiation.
Thank you for your support, and the gift you sent us for the Harley project, your faith is much appreciated. With respect, Paula
Well said Paula , yourself and Derek have been really dignified over the last few year's and to my knowledge this is your first response ever , you know I have been incapacitated over the last few days which has given me time to scan over quite a few post , it has been heart warming to see how many people have stood by you especially on the Aussies post . Yes you have sponsors but just look at the professional videos it enables you to make , keep up the good work .....
@@Moonfleet41 it's a real shame as I used to love the banter and fun Mrs delboy brought to the videos..no more cake and questions with Mr Dyson now..loved that..a real family fun thing..but I gotta admit the hassle this channel gets from some pretty nasty,jealous and pathetic people is so sad to see..I really cant believe you still have the energy and spirit to put yourselves out there...I've always watched from very early on and genuinely think del is a modest..hold your hands up fella..never claimed to be anything he is not and glad he still got the will to keep sticking his head up despite the shit that is chucked at him
@@Moonfleet41 Hi Penny I only saw your reply as I did not get a notification and don't always get notifications to my comments for some reason. I accept your explanation and understand many of your points, I don't know where I picked up that you had mental health issues, i.e. depression over the comments made mainly by the commenters to these channels but can only have been from one of the channels or comments though I thought it was said by Del himself so I stand corrected.
Regarding my initial comment to Tarantula Boy's comment, I believe what you say and I know you have helped people with issues.
I'm not sure if the part of your comment where you state "It is deeply regrettable that a comment made about an individual, who had displayed abusive behaviour towards us yet again, caused him such offence, it was truly not intended" is an apology? If so no matter what he has said in the past it would have been better said to him though I don't know if it would be accepted or any returned and I think this correspondence would have been better if it had come from Del and not yourself.
I too am tired of it all I think Andy is aware of hence my interest.
Thanks for your reply.
I love the work you do and how you explain all the little details. Keep it up.
Having the old ones bolted on as template on the belt sander worked nicely.
I'm impressed... really impressed.
I'm working on a B-King rebuilt-project since february and I can feel the satisfaction in every single little triumph you've reached with your own hands. Go on, boy!
Greetings from germany!
The helical spring washer is not helping the dome nut(Which is good idea I haven't thought of)staying in place, it actually makes it easier to come off buy it self with all the vibration. A nut has better clamping force than a nut + helical spring washer. Just use normal 125/7089 washer and nut will have a better chance of staying put.
Yeah, the cap (dome) nuts were an extra nice touch to this already tasteful plug solution. Lookin good!
What I love about your video's the most is that you do everything the right way!
I like your cool trick. Put a bolt in the drilled hole to keep everything steady while drilling 2nd hole! Thumbs up!
Hi Del, I must admit that I see no practical or aesthetic problem in plugging the air bleed holes but fabbin' bits is always satisfying. As regards the dome nuts, they always concern me in that without very careful measurement of all the nuts for each stud you cannot assume that they will not bottom out before achieving the clamping pressure. Also, spring washers have a terrible reputation for relieving the torque on the nut especially in exhaust applications where there are many heat/cooling cycles, which anneals the metal. I would have dispensed with the spring washers and relied on the silicone exhaust cement to lock the threads - it will prevent the nuts vibrating loose if you must use dome nuts. I prefer shouldered K nuts for this type of application.
I agree .Removing the old studs and threading the AI holes is the engineers solution and looks professional wherever it is possible and guaranteed not to leak , ever . On a scratch build engine I would weld the holes up as part of the eventual gas flowing process and polish of the exhaust ports . I totally agree but began my introduction into the world of mechanical engineering as a kid building racing bikes for my older brother . How many oil galleries , drysump pans etc., do you see with blanking plates closing up the galleries,etc. ?
On my Triumph 675R race engines I have no choice but to machine solid dowels , remove reeds and use one cover as an additional breather in the cam cover and make a blanking plate for the other from 5 mm aluminium plate . Everywhere else where I've altered the block to remove the water pump and build the dry sump system the remains holes are threaded and blanking plugs fitted regardless of size and this operation leaves some pretty big holes to tap and plug throughout the lower crankcase .
However this is not the racing world where K nuts are the only sensible fitment , its street fighter use so what looks like an after thought is the DBs in this application , where you see HT bolts replaced with A4 and even A2 Stainless socket cap scrws/ bolts along with their infererior strength and heat transference capability in , of all places , brake calipers , exhaust stub brackets etc .
There are reasons why a stud and nut/washer is preferred , clamping force on cylinder heads , main bearing caps , etc., and used in every high performance engine design for a purpose , so deviation from this with a stainless socket head screw must not be ventured into on the basis of aesthetics .
A simple enough project, very nicely executed. I especially liked the approach of sandwiching the fabbed aluminum plates and then the gaskets between the steel ones you cut out earlier. Having seen your PAIR valve issues I took a closer look at my '99 Bandit 1200. I don't have 'em, though.
Another job and video well done. Go team DBG!
Thanks mate, really appreciate the support... have a good week, D&Px
Fabricating a part is much more fun than just buying it. Nice video!
I totally agree Scott.
Hats off to you for uploading so frequently and showing us this build in detail, but still very straight forward and no nonsense.
Excellent! 👍
Awesome job as always. I like the way you make your own parts. Del and Penny Have a great weekend and the wonderful week ahead ridesafely and God bless.
Thank you so much Paul, its been a really busy week, and a seriosuly challenging time on UA-cam lately, but onward and onward, staying focused on the bike project, and enjoying a bit of summer sun when we can... take care yourself, and have a Great weekend too.. D&Px
I am amazed by the things you do my friend, I wish I was half of the craftsman you are, well done, the good thing in every of your video I always learn something new. God bless you.
Thank you my friend, you're very kind.
Thanks for another awesome video and an impressive job blocking off those holes, for sure (I've gone the route of tapping them and using a new bolt when doing similar jobs to remove an AIS, but I must admit I like your block-off plates better). Well done, and really enjoying your progress on this bike.
Thanks Donald, Always good to hear from you, yeah, the blot in the hole method is fine, and works really well, i guess i gust wanted to take the long road in this one, and im happy with the outcome.. have a good week mate, and take care.. Del.
It still amazes me how one little thought, can change the way you do things for the rest of your life. Even half a technique adopted, can make life easier....for the next time!
Another question for you, in regards to aftermarket headers, do you think there is any reason the header nuts would come loose? I did a full exhaust system on my MT-09 and didn't think of putting anything besides the stock nuts back onto it. For some reason I have a fear they will loosen over time? I tightened them to a pretty good amount (by feel).
Hi Dan, ok that's a understandably worry, but it'll be fine... remember the exhaust gasket rings you would have fitted with the new exhaust are crushable and as you tightened down the exhaust header, you crush in against the new gaskets to make a seal and generally the gasket pushes back against the header and it's very rare that those nuts will come loose by themselves, they certainly don't need to be lock nuts or have any form of thread locking compound on them (and with the heat in that area most locking compounds won't work anyway)... if you're worried, then it doesn't hurt to take a small quarter drive socket and ratchet and just give them a little gentle tweak to feel if they've come loose, it doesn't mean tighten them up more than they currently are, just some twisting pressure against them, and if they've come loose, then they'll move and do back up, but if they haven't you will just feel resistance and they won't move, so they are fine....
Cracking job Del.
welldone, this is one of the most detailed builds ive seen on UA-cam, keep it up with all the good work Brother
Dankie my broer
It was once said to me many years ago that if it doesn’t work it’s a bodge, if it does work then it’s a modification.... Excellent series, can’t wait for the next instalment.
Yeah, ill go with that... nice way to put it.
great show and nice videos ive got a few bikes and spring is here i must get myself in gear and do some mainntenence tks delboy
I appreciate hearing your thought process
Not only HOW but WHY
Just a word of caution from somebody who has taken apart lots of boat engines and outdrives. Stainless and aluminum is often hopeless to get apart. The ally corrodes and sticks to the stainless like you can´t believe! It´s also worth investigating in if you really should use a copper based anti-seize combined with ally. Copper and ally don´t play well together and ally usually loses, badly. So there could be a good reason Suzuki chose to go with mild steel nuts and screws.
Thank you for yout insight, i have heard this before, and as a result i have ordered some AL1100 from Wurth, in the hope that it will keep things in order once the bike is on the road..
Fantastic outcome and finish. Looks so much neater now in that area Del. Another great vid and lesson in skills which aren’t taught anymore.... bring back the proper apprenticeship 👏👏👏
Amen to that... learning on the job, and earning a living at the same time rather than running up a student debt..
Absolutely. It didn’t do me any harm. A full 4 years at Airbus on the electrical side of things has stood me well.
Nice job Del . Really enjoying this build 👍
I’m about to do this, so you’re helping people all these years later.
I don’t anticipate any problems, with it, but my secondhand exhaust has been a hit to put on, so I wish I’d done the PAURS mod first time around.
Looking for your exhaust vid now. 🙂
Good luck with it my friend, glad the videos could help!
Finally did mine.
Procrastinate so much. 😂
Thanks again 👍
Best videos on UA-cam!!
Nic and tidy job, have a good weekend ride, thanks . Gus
Good job brother! That worked a treat! 🤘🏼💀🤘🏼
Sure did Bruv... Job'za good'un.
Hi Del. How you been? I know you're busy but I was wondering if I could borrow your expertise for a moment.
I've had issues with burning oil on my Hayabusa recently, and was wondering if this sounds familiar to you. A few years ago, I had the bike in to a local mechanic, to get stuck rotting exhaust removed (similar to yours). At some point during the process, they mentioned having to use some machine while remove the oil and 'the oil went everywhere' is what they said - I am forgetting exactly what they said, but they said they had some trouble removing the oil. They also mentioned they had the engine upside down, which I would assume was so they could machine the new threads in (like what you did).
Anyways, since then, I have had issues with burning oil. I don't know if the previous work done is related, or if it is just a matter of time. I was experiencing 'bogging' and noticed I was a piston down. So I replaced the spark plugs and 2 of the coil packs (left the other 2). I have also replaced the oil twice since then. This worked at first, and it seemed to have fixed it, but I could notice some burning of oil coming out of the right exhaust (to the right as you sit on it, could smell it and see smoke). Eventually, the bogging started again, and I had noticed that there was oil on the right-most spark plug (as you sit on the bike), so I cleaned it off, put it back in. It seemed to work for a few months, until it happened again recently. I cleaned them off again, however, it only lasted about 15 minutes or riding, before one of the pistons went out again and it started bogging. So it is either getting worse, or somehow there is oil where there shouldn't be in the upper chamber.
My question is, does that sound like piston ring failure to you? or is there something more mechanical or obvious that I am missing. Obviously, the only sensible thing to do would be to strip it down and have a look, but in your mind, what is the most typical cause of that? I am asking on the outside chance that I am missing something that might be immediately obvious to you. The bike is at 70k miles now for what its worth, a 02 plate.
Anyway sorry for the war and peace. I know this probably isn't the right forum for this kind of lengthy question. I just though it be worth me reaching out to someone who I trust with Haybusa related stuff, before I resort to dropping it off at a mechanic. I guess the end goal here is if I should put any more money into fixing the bike, or will it be something cheap to fix. Thanks for your time anyway Del, yours videos have saved me a lot of money over the years. Maybe this message could help someone else as well.
Wow mate that is war and peace, but I get your question... if the bike rolled in to me, noting 70k miles, first thing I'd do is a leak down test, slightly better than a compression test, it pressurises the cylinders, testing their overall seal.. they will leak down, but the speed with which they do so is measurable data and there are guidelines... if number 4 is suddenly leaking down severely, then to test where it's coming from, check the crank case breather... if it's hissing out of there, then it's going down the bores past the rings... if it's hissing out of the rocker breather, it's going up past the valves... If you want to know which valves, listen to the exhaust, that will tell you it's exhaust valves, listen to the airbox and that'll tell you it's inlet valves..... once you know where your leak is, you can address it! I doubt it's bores, unless you have a broken ring as they are nickasil plated and hardly ever wear, but that's at least a direction to consider! Good luck with it mate, hope it's something not too expensive to fix...
@@Moonfleet41 Yeah my bad Del, I tried to cover the whole story in one go to paint a picture heh. I will check all those out so thanks a lot for your expertise there. Hopefully see your own Hayabusa pop up again in a vid in the future. Be a sad day when mine finally packs it but that's life I suppose. Cheers
Sweet work, Del! The next owner of this machine, whenever you do part with it, will be one lucky guy/gal... Have a great weekend, both of you! 🏍👍🏍
Thanks Gary, it seems a long way off to even consider that at the moment, but its a great motivator to do my best with it though... Have a great weekend too, take care.. D&Px
Moonfleet41 😎
Nice work 👏
Love the pride in the work you do always a great job great vid !!!
Addictive as ever Del, great attention to detail really enjoy watching you work and your simple explanations.
Why you no braze them?
Im curious about removing the pair valves. Will the ecu/and or injection system, now see the engine as running too rich and adjust/ thin down fuel/air mixture . And what electrical connections etc would you need to delete/tune?
Gen 1 has no Lambda sensor in the exhaust, so the ECU has no idea what's marching down the exhaust.. i have a hole to remove from the air box (and blank off) and maybe a power feed to disconnect.. not done one of these yet, done a few Triumphs, and the principles are all the same, just got to check out the anatomy and sort out the details..
Cheers. Makes it simpler for me. 👍👍👍simples good 👍👍👍
@@stevewilliams5428 Thanks for that Input Steve..
I was wishing i had thought of plug welding the existing ones after watching your last vid, great plan - shame it never worked out!
Nice work, Del!
Hi Del. I'm wonder if I'll try to remove the PAIR system on my Suzuki Intruder VZ 1500. The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atmosphere. Blow-by
gas in the engine is constantly drawn into the crankcase. So, is it advise to block the PAIR system? Can you give me your advise, please? Thanks and please take care,
Nicely done Del. Good wee video & good bit of progress. Awrabesht to you both from me & the clan. 😉💙👍
Nice job Del, looks good mate. moving along nicely. Penny and you have a relaxing weekend. Cheers
Have a great weekend!
👍👍👍.
Awesome job Del! As always enjoyed a lot watching this video ;-)
Thanks Abouzar, always good to hear from you..
Mate your videos, your delivery of content, your explanations and tricks of all trades are bloody awesome. Thanks very much. I was just going to say, I use a small pocket sized axe stone to clean off and face gasket surfaces. Don`t cut yourself...
BTW.. I got a K1200r, a ZX9-C2 rat, and some trail bikes. Also a large collection of broken legs, collar bones, wrists and a knee. Keep up the good job my brother from another mother .
All the Best from Perth Western Australia.
And F##K the haters.
Hi! Delboy's first thank you for your videos , i really like the work you do on motorcycle , clean and precise , and with well explain details about what how you doing things or resolve problems , very good approach thank you againtake care Robert in Australia
Thank for your kind comments Robert, we're glad you enjoy the videos, its nice of you to get in touch.. Have a great weekend and ride safe. Del.
@@Moonfleet41 Well you deserve the support. Just remember i be in the UK next year maybe if at the time time if you are not busy i'll visit you we be staying North of London in place call Luton we were there four months ago anyways but again if you plan some holiday to Australia late me know regards Robert
Den Daumen nach oben hast du dir mal wieder verdient.
Nice job Del, enjoying this build 👍
Another great vid del 🖒🖒🖒
Good fix there Del, & saved 30 quid as well, win win situation. All the best both x 👍😎
Exactly Geoff, saved a few quid and had fun on the way..
@@Moonfleet41 Onwards & upwards (even further)guys, I see all this negativity with various contributors, the whole idea is a common help to all , that's my 2 bobs worth 👍👍😎
Great video! Only concern is with aluminum for these and exhaust temps because they don't have the water cooling like the heads, I'm curious to see how they last! I first thought they would heat sink into the cyl head but with the silicone I'm not sure.. Thoughts?
Nicely done
Also, just a thought, is card the best material to use where it might be exposed to exhaust gas.
Sealed air tight under metal plates, no air gets to it.. and the factory uses card gaskets as well.. see @ 2:24
pleasure to watch....as usual.
Looking good buddy, look forward to seeing you put the front end back together, regards Stu
Good job,loved it✌️
great job as usual!
Another inspiring video, thx alot
Great job, you make it look easy.
great work around Del.
Great video Del, I’ve learned a few things watching your projects to keep my CB750 in good nick.
Just a thought that came into my head watching this video, I know it’s really whimsical and a bit of fun, but those blanking plates to me are begging for some individual engraving on them :) , maybe engrave the firing order on each one!
Keep up the good work fella. Rob.
Keep then coming Del. You so represent us home mechanics.
Great job with the plates, really want to see the exhaust go on!
nice job
lovely job mate, cheap and effective !
My thoughts exactly to use the existing flanges and plug weld. 👍
Yeah, shame the braze trashed that plan..!
God that video went too quick 😁 nice work as usual 👍🏻
Esta ficando perfeita parabéns pelo capricho
I now see what you mean by wait until this video....how cheeky with the brass and silver solder. Nevermind great work around with the little Ally plates - simple and great fun to make.
Do your oil filter before sticking the exhaust manifold on, easier access.
I was going to suggest bluing your new headers but bluing SS is quite literally not worth the time/effort/crazyiness required. I'd stick to wrapping them or getting them ceramic coated for some colour goodness plus long term protection.
Hi Marcus, I'm happy with the final outcome. Im just going to bolt the exhaust on loosely for now, it'll come off again in the future once ive decided.. maybe ill seek out a cool ceramic coating when i get to the final buildup, i have so much more to do still, its only in the early stages at the moment... ive cracked the seal on the filter already so its just hand loose ready fo when i change it and put the fresh oil in at the end.... like all projects, everything just gets temporarily hand tightened for now, it saves things like gaskets and seals getting trashed when you have to take things off again.. have a good weekend mate.. Del.
Amazing as usuall
Great vid as always.
Nice job Del
Cheers Tony.. good to hear from you mate.
Looking tidy 👍🏻
Very Clever !!!!!
Used the cutting wheel to grind them down? Why not use the belt sander?
Thats a 36 grit metal sanding disc on a rubber backing pad... like this.
www.ebay.co.uk/itm/Abracs-sanding-disc-fibre-discs-24-36-60-grit-or-backing-pad-4-4-5-5-7-inch/262453630629?hash=item3d1b7496a5:m:mB7R8aFgQDko8iJShziAYuA
I’m doing this to my bandit, so it’s ok to use cardboard as a gasket?
Put some of that rtv on an engine case. Tried to use an amount in which it wouldnt ooz out the sides of the case and fall into the motor. Thought i i did pretty good plus the gasket as well and i tore it back down a while later and that stuff was everywhere
Speaking of Norton, I'll throw out a suggestion for your next project Del. How about a 1974 850 Roadster? Old school - not that I have a vested interest. :) - great work as always.
Not that this matters, but what happened to the music? - at first I thought my TV was broken.
Just keeping the edit varied, sometimes i like a quiet start and straight into the action...
@@Moonfleet41 Nice, didn't wanna come across like a complaint, just curious. Cheers Del
Good using stainless dome nuts. Got them on my 86 kawa gt550 exhaust studs that are only 6mm. I can remove them still with no problems at all
This is a cool build del. Nice one😎😎😎
Another fine example of need a tool,make a tool or in this case a part.good job del keep it up mate
Great video something to learn. They looks new comparing to engine will you be giving it some sort of shine cleaning to engine
Would using stainless studs and nuts cause any problems?
Nice fabrication, a pure joy to watch..
Why thank you most kindly sir..! have a good weekend.
@@Moonfleet41 you too Del thank you..
I saw a survey in the beginning of video ...the survey was to pick Cornetto,Pepsi, Coca-Cola,lays and exit so I picked Pepsi ...hope that it's what you wanted of posted that survey
Not sure what to do with the pipe on the air box and the other pipe witch goes to the other side behind the enjectors
I always thought doughnuts had jam in. Nice job well done.
Hey, would love to see a valve clearance/ adjustment video (will surely need doing on such a high milage bike)
Based on the original gaskets being card and them not flowing exhaust gases I might have just used Loctite 272 on the nuts, being that it's rated for 450F/232C, but I sure liked the job as I hate overpaying for bespoke parts I could make for a fraction of the price considering when you enjoy the fabrication it's all just cheap therapy.
I've just come by this . The reason why the gaskets are card as its an Air Injection System where cold air is mixed with outgoing exhaust gases to reignite unburnt fuel further down the exhaust system . The exhaust gas (after removing the AI system) in this region will now hit up to 900°C in hard use so anything rated under that is useless . Localised temperatures will be around a few hundred degrees less , so get rid of your A2 or even A4 stainless steel fixings etc around the exhaust .
The engineers approach to this is removing old studs and tapping out the hole and fitting a hex , torx , delta etc., blanking screw . You can use your stainless steel here as you are never going to remove them and they are not a stressed item . Tap the hole with a second cut tap just enough for the thread length to bit and tighten down the plug until tight and flush , using no sealant as it will seal itself. Then forget it as it will never leak or give problems ever . Given the luxury of doing a head off strip and porting job I would weld these holes up solid before porting . I know because I'm an engineer have been building race bikes , cars and designing high performance parts solutions for 50 years . Think F1 /aerospace solutions not aesthetics , street fighter look for a solution .
Hey Del, I like how you put stainless steel bolts everywhere because they wont rust, but I have a question. Is it good idea to use stainless? From a guy who is really into all that mechanic stuffs and he is really good with details and knowledge just like you. He told me using stainless bolts is really bad because they tend to get stuck really hard. And by hard he mean the bolt can bring rust from the frame lets say and be really hard to unscrew. So hard that he had to break it somehow and than drill it out. So thats why im asking is it good idea for the long term? I know it will never rust regardless of anything but if it get stuck it will be just as bad as those bolts on the exhaust?
Better than original!
Thank you kindly Sir..
What are these holes originally for ?
Air injection, related to emission control..
air (sometimes recirculates exhaust gas to, depends on type fitted) injection to keep emissions low and government happy (its not law to have it tho)
Nicely done Del. Takes a bit longer but a far better job.👍
Good job!!
Keep it up
Another great vid mate, bet you`re glad to keep moving forwards instead of 3 steps forward and 12 backwards lol,, as for the angle grinder comment below,, i`ve put angle grinders and festool rotex sanders / polishers in my vice for years, never had one fly across the workshop yet, i sometimes wrap a ratchet clamp round mine just to make sure,, but i ain`t gonna tell you how to suck eggs mate as you know the crack already, keep up the good work, have fun and take care. Claypole.
Better watch out using a thin cutting disc like that on the side 😬. Really not what it is made for, use a good thick grinding disc next time. Can easily rupture the disc and take an eye or fly into your arm/leg and cut an artery. Dont believe me, google it! You will see some horrible photos.
Sorry... you lost me.. disc on the side?.. when was that..?
6:20...
#1 Marine Sparky are you sure that’s a cutting disc and not a grinding disc? I recon a cutting disc won’t grind aluminum that quick. 🤔
Bram de Graaf check how much it is flexing?? Nae sure about you but i have never seen a grinding disc flex like that. I used to remove a lot of material with cutting discs like that, until i seen one in someones forearm with blood pouring out. Never again.
#1 Marine Sparky
Its a grinding disc mate... mounted on a rubber baking pad..36 grit, designed for grinding metal..!
One of these..
www.ebay.co.uk/itm/Abracs-sanding-disc-fibre-discs-24-36-60-grit-or-backing-pad-4-4-5-5-7-inch/262453630629?var=561257237946&hash=item3d1b7496a5:m:mB7R8aFgQDko8iJShziAYuA
Greatness as all ways Del..
I respect the fact that you show mistakes or things that didn’t work out as you first planned......a few UA-camrs out there who bitch n moan about what you do, just don’t get the fact that many of us just happen to enjoy what you do, it’s entertaining and we don’t expect you to be a bloody genius, anyways mini rant over. Good Job 👍
Thank you my friend, its "warts-and-all" with this one, all about the adventure, and like the Streetfighter project, it's kind of sad when its over..!
(P) Gotta love making your own, lightweight too... every little helps! 😀 Enjoy the sunshine the PAIR of you.
Ha ha.. i see what you did there mate.. you card..! good to hear from you buddy.