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Article By: Moosmits
Photos By: Garrett Stanley
Originally Published In The July 2018 Issue Of Cycle Source Magazine
It’s not like you can just get on the internet and purchase a sweet set of pipes for the left side of your custom built sidecar project. But building a set, whether it’s for that sidecar or your next full custom build, just got a lot easier thanks to Mooscraft and Icengineworks. I caught up with the crew of Veteran and First Responders building the latest custom creation with Motorcycle Missions in Austin, Texas while preparing for the Revival Cycles Handbuilt Show. The task at hand for the crew was to take the 2010 Triumph Scrambler and convert it into a sidecar toting service vehicle sure to turn more than a few heads. The challenge following this conversion was to take the exhaust out the left-hand side of the bike and knock it out as quick as possible while minimizing error not only while mocking up the desired pipes but in ordering only the exact amount of material needed. Mooscraft and Icengineworks teamed up to put together the Exhaust Tube Fabrication Kit that allows you to model a complete set of pipes in plastic sections that snap together. Each piece of the modeling system has a specific diameter and radius allowing you to decide exactly what tubing is needed for the job. This allows you to check for all potential interferences and routing necessary to construct your pipes. The kit consists of modeling blocks in 2” and 1.5” diameters. Each block represents one linear inch based on the centerline of the tube. You receive 36 blocks of straight for each diameter. For the 1.5” diameter you get 36 modeling blocks in 2”, 3”, and 4” radii. And for the 2” diameter you’ll get 36 blocks in 3” and 4” radii.
Being that the Triumph had a stainless factory exhaust and a great set of flanges to build off of, it was as easy as heading over to the band saw and removing all that waste to get things started.
With the flanges cleaned up and carbon removed they are ready to mount to the heads and using the Block Adapters begin to model our pipes.
The Block Adapters are a set of expanding rubber plugs that allow you to begin your model and attach it to your heads.
Using the supplied allen wrench, snug the Block Adapter to your first modeling block, insert into head and tighten so that it’s firmly in place but still allows a little rotation.
Each set of modeling blocks have alignment marks that allow you to create your pipe model while noting the orientation of each section as you move through the exhaust from one end to the other.
As you work on your design try to optimize the sections length by using the alignment marks to create as few sections as possible. Using the different diameters and radii to build your model you will notice that you will end up with sections where the alignment marks are offset. This represents a new section of tube in the model.
With our model complete we can move to make notes of the pieces needed and order materials. The worksheet also gives you a chance to make notes of the sections, the length of each, direction of flow, and order in the model.
Each section plastic model represents a section cut from a 180° U bend. Using the cutting templates that correspond with the desired tubing, align the plastic model with the gap for the band saw and tighten the wing nut.
Then replacing the model with a tube section, trim to the desired dimension to match your model on your band saw.
Clean edges and deburr tubing to prepare for welding. Each piece should be marked for flow direction and order in assembly by using your worksheet and plastic model as reference.
Using the Tack Weld Clamps, assemble your model one piece at a time starting at the head and working your way back. Check the progress as you carry through the assembly to verify everything is still lined up as originally modeled.
After checking progress through the model it might be necessary to place multiple sections on the bike to assure that all pipes are headed the right direction.
With the whole exhaust finished it’s time to verify all brackets and joints are tacked successfully and there are no interferences and fully weld.
This will insure that items like body components and suspension will clear the exhaust and riders legs.
Now that you know exactly what you need to do to not only build your next pipe, but change it on the fly or replicate it for a customer, head on over to www.Mooscraft.com and order your kit and get to building! —— Moosmits