Author Topic: Leaky Pipe Fix  (Read 11693 times)

0 Members and 2 Guests are viewing this topic.

Offline Larry Wiechman

  • Sr. Member
  • ****
  • Posts: 311
Leaky Pipe Fix
« on: August 12, 2009, 03:38:06 PM »
 The o-rings had worn grooves in the exhaust port counterbore so deep that even new o-rings and a shot of high temp RTV couldn't keep the goo from leaking.
 
The Fix:


Bore out the counterbore and press in a stainless steel sleeve.
« Last Edit: August 12, 2009, 03:44:13 PM by Larry Wiechman »

Offline Danger4u2

  • Administrator
  • Hero Member
  • *****
  • Posts: 1,616
  • KX500 is Danger4u2 Returning from light speed pic.
    • KXRiders.com
Re: Leaky Pipe Fix
« Reply #1 on: August 12, 2009, 04:13:19 PM »
Man, nice work.  Did you glass bead blast?
KX 500 Rider

Offline BDI

  • Hero Member
  • *****
  • Posts: 1,533
Re: Leaky Pipe Fix
« Reply #2 on: August 12, 2009, 04:33:25 PM »
That's awsome :-) great work it's about time someone did something to fix this problem.
Smoke every cigarette like It's your last and ride like you stole something!!!

Offline barryadam

  • Full Member
  • ***
  • Posts: 191
Re: Leaky Pipe Fix
« Reply #3 on: August 12, 2009, 04:37:05 PM »
That looks fantastic.  Did you cut the outlet oversize or just press the insert into the worn port?  If so, did you mill the bottom flat as well?

I like the ss bore AND the end flange.

Didja make more while you were at it?  hmmm?   :-D
"I hate heli-coils. They are like hospice for motorcycle parts."- BDI

Offline Larry Wiechman

  • Sr. Member
  • ****
  • Posts: 311
Re: Leaky Pipe Fix
« Reply #4 on: August 13, 2009, 10:51:35 AM »
Man, nice work.  Did you glass bead blast?

Thanks!
 
The aftermath of glass bead blasting is real hard to clean up. Always seems to be a little bit of the dust or beads imbedded in the soft aluminum or stuck in a porosity. A very small amount will do a lot of damage. Tapped holes + glass beads = broken bolts. My workload of broken/stripped fastener repairs went through the roof after Friendly Local Dealer got a Snap-On benchtop blaster. OK, rant over.
 
The casting in the picture was cleaned by soda blasting. The process is about the same as glass beads, but the blast media (baking soda) is not reused. Clean up with hot soapy water.

Offline Larry Wiechman

  • Sr. Member
  • ****
  • Posts: 311
Re: Leaky Pipe Fix
« Reply #5 on: August 13, 2009, 11:32:31 AM »
That looks fantastic.  Did you cut the outlet oversize or just press the insert into the worn port?  If so, did you mill the bottom flat as well?

I like the ss bore AND the end flange.

Didja make more while you were at it?  hmmm?   :-D

Outlet inside diameter had to be bored to remove the worn material and allow for the sleeve wall thickness. The bottom face got a light clean up cut to remove any damage and make it square with the bore. Heat the outlet area of the casting 250~300 deg. F and freeze the sleeve for an easy .003 press fit.
 
I'll post a CAD drawing later.
« Last Edit: August 13, 2009, 11:39:17 AM by Larry Wiechman »

stewart

  • Guest
Re: Leaky Pipe Fix
« Reply #6 on: August 13, 2009, 12:28:30 PM »
thats a outstanding job  off figuring out and fixing a much needed  repair , could you sell the sleeves or do the job for the   members here on the web site   thanks stewart

Offline kaw rider

  • Hero Member
  • *****
  • Posts: 1,218
  • Cool your engine with water not fuel
Re: Leaky Pipe Fix
« Reply #7 on: August 13, 2009, 03:07:10 PM »
I would buy acouple of those seal sleeve.

Offline Larry Wiechman

  • Sr. Member
  • ****
  • Posts: 311
Re: Leaky Pipe Fix
« Reply #8 on: August 13, 2009, 04:00:07 PM »
Here is a cross section view and the dimensions used in my application. Castings with more severe damage would need to be bored larger, within reason, and adjustments made to the sleeve outside diameter to maintain a .002~.003 press fit.
 
 

Offline maddoggy

  • Hero Member
  • *****
  • Posts: 711
  • K5 @ ST. ANTHONY DUNES
Re: Leaky Pipe Fix
« Reply #9 on: August 14, 2009, 07:16:26 AM »
really nice work. did you make the stainless sleeve or was it a part from something else?

Offline Larry Wiechman

  • Sr. Member
  • ****
  • Posts: 311
Re: Leaky Pipe Fix
« Reply #10 on: August 14, 2009, 08:09:49 AM »
really nice work. did you make the stainless sleeve or was it a part from something else?

2.5 inch diameter 304 stainless steel bar, lathe and time. :-D

Offline nickalosi

  • Newbie
  • *
  • Posts: 1
Re: Leaky Pipe Fix
« Reply #11 on: January 17, 2010, 04:45:09 PM »
Just registered to this site and saw this ,I have been in this biz for 20 years , Very nice work I have been wanting to do this for the last 10 years on my 250's and now my 1996 Danny hamel 5 hundy. I knew someone would beat me to it.
good job

Offline weymouth399

  • Full Member
  • ***
  • Posts: 123
Re: Leaky Pipe Fix
« Reply #12 on: January 18, 2010, 02:28:20 AM »
very  8-) my ice bike could use this,(93 been around the block a time or 2) are you going to make more already asked i know and what do you think it would cost roughly
 thanks in advance bob
93 KX500 ice bike for sale
00 KX 500 ice/dirt
04 KDX220 dirt
04 Kx 500 ice bike
08 KLX 450 on/off
72CT90x2 for sale
76LB80Chappy
86FJ1200
89FJ1200

Offline Swe_K5_89

  • Sr. Member
  • ****
  • Posts: 254
  • >> KX500 -89 <<
Re: Leaky Pipe Fix
« Reply #13 on: January 21, 2010, 06:59:05 AM »
It's really nice to see nice work like this. Almost like art..  :-D
1989 KX500
1981 YZ465
.

Offline hughes

  • Hero Member
  • *****
  • Posts: 1,923
    • Dirt Hammers
Re: Leaky Pipe Fix
« Reply #14 on: January 21, 2010, 07:08:06 AM »
Nice work larry. Thanks for sharing.
Open Class 2-Stroke Kawasaki KX500
Yamaha 2005 YZ250
Richard Hughes
Dirt Hammers - Online Off-Road Journal
hughes@dirthammers.com
http://www.dirthammers.com