Exhaust header fun

[SDN]

Well had mucho fun with new headers, two studs broken, was toatal bar steward getting them drilled out, ended up totally butchering the original threads, so drilled and tapped to M10.

Then had to makes some stepped studs M10 one side M8 the other. The volkswagon ones I found were too short! So got a long stainless steel M10 bolt, cut the head off and made two M10 studs. I then filed all the thread off evenly all the way round and finished it by puting the 10mm side in my pillar drill, turning it on and using the file to achieve 8mm all the way round. Then ran an M8 diestock down it to make my stepped studs. Screwed them in with plenty of locktite and sorted. Would be so much easier if I had a lathe - necessity is indeed the mother of invention.

Bolted the headers on with brass nuts from the same volkswagon supplier as the original stepped studs

Went out for a ride with Mal on Sunday and recounted the whole sorry tale, he laughed his nuts off, seems he has a myford lathe and also a small model engineers lathe, that converts into a milling machine - now mine for the princely sum of £70 including a load of tooling. If I had known that it would have saved me a whole load of pain.

Still now back in business and will have to set up FCR carbs with the colour tune that arrived this morning

[Mincehead]

WOW, stoneage engineering practices but hey, there`s always a way to do this type of stuff SDN as much work as it turned out to be.
Well done for using your ingenuity, jobs done now.

[SDN]

As a maintenance guy you what you have to to get stuff running, you are at the end of the day what you are

[SDN]

Will post some pics of new lathe / mill tomorrow, NOW CAN MAKE the FZR headlights really work - bear with me a bit pissed, watched captain america which totally pissed off wife, though I may have inadvertently lead her to believe it was a rom-com Ha Ha - night all