New (to me) Dominator

Joined
Jan 16, 2015
Messages
4,018
Country flag
First time I seen or head of anyone breaking the mid pipe or battery box
Nope , not first time. I broke my cat X-pipe within 3000 miles . After the first 800 miles my bike was still new and I was revving the nuts off of it after that. I have resolved so far 14,000 miles more , keep the hangar bolt not tight. This is the one below where the x-pipe bolts to the bottom of the frame. I Keep this bolt able to spin with fingers , use a locking nut or jam nut - doulble nut the bolt so you don't lose the nuts. Good alignment of the pipes too , no bending stresses. Not first battery box cracking either . Its all documented on this forum . David C. can tell you much more . Best to know now while your bike is still new/nice , and maybe can prevent it. Maybe someday we can come to a consensus as to what is worth doing (fixes) or not. And start a 961 Do's and Dont's section and put it at the top that way newcomers can find it straight away.
 
Last edited:

Voodooo

VIP MEMBER
Joined
Aug 10, 2016
Messages
1,432
Country flag
Nope , not first time. I broke my cat X-pipe within 3000 miles . After the first 800 miles my bike was still new and I was revving the nuts off of it after that. I have resolved so far 14,000 miles more , keep the hangar bolt not tight. This is the one below where the x-pipe bolts to the bottom of the frame. I Keep this bolt able to spin with fingers , use a locking nut or jam nut - doulble nut the bolt so you don't lose the nuts. Good alignment of the pipes too , no bending stresses. Not first battery box cracking either . Its all documented on this forum . David C. can tell you much more . Best to know now while your bike is still new/nice , and maybe can prevent it. Maybe someday we can come to a consensus as to what is worth doing (fixes) or not. And start a 961 Do's and Dont's section and put it at the top that way newcomers can find it straight away.
I have a X pipe without a center hanger. Interesting
 

Voodooo

VIP MEMBER
Joined
Aug 10, 2016
Messages
1,432
Country flag
So the 2017 and newer don’t have the frame mounting point above the x-pipe. ?
My 16 commando has the mid pipe frame mount as did the stock exhaust.
My Motad decat pipe has the mid mount.
I have a SBN X pipe (decat) and it does not have the mid mount.
 

Vernon240

VIP MEMBER
Joined
Mar 18, 2021
Messages
217
Country flag
Thanks everyone, awesome responses! I’ll be onto Talon and see about a sprocket!
 
Joined
Jan 16, 2015
Messages
4,018
Country flag
My 16 commando has the mid pipe frame mount as did the stock exhaust.
My Motad decat pipe has the mid mount.
I have a SBN X pipe (decat) and it does not have the mid mount.
When Southbay was making those pipes they never used a x-pipe hanger I've heard. But your frames all have the mounting boss on at the bottom.
 

Vernon240

VIP MEMBER
Joined
Mar 18, 2021
Messages
217
Country flag
Time to deal with the cracks and add reinforcements to this, blatantly copying ntst8 and hints fro BlightyBrit S/F
APtGlQTl.jpg


My longest crack was on the coil side:
CwonMjzl.jpg


but the battery side showed a crack as well...
H1RuJ6pl.jpg


but I did also notice a crack developing near one of the tank mounts on this bracket as well (noticed after looking at BlightyBrit's post) so will deal with that tomorrow.

Cleaned the paint of around the suspect areas, dusted off my mig welder and set to:

wjmy2kFl.jpg


tFIwGiXl.jpg


JRlwvb5l.jpg


5JrPnirl.jpg



I cleaned the welds back as far as I dare and pretty happy with the results
Qnlqu7rl.jpg


Next up, templates for reinforcements

36NvW7Gl.jpg


9TAAOSil.jpg


More as it happens...
 

Voodooo

VIP MEMBER
Joined
Aug 10, 2016
Messages
1,432
Country flag
Time to deal with the cracks and add reinforcements to this, blatantly copying ntst8 and hints fro BlightyBrit S/F
APtGlQTl.jpg


My longest crack was on the coil side:
CwonMjzl.jpg


but the battery side showed a crack as well...
H1RuJ6pl.jpg


but I did also notice a crack developing near one of the tank mounts on this bracket as well (noticed after looking at BlightyBrit's post) so will deal with that tomorrow.

Cleaned the paint of around the suspect areas, dusted off my mig welder and set to:

wjmy2kFl.jpg


tFIwGiXl.jpg


JRlwvb5l.jpg


5JrPnirl.jpg



I cleaned the welds back as far as I dare and pretty happy with the results
Qnlqu7rl.jpg


Next up, templates for reinforcements

36NvW7Gl.jpg


9TAAOSil.jpg


More as it happens...
What about the use of a lithium battery. Less weight. Less fatigue.
 

Vernon240

VIP MEMBER
Joined
Mar 18, 2021
Messages
217
Country flag
Nice work, not just ‘fixing’ but strengthening the design.
Plus one on Voodoos comment too, a Li battery will reduce stresses.
Ah, in the true spirit of ‘belt and braces’ as the battery needs replacing, I’m going to try lithium...first time I have tried them...reviews seem to range from ‘awesome’ to ‘never again’. If the cracks had not been apparent, I might have just gone Lithium and called it a day, but as they are there....and more so on the coil pack side, I think some flexing due to vibration is a component here. Adding and improving gives me options, should I want to go back as well. Once done, stripping this assembly (actually, blasting is probably the route I’ll go) will be a pain, so very keen on only doing this once! I have the lithium battery already....I’ll weigh them, but the difference seems remarkable!
 

Vernon240

VIP MEMBER
Joined
Mar 18, 2021
Messages
217
Country flag
How will you cut those shapes ?
I’ll use a thin cutting disc in an angle grinder. That will give me the pieces, but I leave a small margin around the edges. I’ll then fine tune with a flap wheel in the angle grinder, as it’s far less agressive. Finally, I’ll use a hand file. That gives me really nice edges, which I want if they will be exposed..and not welded. For example, those plates underneath, I’ll probably plug weld them in place, making them look a little like spot welds....so I want all the plate edges to be neat and nicely defined. I know it’s a lot of fuss for something that no one will ever see, but I know it’s there and I want it to look right.
 
Joined
Jan 16, 2015
Messages
4,018
Country flag
I’ll use a thin cutting disc in an angle grinder. That will give me the pieces, but I leave a small margin around the edges. I’ll then fine tune with a flap wheel in the angle grinder, as it’s far less agressive. Finally, I’ll use a hand file. That gives me really nice edges, which I want if they will be exposed..and not welded. For example, those plates underneath, I’ll probably plug weld them in place, making them look a little like spot welds....so I want all the plate edges to be neat and nicely defined. I know it’s a lot of fuss for something that no one will ever see, but I know it’s there and I want it to look right.
You are doing great work ! I wish I was your neighbor !
 

Stephen_Spencer

VIP MEMBER
Joined
May 31, 2017
Messages
658
Country flag
Did the frame mount break or the x-pipe ?
The pipe work mounting section, not the frame mount. I had the cats cut out and straight through pipe sections welded in by an exhaust professional; he also gutted the cans. Did a great job but the centre pipe mount failed (at the rubber mount - you can just see it on the image) some time later, which I understand is quite common. Had a good look at the stability/security of the pipes without this mount and decided that it was good to go. That was about 3 years ago - no problems since.
 

Vernon240

VIP MEMBER
Joined
Mar 18, 2021
Messages
217
Country flag
Here are some of the parts when I first cut them out...pretty rough, but from here on in I refine and fine tune....
2kZGVWhl.jpg


and it doesn't always go to plan..here I've abandoned one part and started again..
LS9C6sDl.jpg


Y1xbDtGl.jpg


But I'll eventually get to where I want to be
l3BsKEsl.jpg


so all may parts done!
VdqRDTGl.jpg


Here I've tacked them in place..
OzClndjl.jpg


to see how it fits on the bike

pVIGA8Tl.jpg


but total fail. The coil side is too big and the angle it is tacked on at means the tank won't fit! This is why you tack first!

The final parts were significant smaller, but fine tuned with many many tank on/off cycles! here I'm wedling the parts finally in place, doing shorte seams to keep heat distortion down
UNMbS3fl.jpg


Here I have fixed the tank mount crack
ODPIRgdl.jpg


This is how those smaller parts will fit:
Baw8MH4l.jpg
 

Vernon240

VIP MEMBER
Joined
Mar 18, 2021
Messages
217
Country flag
The two smaller parts in place:
OKqNe1nl.jpg


Test on the bike..
ScN0OzOl.jpg

0RJQ8S1l.jpg


and finally with the tank and making sure the mounting screws still fit
77Fz19ul.jpg


I wanted to keep the rear flush, as the battery and the coil mount right up against my new plates

QLv02Kll.jpg

bK5pt65l.jpg

Closer inspection seems to indicate reasonable weld penetration, but might run a couple of weld seams here and grind right back to flush.

Pretty much done!
ILJtty0l.jpg
 
Top