Welcome back to Airborne Productions. Today is the third part of the expansion chamber build for our DT362 stroke rap bike So last time we welded up that 12 inch long section of pie cuts This time we're gonna work on the cones that expand and contract To get that two stroke hanging right in the right power band in order to do so We are creating pie cuts using the cones. This is done the same way as the first pipe was in part two By cutting the piece as small angles and stacking them back to back in order to create a bend Making these cuts would have been impossible without the bandsaw though We approximated the final angle difference between the start in the end of the conic part of the expansion chamber to be about 100 degrees in our case So we made 10 cuts at five degrees each Since stacking each piece back to back will double the angle of the cut Making each cut created a burr so we quickly clean these up inside and out with a few different harbor freight sanding tools When you stack the cones up as they were cut it recreates the cone shape But when you stack each piece 100-data degrees opposed to the previous piece it creates a curved shape Emulating the typical expansion chamber design So basically I'm putting each one of these pieces on the anvil with the hammer or on the sanders Until I get rid of these gaps I'm not gonna get rid of them completely, but I want to cut these gaps down a little bit After that we're gonna tack this all together and see what we get Here's some of the bit up issues that we're encountering To remedy this I'm going back and forth between the welder The sander and the anvil First one's tacked the fit up on this was definitely a lot rougher than the other one Have some gaps to fill some holes to plug that's okay. It's a good start This material is only 40,000 stick so I'm running my welder at about 35 amps any more and I seem to blow through too easily Okay, we're back at the shop another day So the cones are looking pretty good starting to get those tacked up We need the center sections and those also need to be pie cut So in order to make those I first took some flat sheet metal and I cut a couple strips out of it And with those I ground them down and carefully beat them around the horn of the anvil I probably could have just done this by hand just bending it. This was a little more fun I carefully beat it into close to perfect circle and those will be used in order to connect the expanding cone with the contracting cone Back another day Today we're going to get a finish. Yes today. I got a lot more things tacked I spent a lot of time grinding just to get everything fit up perfectly So today I'll finish tacking get that done quickly and then get on the welding The cones are all tacked up in place So I'm gonna carefully remove the exhaust from the bike and then very carefully add some more tax to give this thing some Strength while I'm wrestling it around. So we got some close clears here We got some Close clearance right here and This fuel line is gonna have to get switched with this one It'll clear just fine, but she's tight. There's quite a few gaps on some spots That'll be fun to fill It's really hard to fit this thing right in this shape And underneath where it needs to go but Time to get welding Here my first few little welds Add a huge gap to fill here and it's pretty rough Now the decent gap here Now learn how to do that struggle into it and we'll get there. Okay. I've ran some welds on one side and Then on the other side A lot of these are stacked up pretty high. I'm running out of my smaller filler running out of 16th inch filler So I'm using 330 seconds filler on a lot of it which is way too big for the size weld when I'm running about 35 amps this 40,000 some material but whatever it's working And she is done And here she is mounted on the bike So a lot of these welds are pretty ugly all of them aren't so bad But really fitment is everything I understand why people say that it is so important to have your pieces fitted up properly Some of mine were higher or lower than others Some of them I mean some of them I had an eighth inch gap. This is 40,000s material So what happens next? Well, we're gonna take this and route it out using this one inch material Which will then turn into a silencer to keep the noise down a little bit We'll move this electrical out of the way with this old post so there'll be plenty of clearance Thanks for watching and please subscribe to watch us out of love through to this thing