{"id":43420,"date":"2019-07-22T20:09:16","date_gmt":"2019-07-22T11:09:16","guid":{"rendered":"https:\/\/www.decoboco.info\/en\/?p=43420"},"modified":"2026-09-24T13:45:15","modified_gmt":"2026-09-24T04:45:15","slug":"fzr750r-ow-01-inspection-tailpipe-muffler-bracket-fabrication","status":"publish","type":"post","link":"https:\/\/www.decoboco.info\/en\/20190722\/everyday-events\/fzr750r-ow-01-inspection-tailpipe-muffler-bracket-fabrication","title":{"rendered":"FZR750R OW-01 Inspection\u2014Tailpipe and Muffler Bracket Fabrication and Sensor Boss Welding"},"content":{"rendered":"
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It’s been ages since I’ve seen an FZR750R OW-01. What an incredibly voluminous machine!
OW-01\/RC30\/RK\u2014wait, did Kawasaki have something like that too??

The customer requested various custom fabrication work to go along with the inspection. <\/figcaption><\/figure>\n\n\n\n\n\n\n\n
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Is the EXUP working?
Never mind\u2014I just snapped photos of the position and moved right along.

Man, digital cameras really are convenient. Back in the 20th century, I was actually taking notes in a notebook… there’s no going back now\u2014it’s like the Edo period. <\/figcaption><\/figure>\n\n\n\n
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The sensor boss came in a box. It had a stepped shape\u2014kind of like apartment buildings, but actually stepped differently. If I just drilled a hole in the pipe and bolted it on, there’d be tons of gaps, so I’m going to machine it down. <\/figcaption><\/figure>\n\n\n\n
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Lathe, then belt sander. It seemed to machine pretty easily, but I hope that’s okay… <\/figcaption><\/figure>\n\n\n\n
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I drilled a hole with a hole saw and stripped the paint from the surrounding area since I’ll be welding. <\/figcaption><\/figure>\n\n\n\n
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I’m going for a nice tight fit. <\/figcaption><\/figure>\n\n\n\n
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That’s how I welded it. The iron seemed to have poor fusion characteristics.
I wonder where it’s from… I should ask when we deliver it. <\/figcaption><\/figure>\n\n\n\n
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I think a touch pen (for brush application?) works better than spray. The mini size is just right. For reference.
But with this much, it’ll probably last me until I die… <\/figcaption><\/figure>\n\n\n\n
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I referenced the RACERS sticky-note pages and sat on the ground staring at it for nearly an hour total.
I kept second-guessing myself\u2014the fairing looks a bit different, and I was wondering about the silencer and end pipe length… <\/figcaption><\/figure>\n\n\n\n
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I looked for material, but since I’ve never made one before, there’s no way I’d have it on hand. Off to Togashi Engineering at a sprint!
I didn’t want to mess up, so I went with t=1.5M\u2014which means it’s heavy. <\/figcaption><\/figure>\n\n\n\n
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The silencer inlet was an odd size, so I expanded it with a flaring tool.
I’m so glad I bought this tool! <\/figcaption><\/figure>\n\n\n\n
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I skipped the homemade positioner\u2014it’s still too risky\u2014and went with hand-feeding instead. I’ll adjust the pulse and current on a test piece before tackling the real thing. <\/figcaption><\/figure>\n\n\n\n
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It got pretty scorched, but somehow it’s done. <\/figcaption><\/figure>\n\n\n\n
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I also quietly made a hook. (\u00b4\uff1b\u2200\uff1b)
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So it came out like this. I agonized over whether it should be a bit forward or a bit back, but including the end pipe length, I think this is about right. <\/figcaption><\/figure>\n\n\n\n
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The customer also asked me to make a silencer bracket.
Last night and even in the inspection car, I kept wondering\u2014pipe? plate? combined? or angle iron?

Even when I got stuck in traffic, I didn’t mind. Thanks to that, I forgot to renew the liability insurance and ended up doing a used-vehicle registration instead (rookie mistake).

Here’s the strategy I came up with.

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I bent pipe on the bender, cut it, and increased the contact surfaces while keeping it space-efficient\u2014that’s the plan for the pipe bracket. <\/figcaption><\/figure>\n\n\n\n
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I’m fitting it nice and tight. I quietly have a die for notching pipe, so I’ll notch it afterward. (Convenient\u2014*I’m a die enthusiast.) <\/figcaption><\/figure>\n\n\n\n
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I barely ever work with aluminum, so it’s refreshing. Machining is easy, and the weld bead is nice and big, which actually helps. <\/figcaption><\/figure>\n\n\n\n
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That’s how the assembly is done.
Recently I switched my welding helmet to an Optrel Panoramaxx. This thing… wow… the weld pool visibility is absolutely incredible! It’s one of the most impressive purchases I’ve made lately.
I used to use an old Speedglas 7000 series, but I really felt the progress of technology… <\/figcaption><\/figure>\n\n\n\n
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The frame side is fixed with two M8 bolts, so it won’t loosen or wobble\u2014peace of mind. <\/figcaption><\/figure>\n\n\n\n
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The silencer-side bracket has an angle and a 4.5mm gap, so it really makes a strong statement: “This is for plate brackets only!”
I tapped M8-1.25 into the bracket side, so it’s nut-free. <\/figcaption><\/figure>\n\n\n\n
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That’s how I made it. (Polished.) It’s bare aluminum, but it probably won’t corrode easily, so it should be fine as-is.
I think so. <\/figcaption><\/figure>\n\n\n\n
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A subtle detail: I don’t want it sticking out and looking ugly, so I’m keeping it as tight as possible. <\/figcaption><\/figure>\n\n\n\n
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I positioned it as close to the swingarm as possible. <\/figcaption><\/figure>\n\n\n\n
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That’s how it is. Making a muffler really is a pain, I thought to myself.
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The sensor should be easy to remove and install. <\/figcaption><\/figure>\n\n\n\n
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The small oval silencer looks period-correct too. (Apparently it’s a SUGU kit part.) <\/figcaption><\/figure>\n\n\n\n
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That’s how it is.

Customization goes to the custom shop.
Fabrication goes to the machine shop.
*Basically, I’m not good at this kind of work, so I don’t do it.
That wraps up today’s work.

I’m glad I didn’t drag it out\u2014phew! \u2606 <\/figcaption><\/figure>\n","protected":false},"excerpt":{"rendered":"","protected":false},"author":2,"featured_media":43392,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"pochipp_cv_data":"","swell_btn_cv_data":"","footnotes":""},"categories":[1924],"tags":[191,166,122],"class_list":["post-43420","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-everyday-events","tag-fzr","tag-production","tag-vehicle-inspection"],"_links":{"self":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/43420","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/comments?post=43420"}],"version-history":[{"count":0,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/43420\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media\/43392"}],"wp:attachment":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media?parent=43420"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/categories?post=43420"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/tags?post=43420"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}