February 2013 - Construction Phase 7
Finishing exhausts and manifolds
![bild2258](/images/content/projekte/18-zyl-ds/2258.jpg)
New starter with 18V in the picture on the left (on the right the old 12V model)
The new model has a ventilated engine case (exhaust air)
![bild2259](/images/content/projekte/18-zyl-ds/2259.jpg)
![bild2260](/images/content/projekte/18-zyl-ds/2260.jpg)
Drilling the ring muffler. 9 holes on the left, 9 holes on the right.
![bild2261](/images/content/projekte/18-zyl-ds/2261.jpg)
![bild2262](/images/content/projekte/18-zyl-ds/2262.jpg)
Fitting the outlet pipes into the radius of the ring muffler
![bild2263](/images/content/projekte/18-zyl-ds/2263.jpg)
![bild2264](/images/content/projekte/18-zyl-ds/2264.jpg)
Filing down the holes for the outlet pipes. Everything has to be custom-fit.
Otherwise you can’t weld it (0,5 mm wall thickness).
![bild2265](/images/content/projekte/18-zyl-ds/2265.jpg)
![bild2266](/images/content/projekte/18-zyl-ds/2266.jpg)
Bent exhaust manifold for the front cylinders. These still have to be cut or adjusted to the right length.
Somehow it’s getting tighter and tighter.
![bild2267](/images/content/projekte/18-zyl-ds/2267.jpg)
![bild2268](/images/content/projekte/18-zyl-ds/2268.jpg)
Fitting the outlet manifolds in/into the ring muffler
![bild2269](/images/content/projekte/18-zyl-ds/2269.jpg)
![bild2270](/images/content/projekte/18-zyl-ds/2270.jpg)
Here the flange sleeves are welded to the outlet manifolds.
![bild2271](/images/content/projekte/18-zyl-ds/2271.jpg)
![bild2272](/images/content/projekte/18-zyl-ds/2272.jpg)
Customized clip-on outlet pipes and then completely welded.
Variation for the test bench. These still have to be fitted to the right model or replaced.
![bild2273](/images/content/projekte/18-zyl-ds/2273.jpg)
![bild2274](/images/content/projekte/18-zyl-ds/2274.jpg)
The finished welded manifolds with flange sleeves are waiting for assembly.
![bild2275](/images/content/projekte/18-zyl-ds/2275.jpg)
![bild2276](/images/content/projekte/18-zyl-ds/2276.jpg)
After everything is fitted and in its place, the manifolds are stapled in the mounted state.
![bild2277](/images/content/projekte/18-zyl-ds/2277.jpg)
![bild2278](/images/content/projekte/18-zyl-ds/2278.jpg)
After stapling everything is disassembled once again and welded completely.
![bild2279](/images/content/projekte/18-zyl-ds/2279.jpg)
![bild2280](/images/content/projekte/18-zyl-ds/2280.jpg)
Adjustment work once again after welding.
The manifolds are annealed tension-free, so they don’t tear later.
![bild2281](/images/content/projekte/18-zyl-ds/2281.jpg)
![bild2282](/images/content/projekte/18-zyl-ds/2282.jpg)
Now the tail pipes (4) are fitted and also welded.
Then the ring muffler is expanded completely and the plating with nickel is prepared.
![bild2283](/images/content/projekte/18-zyl-ds/2283.jpg)