Cynicalriders "J0hnny5 is ALIVE!" 01 build thread.

Another big project done. I wanted to salvage the original second CAT, but the flange was so rusted that I needed to weld a new one on. I had a hard time getting the new one on and used a shop press and relief cuts to do it, but ended up bending the cat in the process. Eventually I just ordered a new CAT.

But everything from the first cat back is new. Borla XS muffler, vibrant resonator, new first cat, new downstream sensor, and made piping to go out the bedside with a Dirt Skum bezel.

New flange:

Untitled by Michael Halat, on Flickr

Bent cat:

Untitled by Michael Halat, on Flickr

Planning out the resonator location:

Untitled by Michael Halat, on Flickr

Mocked up for tacking:

Untitled by Michael Halat, on Flickr

Exit piping:

Untitled by Michael Halat, on Flickr

Painted the exposed mild steel with high heat black:

Untitled by Michael Halat, on Flickr

New exhaust hanger I welded to the frame for the center support:

Untitled by Michael Halat, on Flickr
Untitled by Michael Halat, on Flickr

The stick out I was hoping for:

Untitled by Michael Halat, on Flickr

Crappy welds:

Untitled by Michael Halat, on Flickr

Leak testing:

Untitled by Michael Halat, on Flickr

Final product:

Untitled by Michael Halat, on Flickr

This clearance is too close and the pipe contacts the left side of the bezel after it warms up:

Untitled by Michael Halat, on Flickr

Dirt Skum has a solution for this I plan on adding.

First start:

https://youtu.be/Q3p80NGLIe8

I learned a ton doing this, especially since I never built an exhaust before. Pretty happy with the project overall but I want to add the new pipe mount to center it in the exit better as well as eventually powder coat the plate since it chipped so easily.

 

hell yes bedside exit. rad work

 

I hope that doesn’t rattle around!

 

thanks!

Ha it actually does as it comes to temp and then settled just pressed against the plate. The new mounts will fix that.

 

Oh man this stokes me more than the dorkel

 

Looks slick, can't wait to check out your new rear setup with all the topper and rack.

 

awesome day today dude

 

Guess who couldn't get his brand new elocker motor to unlock....I shit you not.

Go figure, 2 for 2 with you. Glad you came out great time wheeling.
Now let's see those photos edits, and better see the good footage of that oh shit moment!

 

dude no way?! How does the same shit keep happening to us on the same trips?! And yeah I’ll prob upload mini edits or single clips, no time anymore for the fancy shit I used to smash together

 

Man I love this truck. It always cracks me up when people get so hung up on tire/wheel combo and backspacing, and there's ol Mike plugging along with OEMs and big ass spacers.

Looking good man

 

Ha plugging along is probably the best way I can be described. And thank you! No video of the oh shit moment yet, but I got this uploaded.

https://www.youtube.com/watch?v=85Fvguk4_SQ

 

Krawlin 4 cops with @Rockbaron1 and @ToyRyd04

https://www.youtube.com/watch?v=2twL-clT-dw

 

Been a while since I updated. Trucks been sitting since Rausch, I did rewire my 12v blue sea plug back to my old ARB plug on the back wall thanks to @EatSleepTacos telling my my dometic has the same style plug. It makes the connection at the plug a screw in vs the 12v press in.

Untitled by Michael Halat, on Flickr

Def cleans up the wiring behind the fridge a little now.

The rest of the time I have been dealing with trying to get the bike back to mint for fall riding season. Had an issue where the float needle seat was leaking gas, and there was gas in the oil.

So I pulled the carb, cleaned it, replaced some shit, and slapped it back in. Also added radiator cages, swapped the clutch springs to stock stiffness vs stiffer comp springs, changed the oil and plug, and adjusted the clutch to be mint again.

Untitled by Michael Halat, on Flickr
Untitled by Michael Halat, on Flickr
Untitled by Michael Halat, on Flickr
Untitled by Michael Halat, on Flickr

Oh and not sure if I ever posted, but got a winter project lined up for half doors.

Untitled by Michael Halat, on Flickr

Next thing is to rebuild the rear locker actuator.

 

Some lessons learned from my half doors. I would have cut it a bit deeper for more visibility, something like this. I also sewed together some windows with a heavy duty fabric and clear vinyl and used some softopper snaps to connect it to the door. I wish I hadn't done that. Instead, only use clear vinyl and some industrial velcro around the entire border. That way it's easier to make the windows and also totally seals it off.










Here's how I have my door hinges modified to aid in taking the doors on and off. Super easy doing it alone. I think for first gens you can even get a QD kit from 4xinnovations.

 

My plan is basically to copy @ToyRyd04 on his, I like his depth. I don't think he had issues with leaking either but I can see how like snaps in corners and maybe velcro the whole top might seal a little better. The only thing I want to improve on is potentially using the door itself to store the fabric door when the fabric is off. Doesn't have to roll into it or anything fancy, just a little hinge setup that lets me get the fabric in there.

 

Jokes on you @ToyRyd04 my e brake doesn't do anything.

https://www.youtube.com/watch?v=7SaUqyJxPMU

 

Are you a manual trans? assuming that's why you were rolling back after letting off the gas with clutch in?

 

Yeah maybe velcro on top, I get a few drops, but nothing much. Velcro on the full thing might not hold up, especially at highway speed, or when it gets colder, the clear vinyl will shrink some and pull the velcro apart. This is where tarp snaps hold up well as they'll hold tight. I've had the snap in windows on doing 90+ and works great.

PM or give me a call when you get that far, dont just layout the snaps and punch them into the windows.