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#683694 - 02/04/17 4:29 pm ZB Megaphone fabrication  
Joined: Jul 2006
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bsalloyd Online content
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Santa Fe, Texas
I have searched in vain for some time for an early ZB racing megaphone without success. I have been discussing fabricating several for the people that are interested, so far that is five. Actually forming the tapered megaphone is the largest cost, $250 set up and $35 per part. If I am going to move forward with this project I would like to know how many others might want to participate. We are currently trying to get all of the fabrication dimensions. If I make five cones the cost per cone is $85 per part. The cost per cone goes down is the quantity is higher. None of this includes shipping, fabrication, and chrome to get a completed mega. I am estimating that before you have a completed part in your hand you will spend over $275.00


1951 ZB GS
1953 BB GS
1953 Super Flash
1954 Vincent BS
1963 RGS
1974 Trident
1973 850 Commando
BSA Gold Star eBay items

BSA Gold Star forum This board is dedicated to BSA Gold Star motorcycles.

#683711 - 02/04/17 7:33 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
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David Dunfey Offline
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David Dunfey  Offline
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Posts: 312
New Hampshire, USA
Lloyd,

That seems a little pricey. Have you tried Cone Engineering?

http://www.coneeng.com/index.html

David

#683738 - 02/04/17 11:10 pm Re: ZB Megaphone fabrication [Re: David Dunfey]  
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bsalloyd Online content
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bsalloyd  Online Content

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Santa Fe, Texas
That is exactly company that gave me the quote for the cone.


1951 ZB GS
1953 BB GS
1953 Super Flash
1954 Vincent BS
1963 RGS
1974 Trident
1973 850 Commando
#683740 - 02/04/17 11:30 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
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Boomer Online content
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Orygone
Lloyd, if I'm not on the list you can put me down, in fact you can put me down for two.


Bill B...


Boomer
#683788 - 02/05/17 10:46 am Re: ZB Megaphone fabrication [Re: bsalloyd]  
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David Dunfey Offline
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New Hampshire, USA
Originally Posted By bsalloyd
That is exactly company that gave me the quote for the cone.


I was afraid of that. I have a fabricated one that was used on a Grey Flash. It seems like a straight forward design, but it is all in the exact dimensions. The company I used to get cones from was quite reasonable, but they have disappeared.

David

#683806 - 02/05/17 1:14 pm Re: ZB Megaphone fabrication [Re: Boomer]  
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bsalloyd Online content
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Santa Fe, Texas
Bill, You and Dan L are on my first list along with me for a total of six. Lloyd


1951 ZB GS
1953 BB GS
1953 Super Flash
1954 Vincent BS
1963 RGS
1974 Trident
1973 850 Commando
#683892 - 02/06/17 4:33 am Re: ZB Megaphone fabrication [Re: bsalloyd]  
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Dana_twin Online confused
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Oregon
Have you seen these:

http://www.ebay.com/itm/Racing-Megaphones-Ideal-For-BSA-A7-A10-flat-track-bikes/371066572992

But they are only just over 16" long and don;t look quite right.

#683899 - 02/06/17 8:11 am Re: ZB Megaphone fabrication [Re: bsalloyd]  
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Posts: 527
BritTwit Online content
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Posts: 527
Kansas City area
Dana Twin
I bought one unchromed from Emgo. Very nice and a low price. No brackets. These could be acceptable with a little work. Unity Equip also offer a reverse megga that looks and fits nicely but has the wrong style bracket.
What we are looking for are the early open megga for rigid and plunger goldies.
And thanks for the reply.

#683954 - 02/06/17 3:34 pm Re: ZB Megaphone fabrication [Re: BritTwit]  
Joined: Feb 2015
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flowboy Offline
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UK
I have made mega's with only the most basic workshop equipment, not even a sheet roller. Somewhere I have notes on the method, it's pretty simple. The cones came out ok & worked fine in a race bike. If you found an engineer with a roller you could get a cut pattern rolled very nicely. I overlapped & brazed my joints (reverse cone included) but any decent welder will be able to butt-weld them up nicely, plus any tabs or brackets to put on.
Of course then there is the small matter of polishing prior to chroming - better done before any tabs fitted.
There's a nice pic of Tommy McDermott's 1950 plunger Daytona bike with mega' in Roy Bacon's "BSA Singles Restoration"

I assume you are doing this for show purposes? The 500 ZB has a 4 1/2" outlet, quite a beast & quite a thing to ride with too!
Without wishing to hijack your thread there is an interesting article in the Victory Library on Exhausts & Mega's including this from Walter Kaaden, who once remarked “You’ll know when you have the design right, because the chamber will then be impossible to fit on the motorcycle without having it drag the ground, burn the rider’s leg, or force the relocation of one or more major components”

Last edited by flowboy; 02/06/17 4:06 pm. Reason: additional thoughts

na
#683961 - 02/06/17 4:40 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
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Mal Marsden Offline
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UK Carnforth
I know we are a long way over the pond but I just had one made with reverse cone, a small silencing section fitted and a separate clamp to suit my 1&7/8" pipe. Total cost was £125. Same guy does a std mega for Aermacchi at about £59 I think, sounds like $70 or so, complete. If you want, I'll call him and ask how much for a price on 5 or 10. Not sure what you might get charged duty coming into states or how much to ship over, might be worth looking into. There should be no tax added in UK for you either.

You'll find the place at swarbrick-racing.co.uk he's only about 20 miles away so I can go and see him also.

Mal

#683978 - 02/06/17 7:26 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
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bsalloyd Online content
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Santa Fe, Texas
Mal, Thanks, I just sent an email to swarbrick-racing with a request for information. Lets see what happens.
Lloyd


1951 ZB GS
1953 BB GS
1953 Super Flash
1954 Vincent BS
1963 RGS
1974 Trident
1973 850 Commando
#684476 - 02/10/17 11:37 am Re: ZB Megaphone fabrication [Re: bsalloyd]  
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flowboy Offline
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UK
Funnily enough there is a letter in this months Goldie mag with a couple of photos of a genuine ZB mega' plus the T McDermott one & some dimensions. You could certainly make a pretty close rep' bracket wise, just from these. Even better if you have an original to measure up. There are various reliable sources for the cone dimensions.


na
#684504 - 02/10/17 4:12 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
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Ponyboy53 Offline
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Denver Colorado
Please count me in for one.


'51 BSA ZB 34 GS - plunger
'65 BSA D7 Bantam
'68 BSA B24 Starfire
'68 B44 Shooting Star
'71 BSA B25t
'71 BSA B50t
'57 Zundapp KS601S
'42 Harley-Davidson XA
#684517 - 02/10/17 5:44 pm Re: ZB Megaphone fabrication [Re: Ponyboy53]  
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bsalloyd Online content
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Santa Fe, Texas
Well, since I am a GSOC member I will take a look when it arrives here in the colonies. Lloyd L


1951 ZB GS
1953 BB GS
1953 Super Flash
1954 Vincent BS
1963 RGS
1974 Trident
1973 850 Commando
#684990 - 02/15/17 3:15 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
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bsalloyd Online content
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Santa Fe, Texas
I asked Ian Jackson to put a request for information regarding the mega in "Goldie" magazine. There is a response in this months issue that includes most of the information we need to proceed. As soon as I get permission to copy it I will post it on the site. Lloyd L


1951 ZB GS
1953 BB GS
1953 Super Flash
1954 Vincent BS
1963 RGS
1974 Trident
1973 850 Commando
#696797 - 05/29/17 6:52 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
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bsalloyd Online content
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Santa Fe, Texas
I have finally gotten all or the dimensions required to fabricate the ZB mega. So, I wanted to see how to proceed with the project. I have priced the cone at Cone Engineering at $70 each with an order of ten pieces. I can order the cones and send them with the drawing to everyone so they can use their own fabrication people. I could also complete all of the fabrication and send you the completed mega. I think that the price is going to be around $170 for the mega minus chrome plating. Please let me know what you think and will commence with ordering the material. Lloyd L


1951 ZB GS
1953 BB GS
1953 Super Flash
1954 Vincent BS
1963 RGS
1974 Trident
1973 850 Commando
#696810 - 05/29/17 9:41 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
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Boomer Online content
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Orygone
Lloyd,

I'd like mine complete.


Thanks,

Bill B...


Boomer
#696826 - 05/30/17 2:22 am Re: ZB Megaphone fabrication [Re: bsalloyd]  
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BritTwit Online content
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Kansas City area
I'll take two unchromed but complete. Lloyd, will these fit the rigid as well as the plunger frame?

#696873 - 05/30/17 6:20 pm Re: ZB Megaphone fabrication [Re: BritTwit]  
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bsalloyd Online content
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Santa Fe, Texas
That is an excellent question. I did not ask Jake which frame it came from. I will give him a call to be sure. I have my plunger frame ZB so I would use it for fitting.


1951 ZB GS
1953 BB GS
1953 Super Flash
1954 Vincent BS
1963 RGS
1974 Trident
1973 850 Commando
#696904 - 05/30/17 10:41 pm Re: ZB Megaphone fabrication [Re: Boomer]  
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Boomer Online content
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Orygone
Originally Posted by Boomer
Lloyd,

I'd like mine complete.


Thanks,

Bill B...




That should say complete without chrome.


Boomer
#697528 - 06/05/17 8:21 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
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Posts: 185
bsalloyd Online content
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Santa Fe, Texas
I have received the tubing and currently ordering the cones for the mega. I will make them according to the list below:

Ponyboy53 1pc
Jake H. 2pc
Brit twit 2pc
Boomer 2pc
Lloyd L 2pc

Please confirm you are still interested. If anyone else is interested let me know. Thanks, Lloyd L


1951 ZB GS
1953 BB GS
1953 Super Flash
1954 Vincent BS
1963 RGS
1974 Trident
1973 850 Commando
#698061 - 06/10/17 6:20 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
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Boomer Online content
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Boomer  Online Content

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Orygone
Still in Lloyd.


Bill B...


Boomer
#698573 - 06/15/17 4:11 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
Joined: Mar 2013
Posts: 18
Ponyboy53 Offline
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Ponyboy53  Offline
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Posts: 18
Denver Colorado
Still interested in one.


'51 BSA ZB 34 GS - plunger
'65 BSA D7 Bantam
'68 BSA B24 Starfire
'68 B44 Shooting Star
'71 BSA B25t
'71 BSA B50t
'57 Zundapp KS601S
'42 Harley-Davidson XA
#698593 - 06/15/17 7:11 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
Joined: Jul 2006
Posts: 185
bsalloyd Online content
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Santa Fe, Texas
I have ordered enough cones to build twelve megaphones. Armours Ltd has informed me that my exhaust pipe has shipped. I will keep you posted when it all comes together. Lloyd L


1951 ZB GS
1953 BB GS
1953 Super Flash
1954 Vincent BS
1963 RGS
1974 Trident
1973 850 Commando
#711339 - 10/12/17 6:08 pm Re: ZB Megaphone fabrication [Re: bsalloyd]  
Joined: Jul 2006
Posts: 185
bsalloyd Online content
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bsalloyd  Online Content

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Santa Fe, Texas
Thanks for you patience, nothing moves fast at my house. I have everything except the brackets which are being fabrication soon. I have all the other pieces. Next step is welding up and fitting to my GS. Lloyd L


1951 ZB GS
1953 BB GS
1953 Super Flash
1954 Vincent BS
1963 RGS
1974 Trident
1973 850 Commando
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