Exhaust Header Repair
Thread Starter
Member
Squid
Joined: Jan 2008
Posts: 44
From: Kissimmee FL U.S.A
Exhaust Header Repair
I am wanting to take my main exhaust header to a shop and have it repaired. The Tube on the front right where it bends and goes under the bike is smashed in a good 1/2 or more of the normal pipe diameter. I have called several Motorcycle shops in my area and all have told me the same thing "Buy new ones" Can't I just have a shop cut out the damaged section of pipe and have a new section of pipe rebent and welded back on?
I dont know what the previous owner was doing to bend the pipe there. all I can figure He was trying to drive over curbs.
This is the last repair I need to do before I put the bike back together.
As always any suggestions are appreciated.
I dont know what the previous owner was doing to bend the pipe there. all I can figure He was trying to drive over curbs.
This is the last repair I need to do before I put the bike back together.
As always any suggestions are appreciated.
Junior Member
Squid
Joined: Jan 2008
Posts: 27
From: Bay Area, CA
As long as you don't mind a few welded seams, a good muffler shop should have no problem matching the shape of the pipe and splicing in a new section. You may want to leave the bike with them so they can weld in the new piece with the header bolted in place, just to be sure everything lines up.
Senior Member
SuperBike
SuperBike
Joined: Jun 2007
Posts: 1,031
From: Los Angeles ish
I don't see why you couldn't have a piece welded in. I'd check prices of new and used pipes though. A good weldor could charge more to repair than a good used set would be to replace. Emphasis on "could", just better to have a price comparison.
RUNLEVELZERO #99
SuperBike
Joined: Jan 2007
Posts: 2,219
From: Skokie
No lower (chin) fairing? That could hide it. A smooth 1/2" ding may not make a difference. May improve gas scavaging! Wrap it with heat wrap and no one will know but you. I'd be more conderned if the head took a whack and if the copper 0-ring is leaking.
Thread Starter
Member
Squid
Joined: Jan 2008
Posts: 44
From: Kissimmee FL U.S.A
I will check pricing on a new and used pipe also.
the pipe is crushed 1/2 way in. Not 1/2" Sorry if i did not make that clear. I may try and heat the area and pull the dent. Whats the worse thing that happens, I mess up the area and have to weld in a new section.
the pipe is crushed 1/2 way in. Not 1/2" Sorry if i did not make that clear. I may try and heat the area and pull the dent. Whats the worse thing that happens, I mess up the area and have to weld in a new section.
Uhhhhh..huh.huh..Member..
Superstock
Joined: Apr 2008
Posts: 269
From: Vancouver, WA
I bought a used exhaust, with one dented/scratched can on Ebay for $58 with shipping a week ago. It was the second one I have seen on there in the last couple weeks. Might be an option if you want to get a used pipe.
Administrator
World Champion
Joined: Dec 2004
Posts: 105,287
From: Fulton, MO
I've heard of guys using an interesting method to get dents out of expansion chambers on dirt bikes. It involves filling the pipe with water and putting it in the freezer. You have to use some method to ensure the ends freeze before the middle. There is a 10% expansion during the change from water to ice. That is a lot of pressure. The pressure pushes the dent back out. I've seen pics and a how-to on the 'net before. You might want to try a search.
Thread Starter
Member
Squid
Joined: Jan 2008
Posts: 44
From: Kissimmee FL U.S.A
Well. I actually put the pipe under pressure 90/100 psi and heated the bent area to see if I could pull the dent my self. Some of the dent did come out, Maybe 10%. That was just before I got the pipe to hot and the pressure blew a hole in it. I figured what the Hell its messed up any way. I would say if this was a small dent this method would be great. But the dent i had on a bend was just to much.
I have called several shops around here and no one will touch it. they are telling me to small of gauge for them and they don’t have a tig welder.
I’m still checking.
I have called several shops around here and no one will touch it. they are telling me to small of gauge for them and they don’t have a tig welder.
I’m still checking.
Senior Member
SuperBike
Joined: Sep 2005
Posts: 1,572
From: Buffalo, NY
Can you get something down the pipe to where the dent is and with some heat push it out? A hunk of 3/8 steel line should be flexible enough to work it down to that area but firm enough to push it out when that problem area is heated.
Thread Starter
Member
Squid
Joined: Jan 2008
Posts: 44
From: Kissimmee FL U.S.A
Great.
Just an update. Out of 20+ shops I have called. 20+ of them will not touch this type of work.
Still calling around. Im not giving up yet. At this point I may buy my own Tig welder "Need and excuse for a new toy" and do it my self.
Just an update. Out of 20+ shops I have called. 20+ of them will not touch this type of work.
Still calling around. Im not giving up yet. At this point I may buy my own Tig welder "Need and excuse for a new toy" and do it my self.
Junior Member
Squid
Joined: Apr 2008
Posts: 6
From: Seneca SC
I'd ran into the same thing with my hawk. Got it home, removed the chin spoiler to change the oil and discovered it had been bottomed out and the pipe was crushed in about halfway. I showed it to the guy at the muffler shop, and suggested surgery. He told me that wasn't a good idea with stainless. He told me to take it off the bike and bring it back. He then welded a 3inch threaded rod to the middle of the dent, next he took a blow-torch and heated up the whole section til it was red hot, then screwed on a threader looker tool and pulled out the dent. After it cooled, he cut off the rod and ground it smooth. It wasn't perfect but it was 95% and the spoiler hid all the surgery scars. Saved me over 300 clams.(Bike Bandit price) BTW there was no noticable difference in performance but the crushed pipe was buggin me bad on an otherwise perfect specimen.
Last edited by poncho; May 20, 2008 at 08:00 AM.
Thread
Thread Starter
Forum
Replies
Last Post
