DIY Exhaust Pipes

[Guest]

The pipes on my 250 have seen better days and are starting to get holes in them, i could either get them welded up or i have access to a pipe bender i was thinking of making my own? The girlfriends old man used to be a metal fabricator so he could help me but he no longer has an oxy torch to heat the metal up to bend it.

My bike runs an aftermarket exhaust on it, its 2 into 1. I only want to make the section that comes out of the heads and down to the first join, the rest of the exhaust is in good condition and i'll be painting it anyway.

Any ideas?

Cheers Josh

[pete]

If the headers are separate to the pipes and not permanently joined, go for it. I would imagine you could just take off the existing ones and use them for a template.

Be careful with those exhaust bolts in the head though if you haven't taken them off before. Use lots of lube and let it sit overnight or something at least so you don't break any.

[Hammered]

Im making a set for my Chopper project. The best thing to do is buy a box of prebent mandrel bends. I paid $30 or so for 4 Us 4 45s 4 90s off Fleabay. then all you nee is some straight pipe and its cut a tack til you get what you want and weld them up solid. The mandrel bends wont have the wrinkles in the tubing from the bends and will look nicer.

[Woodsy]

Yeah i was thinking of mandrel bends last night, The pipes do join but i cant remember how far along the pipe. I've heard one with a standard exhaust one out each side and they sound horrible, i much prefer my 2 into 1 sound.

I'll see what i can find and put up progress.

[Woodsy]

Well before i can play with the pipes i have to fix my muffler, the insides have completely rotted away so i'm faced with either, A- Building my own muffler insert or B- Just buying another Muffler.

My muffler was semi packed with some brass wool which was caked in soot. The muffler insert pipe is around 1.5 inches in diameter, i have some 2.25 inch exhaust pipe here i was going to drill HEAPS of holes into and then put packing around that, and weld the end to the mufflers cap, or i could pop rivet it.

I dont want to effect my bike with changing jets etc as money does not permit. What would you guys do?

[Woodsy]

Here is the rebuilt muffler, I used the original end cap and got a piece of exhaust pipe, drilled HEAPS of holes in it ( dont worry they werent just random holes ) then wrapped that in steel wool then wrapped that in a muffler packing sheet.

The bike is abit rough but i think she sounds ok, in this vid you can see the front mudguard painted, thats how the whole bike will look.

Click on the pic to be taken to the video on photobucket.

[pete]

Mate that sounds great for a 250

And definitely liking the new paint...

[tas850g]

How did the head pipes come out? I need to do something with my head pipes and thought about having some made out of stainless steel.

[Woodsy]

I havent done them yet, needed to get the muffler fixed first.