Rotting exhaust header, what to do?

[Guest]

Should I have an exhaust place cut it out and replace it? Or do you recommend I simple cut it out and plug the holes? Thanks!

[yank]

Your kiddnig right!!!! I hope your gas tank is in better shape. All kidding aside I would look for a better used one.

[jbthomp]

Whoa that's bad. It doesn't look like there is enough good metal there to weld to.

[tkent02]

It doesn't look like there is enough good metal there to weld to.

How about the rest of the bike?

[motokid837]

Rest of the bike is surprisingly rust free. Some surface rust but thats about it, even the gas tank. since there is little metal to weld to, looks like cutting it out and plugging the holes will do fine.

The bike was in a shed just in dirt for a few years, so the exhaust took a lot of moisture I'm sure.

[motokid837]

oh and yes the picture makes it look bad, but its really just rusted through where the exhaust crosses over, the rest of the pipe is simply surface rust.

[GS1150Pilot]

Looks like something brought up from the Titanic.

[chuck hahn]

Take it all off and throw it in the bin....and take a wire brush to the under side of that engine and get the scale off at a minimum. That oil filter cover doesnt look like its been off in 20 years.

[Bustedknuckles]

Take it all off and throw it in the bin....and take a wire brush to the under side of that engine and get the scale off at a minimum. That oil filter cover doesnt look like its been off in 20 years.

I 2nd that, that exhaust looks BAD, it would be pretty hard to patch that correctly, a section of pipe slotted at the ends, sealed, and clamped MIGHT work? But I dont think for long with all the vibrations...

Better off buying a used exhaust... With rust like that, I would also worry about breaking off the header bolts at the manifold. I would do some prep work before you start wrenching on them.

Looks like something brought up from the Titanic.

Hah! perfect description.

[Gregory]

I agree it is way far gone...BUT.... if I ZERO DOLLARS to spend on the bike I imagine I could find a way to salvage it where it would work.

I would start by removing it from the bike to see what I was working with. Go to town on it with a wire brush. Knock out any loose stuff. Cut away or peel away the thinnest part of the crossover tube. Find something to sleeve over it and clamp on. than save up for a rattle can of black heat paint.

[GSX1000E]

As was stated earlier in this thread... throw it away!
Or, at least place it back next to that rusted cannon on the bottom of the sea where it came from.

[JTGS850GL]

Old school use to use a beer can with the ends cut off to wrap around the hole in the exhaust. Then use hose clamps around the can. Just make sure you use PBR beer as the donor. It goes with the low cost theme. If you want to do it really per vintage, then find some asbestos cloth to wrap around it first before the can layer and clamps.

[Rob S.]

How does it sound?

I've used the "beer can method" on my '68 Camaro back in the day when money was not available.

Best of luck to you. Let us know how it goes.