Header

[Volant1006]

So I was riding home Father's day on a nice sunny day enjoying myself. Started hearing a rumble from down under. At first I thought I blew out a baffle or something. After getting back home I inspected the exhaust. Sounded like I had an exhaust leak or crack, the back pressure wasn't quite there. I didn't see anything so I removed the heat shield from the left side exhaust only to find my muffler was completely broken off of the header! It must have rusted out over time I guess. The bike's always been garaged and there isn't much rust anywhere on it. Anyways I'm wondering what my options are. To weld it back together might take a lot of work not to mention it could always break near the weld again. I'd like to use stock pipes but it looks like those are few and far between. Is my best option to stumble upon one on eBay? I've seen aftermarket exhausts for around $300-$400. I'm guessing I'd have to change the jets to go along with any new exhaust. Had anyone swapped these out before? Am I even gonna be able to get the header bolts out?

[motoman]

So I was riding home Father's day on a nice sunny day enjoying myself. Started hearing a rumble from down under. At first I thought I blew out a baffle or something. After getting back home I inspected the exhaust. Sounded like I had an exhaust leak or crack, the back pressure wasn't quite there. I didn't see anything so I removed the heat shield from the left side exhaust only to find my muffler was completely broken off of the header! It must have rusted out over time I guess. The bike's always been garaged and there isn't much rust anywhere on it. Anyways I'm wondering what my options are. To weld it back together might take a lot of work not to mention it could always break near the weld again. I'd like to use stock pipes but it looks like those are few and far between. Is my best option to stumble upon one on eBay? I've seen aftermarket exhausts for around $300-$400. I'm guessing I'd have to change the jets to go along with any new exhaust. Had anyone swapped these out before? Am I even gonna be able to get the header bolts out?

Have it spot-welded in several places while mounted with a wire-feed welder. Then remove and weld it all the way around, preferabley a torch weld. Using this method, heat is spread over a larger area and won't re-break. Grind smooth, leaving a weld crown. Re-paint area with Dupli-Color's High Heat Ceramic Aluminum DH 1606. Will NEVER dis-color from heat. BTDT with my right side exhaust 32+yrs. ago. Requires a good eye to find the repair location.

[crazy steve]

Great advice, saving the OEM exhaust is better than trying to find a decent aftermarket set. One thing I'll add; before doing the full welding, get some 'heat sink' (try a welding supply store, or you can get this... http://muggyweld.com/heat-dissipation)
and apply it around the muffler. This will help prevent excessive 'bluing' of the chrome from the weld heat.

[ViperRon]

If you decide to get aftermarket replacements there are 2 things to consider first is the originals are almost impossible to beat as far as performance of the bike. The sound will be different from aftermarket pipes. The after market pipes will blue much quicker then original cause original are dual wall pipes.

I replaced mine many years ago with a set of Mac Taper tips that fit but did not like the taper tips. I have since purchased a set of Flare tips and they sound better and they have a true baffle that is easy to modify to tone down or open up depending on what you want.

I have seen where good parts and pieces of original are sold on EBay I would suggest you go that direction if repair of yours is impossible.

[Volant1006]

Thanks guys, I got an e-mail from a member on here who might have what I need. I'll start with that and see what happens. I'd like to keep the bike as stock as possible but might have to update if I can't find the old stuff. I'm not schooled in the welding dept. although my brother-in-law and some of his friends have the ways and means. If I can't get a replacement I guess I'll try and get it welded back together...

[Bergman16]

The SG I bought had the header welded to the pipe under the cover. If you do have it welded, try to make sure the bolt holes for the cover line up (or weld in new ones). Once that chrome cover is on nobody will see the weld. Works great and can't tell the difference looking at it.

[Robsweetland]

Have a set of Mac 4 to 2 on my sf,they were on it when I got it, had no problems, bit of rust on headers but easily painted

[BowlingSS]

Have it spot-welded in several places while mounted with a wire-feed welder. Then remove and weld it all the way around, preferabley a torch weld. Using this method, heat is spread over a larger area and won't re-break. Grind smooth, leaving a weld crown. Re-paint area with Dupli-Color's High Heat Ceramic Aluminum DH 1606. Will NEVER dis-color from heat. BTDT with my right side exhaust 32+yrs. ago. Requires a good eye to find the repair location.

I cannot find any Dupli-Color's High Heat Ceramic Aluminum DH 1606. It looks like they stopped making it.




Bill