Speed Bump Pipe

[MikesBike]

I'm installing a set of used Kerker 4 into 1 pipes on a Special I'm
putting together. A couple of the pipes, where they turn to pass
under the motorcycle, are crushed where the pipes have met too
high of a speed bump one too many times.
Does anyone know of a way of straightening the crushed areas
or replacing that portion with some type of pipe?
Any help is appreciated.

Mike

[MikesBike]

After giving it some thought, I'm wondering if the offending pipe could be sealed off and air pumped in while the crushed area is heated to a cherry red with a torch?

[John]

Can you weld a bolt to the crushed area, and then use some heat and a slide hammer/dent puller to pull the crushed area out?
If you are a good welder, then cut out the affected area and reweld some new pipe in it's place. It's under the bike and a bllind man will never see it anyway.

[Pat Kelly]

How about a pipe expander? Tighten the center bolt and it pushes out to make the pipe round again. Won't work around bends but if it's a straight shot then it would work. If its far inside the pipe then use an extension on the socket, just make sure you can get the expander back out.
Another solution would be to have an exhaust specialist (muffler shop) replace the bad section(s).

[strom]

cut out the offending segment, cut out something similar to cover, weld, use some temp. resistant paint and you're off.... the easiest way anyway.

LP

[MikesBike]

I believe the "replace with new metal" is the way to go... I'll check with a local muffler shop to see if they can do it.
Thanks for all your suggestions!

Mike

BTW, I still have the cart (truck, what ever...) free to a good home. Someone needs to get it before it rusts away.

[MikesBike]

A solution?

A friend of mine, who is a welder, suggested cutting the crushed area out with a moto tool, hammer it back to close to the correct shape and bring it to him to be welded back into place.
I got myself a 20 pack of reinforced cutoff wheels last night!
Thanks to everyone for the suggestions!
Mike

[Dragonrider]

I've had good luck drilling a hole on the opposite side from the smashed part...about a 7/16" or so...and then using a metal rod and hammer through the hole to knock the dent out the other side.

Then you just weld the hole back up.

(used this on gas tanks too!)

[MikesBike]

The crushed area is more than just crushed... it's pushed in and almost has the pipe completely restricted over about a 2 inch length. It looks like this one is a good candidate for the cut, shape and weld method. Or, maybe just cut it out, turn it over and weld it back
Thanks again.

Mike

[Dennyz]

I have been able to use and socket, extention, hammer and tourch.

I use a socket that is close to, but slightly smaller than the inside diameter. I run the socket and extention in through the collector. I start out slow, slightly forcing the socket into the damaged tube. Sometime it take several sizes, starting with a small one to get the pushed in section, pushed out. The the larger to hammer round again. Use is like a forming dolly found in auto body work.

It is a slow process. Applying heat helps speed things up.

[MikesBike]

Well, I did it today... I cut out the crushed area with a moto tool and bashed out the bend with a small ball and peen hammer. I then welded it back into place with an acetylene torch as the metal is too rotten for an arc welder. This repair should last long enough to get my bike on the road but will need replacing soon.
That being said, I'm wondering which header would be best for this machine. I want to be able to access the filter and drain plug without having to remove the pipes and be able to keep the center stand ( am I asking for too much?).
Suggestions? Brand? Favorite supplier? Best price?
Any help is appreciated.

Mike

[John]

I kinda like the Jardine that is on my bike. Check the link below my signature for pics of the bike. You can see the pipes there. There is a Mac header on ebay right now, but it's kinda XSpensive.

[7911special]

I thought the macs had the probs with accessing the filter. If i was going to replce mine i would almost go back to 4 into 2 just for the ease of changing the oil and not spilling it. I hit my pipe all the time going down the road when i make tight right handers. It hits just after the weld where all four go together, just about ground smooth

[thumperjsa]

I have a mac 4-1. I replaced the original 4-1 that was on the bike from the PO that had crushes, holes and bad repairs in the header.

I bought it at http://www.motorcycleproshop.com/det...uct_id=04-0301. It was under $300 with shipping. They also sell a 4-2 turmouts for the same price for the XS and XJ. I am happy with them other than the fact two of the header pipes are bluing now.

As to getting to the oil filter, I have not had the pleasure of replacing the oil since I put on these pipes. However, from the looks of things, the cover will fit between the pipes for removal. One tip I got off of this site and I can't remember who to credit was to cut apart a 2 liter bottle and put it over the pipes when the oil is drained to keep the oil off of the pipes.