Stock exhaust repairs

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Stock exhaust repairs

Post #1 by Whiskerfish » Mon Dec 10, 2007 9:17 pm

The 76 I recently aquired had horrible rot at the header to Horshoe connection. It was unservicable. I got to scrounging and came up with an adapter from Auto Zone that fits very good. It is made by ROL Exhaust and is # 528. I welded the front end to the swedged ring on the header and am going to make a couple of relief cuts so i can clamp it on the Horshoe. Cost was $1.88 each. Pics below:

Image

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"Agreement is not a requirement for Respect" CDR Michael Smith USN (Ret) 2017
"The book is wrong, this whole Conclusion is Fallacious" River Tam
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roadster5580
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Exhaust Repair

Post #2 by roadster5580 » Mon Jan 14, 2008 8:57 am

Just did the exact same repair on my bike. In the middle of the major winter O/H, so I have the header pipes and the H-pipe off the bike.

Decided to give POR-15 Black Velvet Header Paint a try. Don't want to be buying an H-pipe anytime soon. Saw somewhere some maniac wanting $1,400 for one "new - in the box". Guess he thought it was the last one on the planet or that's some kind of collector box.

Any way, ever try the stuff? It's dried flat black, but somebody told me it turns to Hi-gloss as it "bakes".

BTW, that is a tricky weld job -- thin rusted pipe to new metal. How do you plan to "seal" the joint. U-clamp? 1 1/2" Seal-tite?
ROADSTER5580

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Post #3 by Whiskerfish » Mon Jan 14, 2008 9:11 am

I been playing with the home remodeling so I have not gotten back to this yet. I do know that it sealed the way it is. I never expected that but it did. I still plan on doing relief cuts and then I am going to try and use the stock clamps. On the Left side there is a clearance issue with the center stand that precludes the use of a "U" Clamp.

I have not used the POR Products and have not decided on a finish yet. It may get sold as is come spring.
"Agreement is not a requirement for Respect" CDR Michael Smith USN (Ret) 2017
"The book is wrong, this whole Conclusion is Fallacious" River Tam
2008 GL1800 IIIA "TH3DOG"
1975/6/7/8/9 Arthur Fulmer Dressed Road bike
1975 Naked Noisy and Nasty in town bike
and a whole garage full of possibilities!!

Psst. oh and by the way CHANGE YOUR BELTS!!!!

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Post #4 by Frenchy » Mon Jan 14, 2008 10:31 am

The next time I get a fixed, I'll post it..

I've got a local muffler shop, that does a GREAT repair job! It looks very close to OEM... ;)
Frenchy

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Post #5 by starket » Mon Apr 06, 2009 10:00 pm

I took WF idea and built on it. I bought the adaptors and cut about 1/2 off the big end. I bought the 503 adaptor since the 528 was not available at Schucks. I then did some relief cuts so it would fit over the collar on the header. Now it will be easy to weld to the muffler and I can use the original clamps.
Image
Last edited by starket on Wed Apr 08, 2009 1:03 pm, edited 1 time in total.
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Post #6 by LikeMike64 » Tue Apr 07, 2009 6:42 am

I found an easy way to get a good seal on these overlap joints.

Cut 4 slots by hand with a hack saw, from the end of the over lapping pipe straight down the pipe to about 1/4" past where the inside pipe ends. Then install the inside pipe, clamp it. Then weld up the last 3/2"-1/2" of the slot (the end closest to the end of the inside pipe). Don't weld the two pipes together. This allows the clamp to close the outer pipe around the inner more tightly, and as the welds cool, it also camps the pipe on its own.

No leaks, and it is disassemble-able. BTW, Harley camps are great for this (<8$ each from the HD dealer).
Mike
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Post #7 by Peterbylt » Tue Apr 07, 2009 10:57 pm

I used almost the same exact repair on my muffler.
I also used the gaskets and clamps that go on crossover pipe for an 1100 they fit perfectly.

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Peter
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Post #8 by starket » Wed Apr 08, 2009 12:56 pm

Here is the finished repair with the muffler repainted
Image
Here is the header with some fiberglass muffler wrap for a gasket.
Image
And is a pic of everything installed using the stock clamps.
Image
Steve Tarket
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1976 GL1000 LTD
1976 GL1000 - Jigsaw +
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Post #9 by K-2 » Sat May 23, 2009 6:11 pm

NICE!!! This is exactly what I need. Does anyone know if the chrome tips come off the muffler? I want to paint the muffler with them off, but the screw at the chrome tip doesn't want to budge. Thanks.
Kenneth Klabunde
1977 GL1000 x2
Alpine, Indiana

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Whiskerfish
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Post #10 by Whiskerfish » Sat May 23, 2009 7:43 pm

I have read here that some get them off. But I have tried on 2 different sets and only managed to destroy them.
"Agreement is not a requirement for Respect" CDR Michael Smith USN (Ret) 2017
"The book is wrong, this whole Conclusion is Fallacious" River Tam
2008 GL1800 IIIA "TH3DOG"
1975/6/7/8/9 Arthur Fulmer Dressed Road bike
1975 Naked Noisy and Nasty in town bike
and a whole garage full of possibilities!!

Psst. oh and by the way CHANGE YOUR BELTS!!!!

handyandy64
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Re: Stock exhaust repairs

Post #11 by handyandy64 » Thu Sep 06, 2018 9:21 pm

Hey guys, I just found this add for muffler band clamps. /www.bestdeals.today/stainless-exhaust-band-clamp

edit for Working link WF
https://www.bestdeals.today/stainless-e ... band-clamp


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