Bending Headers to fit

The lower header on my new S exhaust set (left exhaust) is too close to the side of the bike by about 1" at the end of the header. It puts a lot of stress on that header and on the dog leg silencer bracket that mounts under the left shock top. Can I bend this thing out enough to get rid of this stress or am I in for trouble if I do? If I can bend it, how do I do it?

Dave
69S

I'm sure that you tried rotating it up already and mounting the muffler and bracket before final tightening of the header flange.
If you haven't than try it. Just be careful not to bugger your threads. Mine seemed the same. I don't think it was ever a good set up as it rattled on the rear Iso nut. It really bothered me.
Short of that I don't know any clean way of bending the pipe.

I tried mounting the silencer and header with the exhaust nut loose, it is near impossible to get the exhaust nut on. I can, but it stresses the pipe when I tighten the exhaust nut. If I just put the header and hand tighten the exhaust nut, the pipe gets real close to the bike. I don't have the exhaust gaskets in yet, that may help in the final tightening, I don't know. The upper pipe is fine.

I remember these S exhausts were always a pain, but for some masochistic reason I wanted to do it.

Dave
69S

DogT said:

I remember these S exhausts were always a pain, but for some masochistic reason I wanted to do it.

Dave
69S

Click to expand...

Probably for the same reason I did it, they look cool 8)

Mark the pipe for the direction it needs to go and then see if you can mount it in any direction or even in the other exhaust port. You need to have it solid in the head before you commence bending. Do the bending in stages.

I have never seen a replacement pipe that fit perfectly, but you can usually make them fit perfectly. If you get stumped, just sit back and ask yourself what a more learned person would do, it never fails...

RS

DogT said:

The lower header on my new S exhaust set (left exhaust) is too close to the side of the bike by about 1" at the end of the header. It puts a lot of stress on that header and on the dog leg silencer bracket that mounts under the left shock top. Can I bend this thing out enough to get rid of this stress or am I in for trouble if I do? If I can bend it, how do I do it?

Dave
69S

Click to expand...

If you must bend them...

Fit them with everything tightened up then use something long to stick down into the pipe (broom handle) and then try to bend into position. Bending anything with a chrome finish is not a good idea to start with, but you can usually get a little bit of movement without causing damage.

It can be done, but proceed with caution. Good Luck!

You need to call your supplier. There are so many makers these days and consistancy is lacking. My experience was very similure to your with a set I got on ebay. After clamp in wooden block and such I ended up putting a kink in it.


To do it right you need special equipment and the chrome will usually crack.

I called the people and he sent another with out have to send back the other. The replcement fit like a charm.

who did you by them from?

Dave, I've got a similar issue with my S-type pipes only in this case it's the upper one that doesn't bend far enough in to meet the rear bracket. It looks like we could build one perfect set from our two sets!

I got these headers from Xanders back in 03. He is not around so sending them back is not a solution. I really only need to move it about 7/16" away from the bike, right now the end of the header is about 3/16" from the Z plate and the front of the silencer is actually just touching the Z plate. Not a good situation, it will beat both of them to death.



I think at this point I am willing to take a chance on the chrome and bend it slowly and evenly as I can with care until it is where it needs to be. If the chrome cracks or the header cracks, I can fix either problem, but it will not be good to run it like it is now. I think it is called fettling in the UK, we in the US don't have an expression that precise that I can think of.

I'll let you know how it works out.

Dave
69S

I stuck a 1x3 piece of wood (leaning on the pipes) between the end of the lower header and the Z plate with the long end up and levered the header out. Heard a bit of creaking, maybe the chrome stressing but it now is in line with the upper header pipe and everything should mount without stress on something. If the chrome peels off, it will go to the chromer later this winter.



Dave
69S

Has anyone had any experiance with the stainless header pipes that come from Epco? I'm looking into buying a full set of pipes & mufflers and so far they seem like the best. Does anyone know how well they fit???

mine went on fine