SuzukiSavage.com - Exhaust pipe fabrication

John in Kalifornia

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Exhaust pipe fabrication
05/23/12 at 10:56:25

Been looking at the Ryca site and the Street Tracker. The guys must be kinda busy with all the ideas and projects they have come up with. I don’t think they will have any of the parts available separately any time soon so we are looking into building our own exhaust. Since I know nothing about fabrication there must be some issues I’m missing.

Checked with my welder. He said to get some aluminized (so it won’t rust as easy) bends and butt-weld the sections together. From a quick look at the high pipe in pictures, it seems there is a 180 bend coming off the motor and another 45-degree or so then a straight shot to the back. Not too complicated. I think I will mock up a pipe from PVC pipe first just to try.

My question is what to do at the motor end? There needs to be a flange that fits against the motor so that the pipe can be clamped to the cylinder. I don’t want to cut up the original pipe just to source this part. Do they make flanged pipe pieces? There must be some source on the ‘Net for this part. I know there are 1 ¾ inch diameter bends available and straight tubing is of course no problem.

We need to do the pipe first so that there is room for the mid mount foot controls.

Thanks,

John in Kalifornia

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Paraquat

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Re: Exhaust pipe fabrication
Reply #1 - 05/23/12 at 11:26:39

I'm actually in the middle of this myself.
I have a thread in Rubber Side Down called "Exhaust tubing size"
I got 135 degrees and 45 degrees. The problem is when I got my tubing the radius was wrong so it's a tight 135 instead of a nice broad radius.

Stainless is cheap, can be polished, and won't go anywhere for years.
I got my tubing from frozenboost.com but also check out acestainless.com
Both my pieces which should cover my whole exhaust (including muffler length if I wanted) were 50 bucks.
As a machinist in a previous life I wouldn't charge more than 20 bucks to make that flange. Find a local machine shop and have 'em rip one out of 300 series stainless. The mom and pop machine shops, not your big time how ya doin' aerospace ones.

--Steve

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Exhaust pipe fabrication Reply #2 - 05/23/12 at 11:41:27 flanges are supposed to be common with one of the other boulevardes probably the m109
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John in Kalifornia

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Re: Exhaust pipe fabrication
Reply #3 - 05/23/12 at 14:19:31

Thanks for the reply. I think you are referring to the "exhaust pipe clamp" item 3 in the picture. This ia a common part that can be scrounged off a junk bike.

What I want to find is the "ring" which needs to be welded on to the end of the pipe so there is something for the clamp to, er clamp against. Like a washer or thicker.

John in Kalifornia

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Exhaust pipe fabrication Reply #4 - 05/23/12 at 14:59:19 yes, I'm talking about the weld on ring, not the clamp. but you might be able to find which bike is similar by that clamp if it is common.
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Paraquat Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2206	Re: Exhaust pipe fabrication Reply #5 - 05/23/12 at 15:17:44 If the gent making mine has a fair enough price I'll ask him to rip off two of them. --Steve
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renegade1 Full Member Offline SAVAGE Posts: 212 Abbotsford B.C. Gender:	Re: Exhaust pipe fabrication Reply #6 - 05/30/12 at 21:52:10 hey guys, can I just put a straight pipe on? if so am i going to have to mess with the carb or any other thing? sorry just been thinking of doing this but want to cover all problems and work needed to be done. and i dont know if that was a stupid question so go easy on me haha
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Exhaust pipe fabrication Reply #7 - 05/31/12 at 07:43:33 There is a reverse cone welded in to catch reflected pulses right up where it clamps to the head. I guess the less restriction in the muffler, the less that would be needed,, IDK,,
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Drifter Senior Member Offline SuzukiSavage.com Rocks! Posts: 430	Re: Exhaust pipe fabrication Reply #8 - 05/31/12 at 08:21:56 Post pics when you get them made up You might be able to sell a few on here, stainless is cool and looks good after being cooked...
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splash07 Serious Thumper Offline Posts: 911 Charleston, SC Gender:	Re: Exhaust pipe fabrication Reply #9 - 05/31/12 at 11:35:02 I would certainly be interested in one
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irondad01 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 25 Osceola Mills, PA Gender:	Re: Exhaust pipe fabrication Reply #10 - 05/31/12 at 15:36:44 I'm right now trying to do the same thing. I was going to run it down the right side until I saw the Ryca one. It is a much better idea. With the shock offset it looks like it was made for a high pipe on that side. I have an old clunky lathe that I think I can carve out a ring for the end of the pipe on. Carl
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jay313 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 15	Re: Exhaust pipe fabrication Reply #11 - 06/01/12 at 05:25:29 Would love the see the finished product and final cost when you get it mounted.
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justin_o_guy2

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Re: Exhaust pipe fabrication
Reply #12 - 06/01/12 at 06:39:39

A piece of pipe to part the ring off of & a plate to shape up & some welding & Yep, youd have it, but I wonder if a guy can get the OEM part
for less less than the value of the time & materials invested.

It wouldnt bother me to go to the muffler shop & have regular Ol', everyday Zaust Pipe bent to fit. Sure, stainless Looks Great & all, but Yee Haaw its Ex PEN Sieve ( as in money runs thru that project like water thru a sieve). Sure nuff if I was running a bobber Id be all over that.

Check into the REverse Cone reflected wave stopper.

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The people never give up their liberties but under some delusion.- Edmund Burke.

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ralfyguy Serious Thumper Offline Posts: 932	Re: Exhaust pipe fabrication Reply #13 - 06/01/12 at 17:41:09 I was thinking about getting one of those tractor replacement mufflers at Atwoods, but I don't know what this is gonna do to the motor.
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