Building Your Own Motorcycle Exhaust Kits

Written by steve smith
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Designing exhausts can be exhausting work. If you want to build your own motorcycle exhaust kits, you need to take the time to design them right. Motorcycle exhaust kits are made for many different kinds of bikes. They are custom styled for extra power and style. To start your design, take accurate measurements of the engine block and exhaust attachment hardware on the bike. Measure the distance from the exhaust opening to the bottom of the frame, and then to the rear end of the bike. Plan and map the path of your exhaust very carefully for better results.

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Bending the Steel

The next step is to cut and bend the steel. For most exhaust systems, you will want to use 14-gage steel piping that is 1 1/2 inches wide. The steel pipe is bent using metal benders. First heat the pipe with a blow torch around the section where the final bend will be made. Then set the pipe into the bender and execute the bend. Use the bender's gages to get the exact angle of the bend. If you are making your first set of pipes, you should line the pipes up to the bike after each bend to be sure you are making an accurate set. If you do not have a bender, send the pipes to a CNC bender to have them bent to your specifications.

Welding the Flanges

The final step before coating and finishing is welding on the flanges. These are the parts that attach the exhaust to the engine. They are sold at parts stores and made for specific engines. Weld the flanges using a TIG welder or gas welder. Clamp them to the end of the pipes. Start with a tack weld, a short fast weld. Then weld cleanly around the seams using a filler bar if necessary. Carefully grind out the weld with a small angle grinder and abrasive disc. Then get ready to coat and finish the pipes.


Many pipes are coated in a ceramic to protect the metal from the intense heat of the exhaust. This process can be completed by a speciality machining shop. It is a complicated process that you probably won't be able to do at home. If you want to chrome your pipes, send them to a chrome shop. Another option is to layer the pipes in carbon fibre. Cut the carbon fibre in strips and lay it on the pipes. Then, using a heat gun, melt and adhere the carbon fibre to the pipes.

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