Homemade Motorcycle Exhaust

Written by scarlett gauthier
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Homemade Motorcycle Exhaust
Motorcycle pipes can have several bends. (Auspuffkrümmer image by Conny from Fotolia.com)

Motorcycle exhaust systems, like a car's exhaust system, use exhaust pipes to carry gas through the muffler and out into the air. Users choose the appropriate system for their motorcycle based on personal preference, and the bike's requirements. Exhaust systems can be tuned and customised for performance, appearance, and sound. Many users choose to customise the exhaust system for a deeper exhaust tone and to provide an increase in power. You can also make your own exhaust system with tools purchased at any hardware store. Once completed, the exhaust system can be painted to your liking.

Skill level:
Moderately Challenging

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Things you need

  • Permanent marker
  • Measuring tape
  • Poster board
  • Note pad
  • Pen
  • Heat source
  • Pipe bender
  • Muffler
  • Hardware and attachments
  • Steel pipes

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  1. 1

    Measure the motorcycle's full system from the head pipe on the engine to the foot pegs and to the rear. Use the pen to mark down the measurements acquired on the notepad. If exhaust is being built on both sides, make sure to measure each side because they are different.

  2. 2

    Build a full-size template for the exhaust system on the poster board. Make sure the measurements are precise when you match up the template to the motorcycle. Build a second one for the other side of the motorcycle if needed.

  3. 3

    Determine how many welds are needed and purchase the pipes for the exhaust system. Make sure to get pipes that are the full length of the system, as per the measurements made. For more accurate measurements, measure the outside edge of the side of the motorcycle. Take the larger measurement and add approximately a foot.

  4. 4

    Make a mark with the permanent marker on the pipe where the bends should start. Leave an extra half foot at the head pipe section so the tube can be inserted in the pipe bender.

  5. 5

    Heat the pipe until it bends without cuffing in and use the bender to bend the pipe at each mark.

  6. 6

    Attach the muffler once the pipe is bent. It should slide on easily. Affix the additional hardware to attach the exhaust to the motorcycle.

  7. 7

    Make sure the exhaust fits all the attachments properly, such as the head pipes and braces.

Tips and warnings

  • Make the bends quickly but accurately in order not to overbend the pipe. You should not have to bend the pipe backwards.
  • Avoid making sharp pipe bends because this will slow down the flow of the exhaust when installed on the motorcycle.
  • Use gloves when operating the bender and heating the pipes for caution.

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