How to Make Motorcycle Exhaust Kits

Written by william machin
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How to Make Motorcycle Exhaust Kits
Motorcycle exhaust kits are manufactured to certain specifications. (Motorcycles on exhibition. image by wrangler from Fotolia.com)

Motorcycle exhaust kits consist of a header pipe, a muffler and tailpipe. Most street bike exhausts have a chrome finish, while many dirt bike exhausts are anodised or finished with high-heat paint. Making exhaust kits requires hydraulic and automated tools, welding equipment and electroplating systems. Kits are fabricated to specifications for certain motorcycles. Specifications are available through the particular motorcycle's manufacturer.

Skill level:
Easy

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Things you need

  • Exhaust tubing (specified diameter)
  • 1/8-inch plate steel
  • Sheet metal (alloy)
  • Packaging supplies

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Instructions

  1. 1

    Mark a length of exhaust tubing at the points where bends are specified. Typical street headers have a bend at the upper end where the pipe connects to the exhaust manifold and another that positions the lower section of the header at the motorcycle frame.

  2. 2

    Insert one end of the pipe into the hydraulic tubing bender. Bend the tubing to the specified angles at the marked locations. Check the angle of each bend using a mechanical or digital angle square.

  3. 3

    Cut the pipe to length using an automated tubing cutter. Place the upper end of the pipe in the flaring tool. Flare the end of the pipe for attachment at the exhaust manifold on the motorcycle.

  4. 4

    Cut the tailpipe section of the exhaust to the manufacturer's specifications regarding the length and termination point of the tailpipe.

  5. 5

    Fabricate brackets that attach the tailpipe section to the motorcycle frame using 1/8-inch plate steel. Bore the brackets for the attachment bolts. Weld the brackets to the tailpipe section at the locations specified by the bike's manufacturer. Allow the welds to cool.

  6. 6

    Seal the open ends of the header and tailpipe with expanding nylon or composite plugs. Place the header and exhaust pipe sections on a rack and submerse the sections into the electroplating solution. Rinse the freshly chromed header and tailpipe sections with fresh water. Remove the plugs.

  7. 7

    Cut a piece sheet metal alloy for the muffler using a hydraulic sheet metal cutter. Place the piece of sheet metal in a tapered roller. Roll the piece of sheet metal alloy to the specified configuration of the muffler.

  8. 8

    Insert the baffles into the muffler. Weld each baffle in place using four electro-welds, evenly spaced at the outside of the muffler. Weld 1/8-inch plate steel attachment brackets with bored holes to the muffler at the locations specified by the bike's manufacturer.

  9. 9

    Seal the open ends of the muffler with expanding nylon or composite plugs. Place the muffler on a rack and submerse it in the electroplating solution. Rinse the freshly chromed muffler with fresh water. Remove the plugs.

  10. 10

    Wrap the individual chrome exhaust pipe sections and muffler for protection. Package the kit in a durable shipping carton. Include installation instructions and a specification sheet. Label the shipping carton and include the model number of the exhaust kit.

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