Exhaust Flange Fabrication

Has anyone tried to fab up an exhaust for a 650 and successfully made the flat flanges that the split collars push against? I'm trying to figure out how I would even do it, so I can make my own exhaust.

I think the easiest way is to get a length of tubing that has an i. d. that matches the o. d. of the pipe and weld a slice of it to the pipe. An alternative would be to machine rings and weld them on.

I machined some collars out of 6061 for the custom header on my 750 twin.

If you don't have access to a mill you could have them laser/waterjet cut from sheet pretty easy

Thanks guys. How does the custom flange work DoctoRot? I think I will go with the pipe on pipe method TexasKZ suggested, but alternative solutions are always a good thing.

I machined all the parts myself because I had never done anything like this before and wanted to try it out, but you can achieve it In a simpler fashion. The collar slides over the exhaust spigot which has a ring sticking out. The retaining rings fit behind this and fit into a bored out step in the collar.

An easier way would be to have the collars waterjet cut and put them on the exhaust tube before you weld the larger pipe on the tip like texaskz suggested. The only bummer with this is the collars are permanent unless the primaries are slip On.

Why not use the collars from a 750/4 bike along with the half moon pieces? All you have to do then is add a doubler piece that slips over the pipe and butts against the head. Basically, same method as the OEM pipes use.

It might be usefull for some of you guys:

What is that tool called undiablo?

I definitely don't have the equipment to drill a 1.4" hole in steel that thick, but it does seem like the best option, if I could find one somewhere.

Yeah I always just hack up a trashed set of old pipes. Why reinvent the wheel. Also it makes for some keen reversion tubes. Helps scavenge exhaust they say.