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Exhaust Flange Fabrication
- TBurglar
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23 Nov 2016 20:57 #748802
by TBurglar
"Courage is rightly esteemed the first of human qualities because it is the quality which guarantees all others." -Winston Churchill
Exhaust Flange Fabrication was created by TBurglar
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.
"Courage is rightly esteemed the first of human qualities because it is the quality which guarantees all others." -Winston Churchill
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- TexasKZ
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23 Nov 2016 21:03 #748803
by TexasKZ
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Replied by TexasKZ on topic Exhaust Flange Fabrication
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.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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- DoctoRot
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24 Nov 2016 00:16 - 24 Nov 2016 00:18 #748809
by DoctoRot
Replied by DoctoRot on topic Exhaust Flange Fabrication
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
If you don't have access to a mill you could have them laser/waterjet cut from sheet pretty easy
Last edit: 24 Nov 2016 00:18 by DoctoRot.
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- TBurglar
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24 Nov 2016 07:24 #748826
by TBurglar
"Courage is rightly esteemed the first of human qualities because it is the quality which guarantees all others." -Winston Churchill
Replied by TBurglar on topic Exhaust Flange Fabrication
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.
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- DoctoRot
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24 Nov 2016 11:44 - 24 Nov 2016 11:47 #748840
by DoctoRot
Replied by DoctoRot on topic Exhaust Flange Fabrication
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.
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.
Last edit: 24 Nov 2016 11:47 by DoctoRot.
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- Nessism
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24 Nov 2016 11:59 #748842
by Nessism
Replied by Nessism on topic Exhaust Flange Fabrication
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.
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- undiablo
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25 Nov 2016 07:01 #748878
by undiablo
Kawasaki KZ 750/4 LTD 1981
Kawasaki KLR 650 2011
Argentina - Buenos Aires
Replied by undiablo on topic Exhaust Flange Fabrication
It might be usefull for some of you guys:
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Kawasaki KZ 750/4 LTD 1981
Kawasaki KLR 650 2011
Argentina - Buenos Aires
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- TBurglar
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26 Nov 2016 16:06 #749002
by TBurglar
"Courage is rightly esteemed the first of human qualities because it is the quality which guarantees all others." -Winston Churchill
Replied by TBurglar on topic Exhaust Flange Fabrication
What is that tool called undiablo?
"Courage is rightly esteemed the first of human qualities because it is the quality which guarantees all others." -Winston Churchill
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- TBurglar
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26 Nov 2016 16:25 #749004
by TBurglar
"Courage is rightly esteemed the first of human qualities because it is the quality which guarantees all others." -Winston Churchill
Replied by TBurglar on topic Exhaust Flange Fabrication
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.
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26 Nov 2016 19:21 #749018
by Jussumguy
Replied by Jussumguy on topic Exhaust Flange Fabrication
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.
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