| Author | Message | ||
     Scs1 |
I've got growing cracks in my header pipes just before the pipes meet. The front lower mounting bracket busted a little while ago. I should have fixed it but didnt. This most likely caused the header pipes to crack. Does anyone know if this can be repaired? Does anyone have a stock or after market header they want to get rid of. I have a V&H muffler on it now. Thanks for your help, Nate | ||
| Jim2 |
I had the same thing on mine. It was cracked in about seven places all around where the two pipes meet. I took it to a speed shop and had it mig welded. He said he did it at a lower than optimum heat because the metal is so thin. It's held up for 3000 miles since but I still need to fix the front muffler bracket. I haven't looked real close but I'm sure there is a small hole or crack that has returned because I can see the mark it has left on the cam cover. I'm sure I paid too much for the welding but he did a great job and I was able to get it on the road again quick. | ||
| Dan9460 |
The tech at local Buell shop said my S1 didn't have a rear bracket and is installing one on my supertrapp - I think you should have a front and rear bracket on the muffler to prevent stress on the header...you might want to check header studs | ||
| Sleez |
my welder charges 90.00/hr, and does great work | ||
| Jim2 |
I should have mentioned that although my front bracket is broken I keep a stainless steel hose clamp around the front of the muffler and muffler mount. This limits vibration travel and might save me if the muffler comes loose from the header pipe. I really need to get this fixed properly soon. Nate. Look for a new header pipe. It will be cheaper than the weld job and you can keep the old one around if you need it. Right after I had my header welded I found an add for a header pipe for $50. I paid three times that. Live and learn but learn from others when you can. | ||
| Brinnutz |
I know where there is a new or like new header from a dealer...It was there a few months ago anyway. I want to say they wanted like $250, which I thought was ridiculous. But ping me if you are interested and I'll let you know who to get ahold of. | ||
| Scs1 |
Jim2, Sounds like your bike had the same stress fractures as mine. Probably caused by vibration and an unsupported front exhaust. I dont think that the front, upper bracket was ever doing much, it's so wimpy. Looks like I need the new version. The larger front lower bracket busted off a while back, looks like it may have happened before. It left a hole in the exhaust. I patched it with a hole collar from Napa. I also installed a big hose clamp through the frame mount like you did. The hose clamp failed real quick. If yours is still working, then I should have gotten a beefier clamp. Oh well, now its time to fix it right. As cheep as possible. I do know an ace welder who may hook me up. I'd have him fix the cracks and re-reinstal the mount, if it doesnt cost too much. Dan, Your probably right. Thats a lot of stress on the studs. Will check it out. Sleez, maybe an option if my guy doesnt have time. Brinnutz, I'll try to fix it first. I'll get back to if a new one is needed. Thanks. | ||
| Sportyeric |
S1W would be a 2 1/2" collector, right? | ||
| Jim2 |
About the hose clamp. I've replaced a bunch of them until I figured out that the slanted grooves where the screw thread rides cannot be near the top. If it's at the top the up-and-down shacking action will cause the clamp to fail quick. I moved them to the side and down and don't have to buy new ones anymore. Also you can't have it too tight. I had hoped that the HD/Buell dealer would give me the new bracket but it wasn't safety so I only got the shock (I'm not complaining). I have a friend with a welder so when I can pin him down I'll get the tabs welded back on the front of the muffler and run a bolt through with a rubber doughnut to soak up the vibes. | ||
| Scs1 |
It is a 2 1/2" collector. I havent spoken a welder yet, but one of the pipes is 75% busted. I've got a feeling that I'll need to buy a new/used one.  | ||
| Scs1 |
These cracks were weldable. Had a reputable welder fix it up for a hundred bucks. I also replaced the "L" bracket with the "Y" bracket. Put about 2k miles on it and everything is fine. I do have another question about the "Y" bracket.  | ||
| Buellistic |
EXHAUST SYSTEM ASSEMBLY Class 101 available upon request, just e-mail me(Ljenne73c@verizon.net) and a copy is yours ... |
