Topic: Fix a hole in a header? (Lets get creative!!)

[dangerdave]

So after cleaning up my headers, i noticed a crack in the chrome at the bottom of one of the pipes.  I got curious so i stabbed it with a screwdriver and sure enough...hole! The bikes PO had let it sit outside for 15 years, so it wasnt that big of a surprise. Now, I was already planning on using header wrap on the pipes anyway, so no biggie. There is a decent amount of rust already shaken loose out of them, but there doesn't seem to be any more really 'soft' spots. I'm sure i can macgyver something up, but I'm curious to know what any one else has done in this situation.




1. I'm not buying new pipes.
2. Hose clamps are out of the question
3. Not worried about aesthetics. (Trying to get 'near' flush though)
4. I do have lots of empty beer cans lying around...possibility maybe?

[dave500]

make a hole on the other one so they match.

[dangerdave]

Symmetry should ALWAYS be factored in....

[750K]

I'd just get a patch welded in and wrap them, problem solved

[dave500]

use a new piece of steel though,like some exhaust pipe split then wrapped partially over it?

[Dave Voss]

1. I'm not buying new pipes.
2. Hose clamps are out of the question
3. Not worried about aesthetics. (Trying to get 'near' flush though)
4. I do have lots of empty beer cans lying around...possibility maybe?

If you're sure about not relaxing your stance on rule No.1 above, I would find a piece of the same diameter pipe, cut a half-round section a few inches long, and use it as a template to trim out the rotted section of your header pipe, and then have the new section welded in place.  It may be hard to prevent the shape of the pipe from distorting during the weld repair, which could cause installation woes, so try to jig it with something that will keep the pipe ends at the correct distance and orientation to each other.

[Xnavylfr]

Since you are wrapping the pipes , you could use the Muffler repair kit. It has a mesh tape then some HI-TEMP epoxy you put over the tape. It can be smoothed out so once the wrap is installed you'd never know it was patched. I KNOW this is not the BEST way but probably the cheapest. The perfect way would be to route out the hole to an oval shape and cut an oval patch and weld it in !!


Xnavylfr(CHUCK)

[flybox1]

patch weld that hole up and pipe wrap them. 
done.

tried that header patch kit stuff on my old K8 pipes.
it blew out as soon as it hardened.  welding in a patch is the way to go.

[Powderman]

You do realize that if they are that rusted out your repair is only gonna fix that hole, more will come shortly. You may find issues welding a patch on if they are all rusted out inside.

[dangerdave]

I'm liking the idea of a split pipe section wrapped around and welded in. I think I'm gonna shy away from the epoxy. That stuff never seems to work all that well for me. Although, how about like a 3in section of thin wall pipe, or even some 18ga mild sheet bent into shape, a couple holes drilled through it and pipe, then welded closed, with a bit of epoxy sandwiched between to stop leaks? A section cut out and welded fully in wouldn't work I'm thinking because of the bit of rust in that area making the pipes pretty thin at that point.

[bjbuchanan]

The epoxy will fail pretty quickly, the kits pretty much suck. The work initially but after heat cycles usually blow off. I swear the only reason they are on a shelf is for wishful thinkers

[mono]

I'm liking the idea of a split pipe section wrapped around and welded in. I think I'm gonna shy away from the epoxy. That stuff never seems to work all that well for me. Although, how about like a 3in section of thin wall pipe, or even some 18ga mild sheet bent into shape, a couple holes drilled through it and pipe, then welded closed, with a bit of epoxy sandwiched between to stop leaks? A section cut out and welded fully in wouldn't work I'm thinking because of the bit of rust in that area making the pipes pretty thin at that point.

i agree with the previous comment that if the pipes are rusted inside, and to the point that you're concerned that welding is not going to work, that they will just experience other failure points in the near future.

If you just want a set of pipes to wrap, you should be able to find a set fairly cheap that are structurally sound but cosmetically flawed.

[Vinhead1957]

You said creative! Find an old exhaust and cut a patch from it. Make the existing hole larger the accommodate the patch fm the inside drill a hole in the middle of the patch to put a screw into pull it from with vice grips. Insert the patch ( a little larger than the hole) in the inside of the pipe. Go to homedepot and get some brazing rods and mapp gas and braze that new patch in you can then sand off the excess and it will be less noticeable

[silent_k]

It looks like tha hole is in a straight section of pipe. If so cut that 3-6" section of tube out, buy a new chunk of exhaust tube and weld it in. Grid/ sand it down flat.

Another option is to just bring the header an a piece of samediameter rxhaust pipe into an automotive exhaust shop and ask them to patch it. Will probably be dirt cheap.

Cheers

[dangerdave]

I do like the idea of brazing... any solution that lets me have fun with fire is always worth a try!

[CB750F2]

I suggest that you consider having someone bend up two new pipes from s/s and weld them into your existing collector. This would look good and probably cheaper in the long run. Pat

[mono]

I do like the idea of brazing... any solution that lets me have fun with fire is always worth a try!

that is a good idea, but remember that you can't braze (or weld) onto rust.  i would do the patch on the outside, where you would be able to get the cleanest contact surfaces.

[DaveBarbier]

The original posted pictures are gone so I can't tell if my headers are worse off or not.

Do you think these small pin holes can be welded and then prepped (sandblasted) for paint? The inside of the pipes seem to have no rust...just sooty, but I can only tell as far as a flash light can see.

I plan on painting them with heat paint and then wrapping them because they look pretty gnarly.







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1978 Honda CB550K

[nccb]

The original posted pictures are gone so I can't tell if my headers are worse off or not.

Do you think these small pin holes can be welded and then prepped (sandblasted) for paint? The inside of the pipes seem to have no rust...just sooty, but I can only tell as far as a flash light can see.

I plan on painting them with heat paint and then wrapping them because they look pretty gnarly.







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1978 Honda CB550K

Those things look like #$%*

[martin99]

The only creative thing I can think of to do with that exhaust is to turn it into garden art.

Maybe I'm just picky, but IMO that exhaust is.. well.. totally #$%*ed

[DaveBarbier]

The only creative thing I can think of to do with that exhaust is to turn it into garden art.

Maybe I'm just picky, but IMO that exhaust is.. well.. totally #$%*ed

All I'll say is that they were free, haha.

I know they look like a pile of rocks but I'm just curious if they'll just deteriorate while trying to weld those holes or mediablasting. I really want to try and save these poor things. Exhaust headers are expensive. Especially since looks don't matter to me. It's what's on the inside that matters...and in this case, I hope it's not rust.


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1978 Honda CB550K

[LesterPiglet]

If you want to use them braze them. You could get a nice layer along that pitted area, after a good derust of course.

[DaveBarbier]

If you want to use them braze them. You could get a nice layer along that pitted area, after a good derust of course.

Thanks Lester, I just brought it to a local sandblaster who builds custom bikes in his free time and that's exactly what he said, too. Shouldn't be more than $30 he says.


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1978 Honda CB550K

[martin99]

Maybe I was being a bit harsh Dave, I'm all for not spending money so if you can get those headers fixed good on ya'

[DaveBarbier]

Maybe I was being a bit harsh Dave, I'm all for not spending money so if you can get those headers fixed good on ya'

Ha, no problem, oldskoolnuts. At first glance they look awful...and at second and third... but hopefully they'll last for a season or two once patched.


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1978 Honda CB550K

[LesterPiglet]

Bit of flat black and they will look sweet.

[DaveBarbier]

Bit of flat black and they will look sweet.

I'm actually not 100% sold on wrapping them. After I paint them I'm going to see if I can wrap them with some tan fabric strips to see if they look alright. I may just keep them plain.


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1978 Honda CB550K