Topic: Removing stuck mufflers CB400T

[KB02]

Okay, one the of obvious areas of concern on this bike I've got is the exhaust collector that goesa from headers to mufflers. That thing is wicked rusty. The only problem is that I can't get the mufflers off. I have soaked them in WD-40 tried hitting the junction with a hammer (to loosen up the rust) as well as trying to just wiggle them back and forth in opposite directions. I can get a little bit of movement, but not much. I have even tried a coal chissel to open up the flanges a little bit more. nothing.

My next step is going with heat. If that doesn't work, what else should I try? Any suggestions?

[nickjtc]

The $64,000 question is whether you want to re-use whatever you take off. If you do then it's a case of controlled bfai (brute force and ignorance) using whatever it takes. Heat is a good resource for expanding and contracting stubborn parts. A big rubber mallett (don't want to do too much damage, do we?) helps persuade bits to move, too.

Push comes to shove you may have to use the hacksaw/angle grinder/even bigger hammer to achieve the end result...and then start shopping for another exhaust system.

[KB02]

Well, the red-tipped-wrench got hotter and hotter as I went until I finally said, "Screw it," and cut off the flange  THEN I was able to get it off. I figure I can either weld another flange on afterwards or just bypass that collector all together with a small straight pipe to connect the header and the megaphone. We'll see.

[nickjtc]

Well, the red-tipped-wrench got hotter and hotter as I went until I finally said, "Screw it," and cut off the flange  THEN I was able to get it off. I figure I can either weld another flange on afterwards or just bypass that collector all together with a small straight pipe to connect the header and the megaphone. We'll see.

Nowthe creative juices are flowing! If in doubt, compromise. Unless, that is, you are trying to recreate a 'from-the-factory' appearnace.

[ProTeal55]

Sawzall ? 

[KB02]

Nowthe creative juices are flowing! If in doubt, compromise. Unless, that is, you are trying to recreate a 'from-the-factory' appearnace.

Well, its not that I am trying to stay restoration quality, but this bike was running great before I started mucking with it and I would like it to stay that way without having to do a whole lot of adjustments and what not (yet). It's going to be my wife's bike to start with, but I do have some really cool, stripped down, cafe lookin' plans for it after she gets a better bike.

Sawzall ? 

 

[KB02]

Well, as it turns out, I ended up cutting off the ends of the collector and removing the pipes that way. Those things were just jammed up in there. In the picture you can see the remnants of the old parts I cut off on the left.

You can also see the new parts that I welded on. Not exactly a factory replacement, but it will work. Now it is off to the sand blaster's shop to get it cleaned up. It's the same guy who's painting the tank. He hoping to have it all done by tomorrow.