Sorted these a while back but well chuffed with the results!
Was getting a female friends CBR ready for its MOT - pulled off the loose putty around the header tops to reveal... neat teabag perforations around 3 of them... Hmmmm... Upon removing the exhaust one of the flanges snapped off completely, being paperthin & rotten and all....

http://i109.photobucket.com/albums/n61/ ... C03569.jpg

http://i109.photobucket.com/albums/n61/ ... C03568.jpg

By now I was firmly of the opinion that the headers were "w@nked" & "not even fit for the bin!"

http://i109.photobucket.com/albums/n61/ ... C03571.jpg

Upon further investigation stainless systems were well out of the funds available (Can afford like £50?) and secondhand systems were set to be equally rotten.

"Can it be welded better again?"

"Errrrm..."

http://i109.photobucket.com/albums/n61/ ... C03572.jpg

Dig out suitable tubing - ie old bicycle frame etc and cut 4 18mm wide rings to fit over the damaged bits, the one that was broken off being no prob, just slide it straight on - the rings being slit & prised over the other 3...

Fit jubilee clips round the rings to keep them tight and snug whilst they are being welded, note tincan wedge keeping the broken bit in place....

http://i109.photobucket.com/albums/n61/ ... C03575.jpg

Welding all done by my Uncle who convieniently has his own Fabrication business... cost £30!

http://i109.photobucket.com/albums/n61/ ... C03577.jpg

Finish getting all the old rust & crap off and spray with hi-temp paint...

http://i109.photobucket.com/albums/n61/ ... C03585.jpg

Tis like a new-un!

If anyone wants to sticky the pics then please - go right ahead!

I just sold a set of stainless headers on here for £60 posted!

Wozza wrote:I just sold a set of stainless headers on here for £60 posted!

This was all done back in March I think? We got the bike a year or two back from a bloke in Wales who apparently used it for towing a road-gritting trailer/undersea exploration?? Had a rough life, but now a lot better with some tlc...

Excellent job, good thinking about cycle tubing for bends, I may think about making a complete system from cycle tubing.Inspiring!