Further to my earlier post re' the exhaust rear cut section being the wrong size I have tried fitting it and it sure is an interference fit

I seem to have run into a couple of challenges:

Lining it up and geting it all to slot home, the front to rear joints are a tight interference fit, I've cleaned everything and used silicone grease but when trying to whack it home the rear headers seem a bit out of line too, it just doesn't seem to be keen to slot together. ls it becauase I'm joining onto standard front pipes?

When I do get it close and give the rubber mallet some action the new exhaust gaskets keep falling out, I've tried copper grease to keep them in but when I give the whole thing a good blatt with the mallet ocaissionally one falls out, so how best to secure it?

Any suggestions as to how to get it all to come together much appreciated

Can I just ask if the rewelded collars actually fit the front pipes?

If they do, that's fine. You will need to slacken off the front pipes quite a lot to get it in place, then the back manifold will spring into place. It's a bitch to fit but you will get there.

i think id remove the whole system , get the front headers and twist them into the rear section as far in as they'll go then try refit the sytem to the bike all in one piece ,you will obviously have to wiggle it about and get it all lined up nice then tighten it up , that way you wont have to wack it while its on the bike dropping gaskets

ibby4585 wrote:Can I just ask if the rewelded collars actually fit the front pipes?

If they do, that's fine. You will need to slacken off the front pipes quite a lot to get it in place, then the back manifold will spring into place. It's a bitch to fit but you will get there.

Thanks
They do seem to be OK fit wise. I haven't undone the front pipes, so I'll have to do that (potential for stud breakages! ) and the need for some more copper gaskets. I assume I'll need to replace those at the front if I loosen the fronts?

cheers

Deviant400 wrote:i think id remove the whole system , get the front headers and twist them into the rear section as far in as they'll go then try refit the sytem to the bike all in one piece ,you will obviously have to wiggle it about and get it all lined up nice then tighten it up , that way you wont have to wack it while its on the bike dropping gaskets

OK front headers off it is then!

yeah i think thats how id do it if i was having trouble getting the headers to slot in the rears , then when you put it back on put the headers in first then hook the the rear up to the manafold , wiggle it about settle it in and then bobs yer brother

Deviant400 wrote:yeah i think thats how id do it if i was having trouble getting the headers to slot in the rears , then when you put it back on put the headers in first then hook the the rear up to the manafold , wiggle it about settle it in and then bobs yer brother

Sadly I think Bob's my brothers b'st*rd twin!

Fronts off, but the studs cane out with the nuts on 3 of them, I guess no problem if I just screw them back in on reassembly? However trying to fit the fronts to the rears is a bit of a problem, the left seems to go in quite well but the right.....jeez no chance its getting stuck before its even a third way in.

Any suggestions as to how to overcome this? I reckon the fronts are standard and the rear cut system is one I got second hand so I have no idea of what make but it looks like it should fit OK.

hmm seems odd , most half systems are designed to fit standard headers ,"just to test" does the left header slot into both holes on the rear section, or in that case, does the right header not fit either holes on the rear section,
if the right header wont fit both sides then im guessing it needs a bit of rough wetndry on the end to try rub it back a bit or something

p.s get some pics up , some one will be able to identify the system

Deviant400 wrote:hmm seems odd , most half systems are designed to fit standard headers ,"just to test" does the left header slot into both holes on the rear section, or in that case, does the right header not fit either holes on the rear section,
if the right header wont fit both sides then im guessing it needs a bit of rough wetndry on the end to try rub it back a bit or something

Good thought, now why didn't I think of that I reckon its the rear bit thats the problem though it looks very slightly "out"

I'll try again later in the week, sadly work demands = no workshop time for as bit

Thanks