Holey Exhaust Collector Box Bat-Man

**RiderInBlack** · 25th February 2004, 06:45

Just got a 90 CBR1000F. It has two holes in the exhaust collector box. Does anyone know a good (cheapish) place to get a replacement box or total exhaust system for this bike, or would I get away with just welding it

?

**RiderInBlack** · 21st March 2004, 13:50

Too bad, noone on this site has been of much help with this problem. Have put it my forth lot of "Kned-It" to temp block holes. No surprise the CRB spit it out going arounmd Puke last Friday

Did it again Saturday on the Wellford Poker run thrashing it between KKK and Wellford, but still could not hear it over the HD's

Have planned to get the pipe works done probably by Custom Chambers (don't know where I'll get the money but) in AK after the Akarana Rage (26-28 March). I'll be stipping the bike down then and seeing what other jobs need doing

**What?** · 21st March 2004, 20:12

Originally Posted by RiderInBlack

Too bad, noone on this site has been of much help

Shit - I missed your post, somehow.
I would have suggested Custom Chambers, so I reckon you are on track. I don't think you will find anywhere cheaper to do this sort of work.

**RiderInBlack** · 21st March 2004, 20:20

Thanks What. Tried "Staintune" but they stopped making pipes for my bike last year and have none in stock. I am hoping to get Stainless Steel if there is not too bigger price difference.

**laRIKin** · 21st March 2004, 21:23

Originally Posted by RiderInBlack

Too bad, noone on this site has been of much help with this problem.

Sorry but I do not read all the posts.
You asked about welding up your pipe, well mate it's hard to say with out
seeing it.
But you should be able to weld it, but you may need a patch if the hole is to
big or the metal is to thin.
Hopefully the hole is not where you can see it and it will look ugly.
I would weld it, because I can and I'm sure that it will be OK.
After all it's going to be the cheapest and you have got nothing to lose, from
where I stand, after all the exhaust collector box is stuff anyway.
The box way distort abit so it may be abit harder to put back on.
I would try a sheet metal shop or a panel beaters shop for repairs, as they
are use to welding thin metal.
Hope this is what you wanted to hear, and this is of some help.

**Two Smoker** · 21st March 2004, 21:29

Originally Posted by RiderInBlack

Thanks What. Tried "Staintune" but they stopped making pipes for my bike last year and have none in stock. I am hoping to get Stainless Steel if there is not too bigger price difference.

Custom Chambers did a nice job on my Dad's old XJ750, stainless, and changed it from 4-2-Collector Box-2 to, 4 into 2. I thought your bike was sounding a bit loud for a standard exhaust

lol, but definately sounded nice, so maybe a whole new system?

**pete376403** · 22nd March 2004, 00:00

Staintune are very expensive - cycleworks quoted $3K for a full set for a GS1100. LeMans suggests welding - I agree, what have you got to loose?
If you're really cheap, like me, hire an oxy-acetylene set from HirePool and do it yourself.

**RiderInBlack** · 22nd March 2004, 04:51

Have gas torch here but thought it might just blow a biggger hole in it. I'll take the pipes out today and look. Maybe be able to braze it, otherwise would need MIG welder. A little worried the box is totally rotten. Money is tight, but would still like Stainless one day.

**laRIKin** · 22nd March 2004, 18:42

Originally Posted by RiderInBlack

Have gas torch here but thought it might just blow a biggger hole in it. I'll take the pipes out today and look. Maybe be able to braze it, otherwise would need MIG welder. A little worried the box is totally rotten. Money is tight, but would still like Stainless one day.

Don't braze it mate weld it (or MIG). Use a small tip 6 or a 8 with a soft flame
Keep the rod close to the flame, and ever heat the rod abit and drop the hot metal around the edge of the hole and stop for a second to let the metal cool again. This will help you get a better edge to weld to and keep adding to that.
When you have a good edge, you'll be away

Brazing is not a good idear, but can not remember exactly why

.
Someone please remind me

**Motu** · 22nd March 2004, 19:34

Originally Posted by lemans

Brazing is not a good idear, but can not remember exactly why

.
Someone please remind me

Mainly because you can't weld over it again,so once you done the brazing bit,you're stuck with it.I only use braze to go over and fill up holes and smooth things out if it has to be fluid tight,or look good.MIG it using the same technique as lemans suggests....just a little on the edge,then stop and when the glow just fades,do it again,and again,until you have built up a soild edge to work with.It will look nasty on the inside,like a dead hedgehog...but you won't be spending much time inside your collector box...or will you?

**dangerous** · 22nd March 2004, 19:47

1st up Im not to fimiler with your bike Im thinking that it has a typical muffler type box underneth the bike. If this is whats buggered then try welding as you cant see it, can you?
Now if its the mufflers (cans) themselves and you are looking at a rebuilt pair then you may want to contact a Brisbane bloke who builds origional mufflers up.
He did some for my CX 500 turbo to look the same as the origional but were more like a moderen day race can inside.
He was cheaper than anywere here but then you have to add on the fraight costs. I was living there at the time even though the bike was in NZ.

**RiderInBlack** · 22nd March 2004, 21:23

Well thanks guys. Should have read a bit of this before taking to it with the torch

! There was f*cken holes all over the collector box. Run out of steel gas welding rod so cheated using arc rods with the flux knocked off it. Found some thin steel plate for the bigger holes, then run out of Acedolene before I had it finnish

Knead-It'ed the remaining holes until I can get to Town for some more gas. I'm a real butcher when it comes to welding. It is just as well the collector box is well hidden. Will get new pipe works done as soon as I can get the pinggers together (looks like a job for the VISA).

PS: Both the mufflers rattle, so the baffles must be loose as well.

**Holy Roller** · 22nd March 2004, 22:38

I used gas to weld up the holes on my XZ400, rather I used some steel corners that go over hardie plank weather boards, to cover the holes and welded that to the collector box. Looked quite good when finished.

Now I need to do something similar again for my XV

**pete376403** · 22nd March 2004, 22:46

When you were using the Hardies corners did the metal give off a lot of fumes / white smoke? If the metal is galvanised the smoke is zinc burning off. Its nasty shit to inhale, it will do bad things to your lungs. Worth keeping this in mind when looking for patching steel.

**Holy Roller** · 22nd March 2004, 22:56

Originally Posted by pete376403

When you were using the Hardies corners did the metal give off a lot of fumes / white smoke? If the metal is galvanised the smoke is zinc burning off. Its nasty shit to inhale, it will do bad things to your lungs. Worth keeping this in mind when looking for patching steel.

It was all I had ask any student about funds

then try it with a Mrs. and 5 kids. There was not lots of smoke but did the job outside, one doesn't always think about the hazzards.

But thanks for the advise will use better steel next time or just get the shop to fix it with a new or 2nd hand one.