Made-To-Order Exhaust Part 2 of 2

Building the ultimate pipe

how to build harley exhaust

Made-To-Order Exhaust

Burns Stainless provided a nice package consisting of a bunch of its bends, a collector, and a muffler. Each system has to go through its exhaust system software, which allows Burns to give you the correct pipe materials for your size engine build

Words: Chip Kastelnik Photos: Mikey Van Senus

Making an exhaust system that works is not an easy task. When we decided on our motor size, we also decided that no store-bought exhaust systems would be able to provide us the performance we needed to ride the bike the way we wanted to. We have had our eye on a few of the high pipes on the market due to them not scraping all over the tarmac and for their race-ready looks. We contacted our friends at Burns Stainless and received a nice pile of raw materials to fab a system that would suit our bike’s needs. By simply showing them the design of the system we wanted to make, Burns provided us with the correct stepped tubing that is required to get the most out of our S&S V111 motor. We had our über-capable buddy Steve at Steve’s Precision Fabrication handle the cutting and welding duties on our exhaust, but any of you with adequate welding skills can fabricate one up for yourself. Here’s a step-by-step of how we did ours so you can see how it’s done.

Sources

Burns Stainless

San Diego Customs

S&S Cycle

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how to build harley exhaust

Made-To-Order Exhaust Part 2 of 2

Next we move to the rear exhaust mount. Using round bar, we cut and bend the pieces to fit where the exhaust wants to sit.

Words: Chip Kastelnik Photos: Mikey Van Senus

how to build harley exhaust

Made-To-Order Exhaust Part 2 of 2

We then tack the mount pieces into place and recheck the positioning.

Words: Chip Kastelnik Photos: Mikey Van Senus

how to build harley exhaust

Made-To-Order Exhaust Part 2 of 2

Once happy with the positioning of the mount, we lay beads over the tack welds and finish the rear-mount setup.

Words: Chip Kastelnik Photos: Mikey Van Senus

how to build harley exhaust

Made-To-Order Exhaust Part 2 of 2

Exhaust springs are added to ensure a proper exhaust seal at the collector. These springs also act as a quick disconnect. This makes changing mufflers for exhaust tuning an easy task. First, we make guidelines for the springs to be mounted.

Words: Chip Kastelnik Photos: Mikey Van Senus

how to build harley exhaust

Made-To-Order Exhaust Part 2 of 2

Next, we remove the exhaust setup and start to do the finishing welds.

Words: Chip Kastelnik Photos: Mikey Van Senus

how to build harley exhaust

Made-To-Order Exhaust Part 2 of 2

A basic overview of what is next.

Words: Chip Kastelnik Photos: Mikey Van Senus

how to build harley exhaust

Made-To-Order Exhaust Part 2 of 2

Steve welds the spring tabs to the collector.

Words: Chip Kastelnik Photos: Mikey Van Senus

how to build harley exhaust

Made-To-Order Exhaust Part 2 of 2

Finish welding the exhaust header pipes and collector.

Words: Chip Kastelnik Photos: Mikey Van Senus

how to build harley exhaust

Made-To-Order Exhaust Part 2 of 2

After finishing the exhaust fabrication, we take additional pipe and cut to fit a heat shield for the rear header pipe. This ensures that your heel won’t melt on those long rides to nowhere. The SDC x SPF “High Pipe” is complete and ready to rip.

Words: Chip Kastelnik Photos: Mikey Van Senus