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August 30th, 2010, 03:14 PM
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#1
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Join Date: May 2007
Location: Stockholm, NJ
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Cracked Exhaust
Has anyone had success welding exhaust cracks like this? Or should I just replace new?
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08 BF750
Warn Winch
27" MST's on Delta Steel Black
Bison Bumper,Twin Air 
Kolpin Box
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August 30th, 2010, 03:31 PM
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#2
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Join Date: Apr 2008
Location: Magnolia, AR.
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I think Gus from Greece posted something about this awhile back. You can brase it up but I think it cracked again after a little while. Wouldn't stay. I cracked a header pipe on one of my dirt bikes and wire brazed it back up and rode it 4 more years. Won't hurt to try it. The vibration is what will get to it if it doesn't hold... Will buy you time till you decide what kind of exhaust you want to go to....
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05 750 Brute Force, Frt. and Rear baskets, Gun Scabard, 08 dry box upgrade, K&N air filter, VX-3000 Viper winch, pass. pad, 27" swamplites all around, ss108 wheels, skid pkg and frt bumper, Dynatek CDI and Maroon Primary clutch spring, HighLifter HD Springs on the rear from SS ATV along with their stainless custom floor board protectors, HD tie rod ends and HD stainless tie rods from ATV Trick Stuff, Mudlid breather from EHS racing, TwinAir Powerflow Kit and More to come!!!
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August 30th, 2010, 07:11 PM
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#3
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Join Date: Jun 2008
Location: GREECE
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Ooooh no...this header is a gonner......forget it my friend.I welded a smaller crack than this and in 6 months it cracked again.I have already changed 2 headers and welded one.Buy a new one,it costs around 150 $ from what i saw in the site i shop from...But the raplacing of the exaust is the worse thing....having to take the entire left side of the bike apart and take out the pipe also....good luck my friend...done it 3 times....
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'08 750i black and red brute,acerbis handguards,2000 lbs hulk winch,
Douglas Rattlesnake rims with Maxxis dirt road tires
Kimpex storage box
HMF utility slip on
Overfenders guard flares
K&N air filter
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August 30th, 2010, 07:36 PM
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#4
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Join Date: May 2007
Location: Stockholm, NJ
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Quote:
Originally Posted by gusmx5
Ooooh no...this header is a gonner......forget it my friend.I welded a smaller crack than this and in 6 months it cracked again.I have already changed 2 headers and welded one.Buy a new one,it costs around 150 $ from what i saw in the site i shop from...But the raplacing of the exaust is the worse thing....having to take the entire left side of the bike apart and take out the pipe also....good luck my friend...done it 3 times....
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well the worst is over...getting the bolts off without breaking the studs...
did you just weld the cracks or weld a plate over top?
__________________
08 BF750
Warn Winch
27" MST's on Delta Steel Black
Bison Bumper,Twin Air
Kolpin Box
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August 30th, 2010, 07:39 PM
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#5
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Join Date: Jun 2008
Location: GREECE
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I just welded the cracks but they were a lot smaller.I do not think that a simple welding will help you....
__________________
'08 750i black and red brute,acerbis handguards,2000 lbs hulk winch,
Douglas Rattlesnake rims with Maxxis dirt road tires
Kimpex storage box
HMF utility slip on
Overfenders guard flares
K&N air filter
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August 30th, 2010, 09:39 PM
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#6
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Join Date: Oct 2009
Location: WV
Posts: 730
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Maybe time to think about a full muzzy or big gun exhaust system! I would consider it if this happened to me, but probably only if this happened. Otherwise, I'll stick with stock
Last edited by DLB; August 30th, 2010 at 10:12 PM..
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August 30th, 2010, 10:17 PM
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#7
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Join Date: Aug 2008
Location: Albuquerque, NM
Posts: 6,018
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Who was it that welded theirs, then welded plates all around it? Also, I wonder if a good muffler shop could build some new ones but even stronger.
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06 750 (Silver)
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August 31st, 2010, 03:54 AM
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#8
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Join Date: Jun 2008
Location: GREECE
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Quote:
Originally Posted by NMKAWIERIDER
Who was it that welded theirs, then welded plates all around it? Also, I wonder if a good muffler shop could build some new ones but even stronger.
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In a muffler shop here,they told me that he could make a new header,steel one and probably stronger for around 80 euros.When this one i have on cracks i will go and make one.My buddy needs one too in his '06.His is like rrocke17's....When we fix it photos will be posted as always....
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'08 750i black and red brute,acerbis handguards,2000 lbs hulk winch,
Douglas Rattlesnake rims with Maxxis dirt road tires
Kimpex storage box
HMF utility slip on
Overfenders guard flares
K&N air filter
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September 3rd, 2010, 03:55 AM
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#9
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Join Date: Jan 2008
Posts: 653
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that was mee, i repaired my exhaust that cracked like that 3 times last time with thicker plates over top.... what i would suggest is some how get a spring, flex joint. if you wanna keep it stock.. if you weld it you will be lucky to get 300-400 miles out of it before it happens again. im 90% sure the exhaust is cracking dude to not being able to flex cuz very rarely does the front pipe crack. its got the slip joint.. . i now have a big guns full system (all held together with springs).. so far no backfiring or cracking of pipes, its a little loud even with the quiet core.. but oh well
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08 750i, 26" mud lights on itp 108ss rims. Ricochet armor. warn 2500RT winch, 2"SS atv lift, NO sway bar  , snorkeled. BLUE back lighting for pod, PIAA lights, heated grips, water temp gauge, oil pressure gauge, custom rear rack(flat pack), EHS racing lid, poly upper a arm bushings. big guns full system, big guns EFI controller. zerk's on every suspension joint,
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September 3rd, 2010, 11:55 AM
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#10
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Join Date: May 2007
Location: Stockholm, NJ
Posts: 65
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if you weld it you will be lucky to get 300-400 miles out of it before it happens again. im 90% sure the exhaust is cracking dude to not being able to flex cuz very rarely does the front pipe crack. its got the slip joint.. .
Has anyone tried some rubber bushings at the muffler mountinng points to relieve some stress?
Two at the muffler and I think one along the pipe?
Or is the flex issue just around the "header" bend?
__________________
08 BF750
Warn Winch
27" MST's on Delta Steel Black
Bison Bumper,Twin Air
Kolpin Box
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