Exhaust pipe issues

[honda_atc200es]

ok so i am almost done with my rebuild, and i go to put the exhaust on and the threads coming off the head are too short, and come to just the edge of the flange, not enough to get a nut on and bolt it down.

i tried hammering it in, i tried getting the threads out (my old head, they were removable) and i figured, screw it, i think i should weld it. now before i do this, what do you all think?

my first idea, was cut the exhaust near the inlet (the wide end piece which fits into the exhaust port ) so i could get the flange off, and then grind it down enough to fit a nut on the bolts and be able to bolt the exhaust down like normal, welding where the exhaust was cut once i put the flange back on.

but that has alot of ways it can go wrong. now if i just weld the flange to the bolts, maybe put a little high heat silicone around the inlet, i think it will be easier, and more effective.

if i ever need it off, i can just sawzall it. also i would be using a tig welder for this, are there any special recommendations you could make (wire speed, if i should use additional metal) thanks for any advice

[Vealmonkey]

Make sure you don't have too many old exhaust gaskets jammed up into the exhaust hole. Don't laugh or think I'm crazy, I've seen it several times and other members on here have seen it too.

[honda_atc200es]

i wouldn't be surprised, i checked that though, the flange sits flush with the head, its really just the flange thats the issue

[SWIGIN]

if you need to ask wich way is best you need to lock your garage and dont go back in.

i have made many pipes and here is a pic of the one on my quad now, i have shortend it at the flange so it hugs the motor. i didnt shorten the thick area since my studs are right but you could.

any way you do this other then this way would be a shame and will not seal.

[honda_atc200es]

yeah, my metal shop teacher said the same thing, so thats what i am going to do, in fact ima fire up the grinder now =] i just hope the bolts arent too stripped =[

[honda_atc200es]

I fixed it, originally i only got one nut to fit and it was a poor seal, but i manage to grind down the flange enough for two, seems to seal pretty well even without an exhaust gasket