Here's how you build a 200x exhaust...

[WIkid500]

Over spring break I got the exhaust done for the 85 200x project. I would have bought a head pipe alone from cobra but they aren't making them again until July.. I need mine now. So I ordered a 1-3/8" J bend from Jegs for 14 dollars and a chunk of 1-3/8" tube from Discount Steel for 20 dollars. The rest was my time. I kinda guessed on the bend radius as I am here at college and the wheeler is at home, luck would have it the radius worked out perfect and is exactly the same as the stock bend head pipe. From there I began cutting, fitting, welding and refitting. I have some time in this as I wanted it done right and done once, it took me a whole day in the garage working. As you can see in the pic's I am using the stock muffler with bigger pipe going back all the way from the head pipe into the muffler. Reason for the stock muffler is I trail ride this thing it needs to be somewhat legit so I don't get tickets and piss people off. The rear baffle is removed and I did a little work on the inside, it should be a bit louder and flow better but not cause problems. Oh yeah the other thing this needs to keep the sleeper look, and I think the stock muffler achieves that for me. After everything was fit I took a bunch of time filling welds and smoothing everything out so it looks almost seamless, I also added the stock heat shield for the finished look. I will post pic's of that when I get home next time. Over Easter break I am going to go home to finish the pipe, I need to lightly sand blast it and spray on the ceramic coating and bake it. I bought the chrome ceramic stuff you have to bake for an hr. at 500 deg. If it turns out like it should this thing should look real sweet. I'm going to spray the pipe and muffler.



http://img12.imageshack.us/img12/9779/0314090956.jpg (http://img12.imageshack.us/my.php?image=0314090956.jpg)


http://img12.imageshack.us/img12/2718/0314090957.jpg (http://img12.imageshack.us/my.php?image=0314090957.jpg)


http://img3.imageshack.us/img3/6566/0314091312.jpg (http://img3.imageshack.us/my.php?image=0314091312.jpg)


http://img12.imageshack.us/img12/6469/0314092026.jpg (http://img12.imageshack.us/my.php?image=0314092026.jpg)


http://img12.imageshack.us/img12/4919/0314092027.jpg (http://img12.imageshack.us/my.php?image=0314092027.jpg)

[braunz200x]

thats badass thanks for sharing

[Dirtcrasher]

Very nice fab work! You must have one big arse tubing bender!!

The only thing I would have considered was the flange. I think I'd slide it over that tubing and weld a collar onto the header. At least then you have some forgiveness in both alignment to the head and it would allow you to rotate it when fitting it up or assm/disassembly.

Fab work takes ALLOT of time. Anyone can do it, but clearing things like the frame, motor, master cyl etc etc is where the time goes no matter what your making....

[WIkid500]

Thanks Guys!

DC I didn't bend any of the bends, I ordered the Mandrel bend from Jegs as a J-bend. The rest of it was cut at angles and welded together.

I have everything so it clears very nicely, the way it's set up you put the head pipe on then slide the muffler on and mount it up. It seems to work. If I would have known I was going to have to make a header earlier I would have turned a nice collar with a shoulder on it for the flange to press against so it could still swivel. Didn't have the parts or time so I went at it like I did. I think it will work.

[dcreel]

Awesome job.

[beets442]

Nice job! Did you change anything inside the stock muff? I like your intake extention. Beets

[saleen_n_around]

I feel bad, I had an 85 head pipe that does me no good and I have been chasing it around the shop, moving it around to get it out of my way!

Looks good tho!!!!

[oscarmayer]

looks good.

the issue i can see is the pipe may be too big for the motor. A Na motor needs "some" backpressure after the exhaust port (close to it) to help with performance. (learned this in import drag racing testing) You may find you'll end up with less performance on the low-mid areas. (unless your drag racing you need some low and mid) If it were me, I'd drop the header pipe (pipe form the head to just after the u curve) down a couple of sizes. If your going to run nitrous or a turbo setup, then I can see having a big pipe, but that i think is going to cause you issues. Anyway, it's just a thought. the fab work does look good man!

[WIkid500]

Thanks guys. I did not mess with the muffler on the inside, I just cut the small pipe off and ran it into the muffler like the stock set up is. As for back pressure I think there will be enough from the muffler it's self. I went with 1-3/8" pipe because cobra, DG, and several others use that size pipe in their performance exhausts. Remember they have a straight through exhaust, my muffler is more restrictive compared to say a DG or a cobra muffler. The only thing missing in my muffler is the rear baffle/ spark arrestor but aren't they all? lol I can't wait to get the chrome ceramic coating on this thing and polish it up, hope it turns out looking good. This is what I'm spraying it with. http://store.columbiacoatings.com/cgi-bin/commerce.cgi?preadd=action&key=CCC&reference=/cgi-bin/commerce.cgi%3Fsearch%3Daction%26keywords%3Dall%26 searchstart%3D0%26template%3DPDGCommTemplates/HTN/SearchResult.html%26category%3DCRCH

[AutoXer]

Real sweet work. Where are you guys getting that intake for the carb?

[bigpimpin]

you should post the Jegs part #'s so if someone else wants to take that journey it will be easier

[cr480r]

whats up with the kinks?

[oscarmayer]

sounds good man! that should help then!

[WIkid500]

http://www.jegs.com/p/Hooker/744799/10002/-1
Part # 520-12520

There is the J-bend page and part number.

The reason for the kink is I only notched about 3/4 of the pipe and just bent it. I welded it up and smoothed everything out, it looks real good with the heat shield on.


Autoxer the intake manifold I made. I needed one that would fit the 30mm XR carb. I tapered it from 30mm to 29 and then it flows into the head. It was pretty simple to make. Do ya need one?

[oscarmayer]

^ i need 1!!! how much?

[WIkid500]

Idk... What I really need is a good intake that is stock so I can get the angles exactly the same. Mine is a bit off because I chopped up the original not knowing it was rubber molded. If I could get a stock one to make a few good ones out of it wouldn't be to bad and they would be exact. Mine turned out good for guessing the angles and length lol. What do you guy's think a fair price would be on these things?

[oscarmayer]

i can send you a stock intake to mock up with. I'm not using my 200x right now. if you give me a good deal on one of them u made, I'll send it to ya.

one thing that may help ya, on the carb side of the itnake, make the hole a slight bit larger, jsut a hair so there's no lip from the carb touching the intake hole and then on the port side do the same except make the end jsut a hair smaller than the intake port so there's no lip it hits when flowing. this helps flow due to no lip or dip in the flow.

[WIkid500]

Yeah that would work I guess. I don't have a clue what these things are worth and I have mine done so if a bunch of people want these things tell me what they are worth to ya, and I will see if they are worth my time making them.

Oscar when I made mine I aligned everything to match the new carb. Everything is matched with the die grinder in the end and finished with 80 grit sand paper. You don't want a smooth intake wall, the 80 grit gives enough turbulence to keep the gas from falling out of atomization and sticking to the walls.

[gizmo_22]

well i had to buy a new one from the stealership here and it was like 16$ cdn if i remember right. Give em a call and price one, their not overly expensive.

[WIkid500]

well i had to buy a new one from the stealership here and it was like 16$ cdn if i remember right. Give em a call and price one, their not overly expensive.



New intake and billet intake that fits a larger 30mm carb are two different things. Machine time costs money, I don't crank handles for free..... :beer

[gizmo_22]

ah didn't notice it was for a larger carb, my bad :P

[Billy Golightly]

This is a good thread, I would have never thought to look at pre-bent tubing to fab an exhaust. Nice work. I'm gonna move it to the Mad Scientists lair.

[WIkid500]

Haha Thanks Billy I feel Honored to contribute to the Mad Scientists layer.


Another tip with the pre-bent stuff some of the different companies measure bend radius's differently. Some measure to inside of pipe, some to middle. Jeg's shows a lot of the measurements, and if it's not listed give them a call.

[harryredtrike]

nice job,you may need to go up one on your carb jet.i think the diameter is good on your pipe,you should be fine.looks the same as aftermarket pipes

[WIkid500]

http://img25.imageshack.us/img25/2625/0503091100.jpg (http://img25.imageshack.us/my.php?image=0503091100.jpg)



There's the final product after it has been ceramic coated. It turned out very nice, and sounds good too.

After all the engine mods I wet from a 115 jet to a 135 jet. She runs good.

[Yamada]

Very nice X you have there! Maybe I should try something like you did, but for my 225dx.

[3some]

Man that is nice looking. Good job on the fab work it looks great!

[300rman]

What is that spray-and bake coating called?