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Exhaust Header Questions

Charlie J

Charlie J

Cruisin' Guzzisti
Joined
Jun 19, 2009
Messages
162
Location
Taree, Australia
The headers on my 2006 1100 Griso rattle.It is most notable around 3600 RPM to 4000 RPM in 3rd,around town speeds. I always warm the bike up while I put on my helmet and gloves.If the warm up period is shortened or give it more revs quicker once under way the rattle is worse. If I rev through the above revs it is more a buzzing noise. It is not as noticeable in top gear.
I asked Mario from Thunderbikes (W.A.Australia) about it and hes heard a few twin skinned header bikes do it. He said to drill a 6 mm hole on the underside of each header (so it wont be seen) and get it Tig welded so as to plug the hole thus securing the inner to the outer. I did this and bingo no rattle.......for a while.
At the time I was concerned that the different expansion rates of the Inner and Outer may lead to cracking. I purchased a cheap bore inspection camera from Aldi and have tried to look for cracks in the inner but could not see any.It is difficult to get a thorough look due to the shape of the pipes.
However at the collector pipe end of each header there is a build up of carbon on the inside of the outer pipe. There is a space between the end of the inner pipe and the carbon, the right side is about 1.5 mm and the left its 3.5 mm. I assume that the right side would not move so much due to its shape prior to the last section of pipe. More than happy to be corrected if that's wrong.
Does anybody know of any sort of filler that could be put between the inner and outer pipes?
Is there single skin headers that could be used instead of the OEM ones?
If I made single skin pipes do you think it would be detrimental to performance as the exhaust gas would be cooler and not move so fast? Thank you for your help. Charlie.
 
Charlie J said:
Is there single skin headers that could be used instead of the OEM ones?
If I made single skin pipes do you think it would be detrimental to performance as the exhaust gas would be cooler and not move so fast? Thank you for your help. Charlie.
Click to expand...
Charlie, only one special order full system I'm aware of from Arrow. I've been considering doing a header offering as well to my slip-on systems. We've done one already in stainless, but we didn't jig it, just built in place. There should be zero performance issues with replacing the stock headers as the inner pipe diameter is the only real importance. Hope that helps, and let me know if you'd be interested in a set.
 
You may also want to check the mount that supports the exhaust system located under the bike. Here's a pic of mine before being replaced at 6500 miles. It made very loud noises, as the two pieces where cracked rubbed together. A good tech indicated he'd seen this on more than one Griso. One bike had cracked this mount a second or third time.



Bob
 
Charlie, If you fancy a ride to Brisbane, Peter Gray from Pipemaster could build you a set on the bike. Send you back home with your stock pipes while the headers are being ceramic coated/polished etc, then ship them to you.
Ph (07) 3252 3939.

He built the full system on Bella.
I've got stock headers from the Bellagio, if they're the same part # he could even use them as a pro-former to have your new pipes partially constructed before you arrive.
 
Have recently purchased the GTRX underbody Ti system, which includes Y pipe. Have not yet fitted it, but will get around to it sooner or later. Will consult Todd about my PCV mapping then. So Todd, I am interested in a set of Stainless, or even Titanium headers for my G8V, that will slot perfectly onto my purchased system above.
 
You can get rolls of aluminum tape to wrap around the ends of connections. I've used it on mufflers and worn out exhaust ports. Works pretty well. Also, some silicone sealer for exhausts doesn't hurt either.
As for double walled exhaust pipes cracking, that has to be a very rare occurrence. I've heard of a lot more muffler internals breaking up than pipes.
But, yeah, checking mounting brackets could prove beneficial.
Bare
 
Thanks for the replies.I contacted Peter Gray, a Mk3 owner,and he has been very helpful. I do not think my pipe(s) are cracked,but think that when hot the inners are contacting the outers. The movement marks at the ends (on the inside of outer) lead me to this conclusion. The brackets have nothing to do with it, there are none. The bike has made this noise since he was 2 to 3 years old,I blamed the headlight .
Fair enough ,matched header lengths is not important. But what about the shape and lengths before any bends in the pipe at the port? Shouldn't that be the same ? Thank you.
 
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