XS 650 2 into 1 exhaust

[montessa172]

I want to merge my stock headers I have the ability but two things are making me hesitant, my stock head pipes are factory double wall construction, what is the best way to work with this? Problem two, the exhaust ports on the 650 are splayed, is it possible to get a one piece head pipe on and off. Any creative thinking you guys have on this one is appreciated… thx

 

[djelliott]

Totally possible. Usually with 2 - 1 set ups the headers are still separate and they meet up into a collector before the muffler. If you have the ability then I'd get some mandril bends and some exhaust pipe and fab the whole thing up from scratch. It's not far off from what you're trying to do now and you'll be able to route it as you see fit. or just buy a 2-1 set up from mikesxs.com

 

[montessa172]

Thanks! I got it off to a good start last night. I'll throw up a picture once the collector is welded up.

 

[djelliott]

Thanks! I got it off to a good start last night. I'll throw up a picture once the collector is welded up.

Please do. I'm newer to welding and love to see what other folks are doing.

 

[montessa172]

All righty..

Head pipes were trimmed to length, and outer skin cut away from the last 2 inches or so, then I adjusted fiddled wibbled and screwed around and scratched the frame and got angry, then got smart and wrapped rags around the tubes and then I got them in a spot that I liked.. and tacked them, removed and welded them

Put the exhaust back on, made sure that there was no interference with the sump or drain plugs or that my expert welding skills hadn't warped everything so badly that it wouldn't go back on and I lined up the ring of the collector

tacked, removed, welded, reinstalled and removed again

next series is sealing the deal, I took a chunk of pipe, cut a slit in it, flattened it in the vise, tacked one end, put the oxy torch on her, got the parts that didn't fit red hot and then beat them into a more pleasing shape.. and welded it up

Top

Bottom

Cleaned up a bit with a flap disk

I'm by no means an expert welder but i'm fairly happy with how it turned out.. How it will sound and perform, will have to wait but hopefully both will be ok also..

 

[djelliott]

Nice. I love any DIY job that is a success. Great work making use out of what you had.

 

[montessa172]

Well I just bought a house, so my expendable income is almost non existent right now, I spend alot of time rummaging scrap metal bins at work and thinking up ways to modify for almost free. DIY is what I gotta do so that I can buy what I can't make! And its more satisfying anyways!

 

[djelliott]

Totally agree.