"Cleaning up & Modifying" Stock Exhausts VZ800 1998

Hey guys.

Starting the write-up, on how i decided to get rid of the rattling stock exhausts for the Marauder.

Had an old stock exhaust that was rattling laying around that i decided to cut to pieces to see what i could do with it.
The work is still in progress but going along quite nice. 

Things needed:
Angel grinder, permanent marker, welder, round file, and some 2" steel pipes... I went for stainless. 

Optional/Nice to have:
Pipe cutter, turning machine.

I started of with cutting the stock pipes next to the weld just where the pipes goes down to 1" or if it is 1,1/4"


Then i marked the next cut just before the first bend, (I started at the end and worked my way to the cylinder flange).
Remember to make a mark along the pipe, the goes through the mark that you plan to cut. So you are sure that the pipe gets welded back in the right position/angle.


Remove the outer pipe and cut of the inner pipe.
Repeat the action on the other side of the bend.


Weld the pieces back together as you go along, so the pieces doesn't get mixed up.

When the old pipes are all put together you have a cleaned  exhaust system. But it is quite short ;)So here is where the 2" pipes come in. Cut them to the desired length, straight, slash cut or what ever you like. Weld the pipe to the exhaust system..... And "ta da!" you are done with the pipe.

To cover the welds i have decided to paint the exhausts black (havent gotten to the painting part yet) with heat resistant paint and make some custom heat shields out of a 2" pipe that i have split into two halves.
Made some distances to get some air between the shield and the pipe. This is where i used the turning machine. The distances are threaded so the heat shield will be easy to mount and remove.

This is how the first pipe looks at this point. Heat shields are mounted but it is the wrong kind of skews and the pipe aint painted yet. 



Will do the second pipe next week and also figure out  how to make a mounting bracket for them.
Will continue the write-up as i go along.

I reckon it will look the dogs bollox when it is installed. Cant wait  

All the welding is hopfully done now.
Will look for a universal 2" bracket to fit the pipe to the bike. But it will take some time, the bike is at the shop due to a leaking front carb.

Pipes painted and shields are mounted. Really satisfied with the results this far.... cant wait to get the bike back  so i can find a way to mount them and see it for real. 

I love a man that can, those pipes look Fekin ace. Can't wait to see them fitted.  

Woah...That's going to be what...110db?       

Love the styling...they look 100% pro.

Very Nice! They look real good  

Love em, well done  

Great piece of work well done.

Thanks for the response guys
Am really happy with the results this far.  It has been a quite straight forward job to do this and not that hard if you have basic welding skills and access to equipment.

To night everything got put together
i think it looks awsome.
Still need to cut the old exhaust bracket away. but that is a later task


Wimped out last week and ordered a pair of 4" baffels. But the dB meter-app on my iphone still peaked at 100dB. Sounds great, allmost like " a big bike".

Some new pictures for you guys to look at.
Please tell me what you think, good and bad.

O my word that is flippin ace looking now, even smarter looking than I thought it could be  

I have no doubt that you are proud of your modified pipes, they are awesome looking.   

It's a 'Good' from me! in fact, it's a 'Great'!!     

Well done looks sound m8.

thanks guys.
I am both satisfied and proud of the pipes. It is nice to hear that you like them. ;D

That is a great looking exhaust. I would love to hear how it sounds.