Jump to content

Fixing a dented header for cheap!


JohnnyAirtime

Anyone a skeptic??? I sure was, until last night. Here's what I did, and to what:

I dented my FMF Ti header pre-running for the Baja 500 recently. Sure it wasn't too bad, but bad enough where people see it and say "hey... your pipes dented..." Enough to make you want to fix it right?!

After reading on several forums about filling the pipe with water and putting it in the freezer to pop out the dent, I was pretty skeptical. I thought, "how can freezing water be that powerful?" Also, not being any kind of engineer or scientist, I had to try it!

Skeptic? Yes. That is until I actually did it last night and found it to be 100% true! Simply amazing and so easy! Here's just how easy it was:

- Took the header off in about 5 minutes (from CRF450X).

- Added enough water to fill the dented area of the pipe, plus a bit more

(did not end cap the pipe or plug anything).

- Placed in freezer so that the pipe wouldn't leak any water.

- Woke this a.m. to a near perfect repair!

This repair sure saves taking the pipe to a welder (which I am by hobby) and having them use a rosebud and air to blow out the dent!! Plus, this is MUCH cheaper. You may need to attempt this two, three or four times to get the dent completely removed. But don't give up, the reward is worth it.

Good luck!! And have fun!

An edition to this article by sootgrinder

In the tech tips section there is a nice write up on how to use the freezer to pop out dents in your exhaust header pipe. It is a nice article, and the process works well for four stroke pipes that are a consistent diameter, I.E. not stepped headers or Powerbomb type headers. But it would be nice is you could put some language at the end of the article to warn against using this tip on stepped headers and definately not two stroke expansion chambers. I have personally seen expansion chambers ripped apart at the welds when trying to use the freeze technique. I just want to prevent someone from ruining an exhaust system, and getting upset because they thought it would work for expansion chamber pipes as well.



User Feedback

Recommended Comments

i did it with my expansion chamber and yes ! it did split it an not even at the weld it split a 6in. crack down the middle little over an inch from the weld heads up do not try this with an expansion chamber ! lol

Share this comment


Link to comment
Share on other sites

Glad you guys put that bit on there about the expansion chamber!!  I was thinking about trying this out!!

Share this comment


Link to comment
Share on other sites

I wonder if this would work in an expansion chamber if you used less water? The key would be to add just enough so that when it expanded it would just fill out the original pipe. One problem is that the dent material will likely be harder than the rest of the pipe due to work hardening. To fix this, you could anneal the pipe by heating it up just below cherry red, then cooling it very slowly. Easy to do by burying it in a nice bed of hot campfire coals and just leaving it there to cool as the coals die out, say overnight. Just a thought.

Share this comment


Link to comment
Share on other sites


Create an account or sign in to comment

You need to be a member in order to leave a comment

Reply with:


  • Similar Content

    • By ThumperTalk
      Material: Aluminum
      Several pounds lighter that stock
      Incredible performance at a great price
      Hi-Flo stainless steel core and formed end caps with aircraft grade aluminum canister
      Spark Arrestor included in S/A version
    • By 400yzturbo
      I have some CRF250 Exhaust repack kits.  They are for the CRF250  Honda Dual Exhaust setups.
      These are new, I just never used them. 
      Asking $65 + free shipping to the lower 48 states.
      price is for both kits; enough to do two bikes
       
    • By Powerban
      P3 Carbon Composite protection components set the industry standard for performance. From the Iron Giant at Erzberg, to GNCC and National Enduro, to Hare & Hound, P3 Carbon Pipe Guards are race proven by the fastest off-road racers in the world.
      Carbon, Fiberglass and Kevlar composites for super high impact strength
      Our special blend of high temperature resins for long life and high strength
      Hi temp coating on under side to resist heat
      Molded design for a perfect fit
      Extremely easy to mount
      Made in the USA
       
       
    • By Powerban
      Protection for the cylinder exhaust flange with this Exhaust Flange Guard. Protects against cylinder exhaust flange damage should the exhaust pipe receive an impact.  KTM owners who have experienced a broken exhaust flange know that it will end the ride and leave the bike “open header.”  A damaged or broken exhaust flange automatically means the end of the journey. This will prevent that from happening again with the exhaust flange protector.
      Protects exhaust flange if the pipe is hit or damaged
      Complete with all mounting hardware
      A must have for any 250/300 owner
      Aluminum
    • By Chuckster
      Got new laws starting here about noise. My xr has a xrs only supertrapp disk type exhaust on it. I have a gutted stock exhaust buddy gave me, but no stock tip. Like the way bike performs just fine, air box, jetted 68s 171 runs great street or dirt, probably, probably my favorite bike ever.

      Any ideas , cheap ideas to get noise down but not sacrifice too much performance? Stock pipe label will b a big help out here. I've seen down turn tips, my sticker someone cored out about 2 inches but never put in back pipe, down turn. Trying to get under 95 db at speed or less. Laws here say 86 db but may have some wiggle room.

      Thanks
      Chuckster
×