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View Full Version : Header pipe dent removal


rover67
11-13-2012, 10:48 PM
Has anybody tried this?

http://www.youtube.com/watch?v=HhWzxYLG9sM&feature=youtube_gdata_player

The header on the 525 is pretty mangled...
Should I just send it out instead?

60wag
11-14-2012, 08:10 AM
I've seen that technique on the internet before. It looks like a good idea. I think the only risk is that it splits the pipe along with pushing out the dent. What does a replacement pipe cost?

farnhamstj
11-14-2012, 09:10 AM
I tried last winter with little success. I didn't plug the ends. Just filled with water and left outdoors to freeze.

nakman
11-14-2012, 11:00 AM
Huh. So the expansion is going to alter whatever the path of least resistance is, so the theory is the newly dented metal is weaker than the surrounding tubing? But if you had a crack anywhere, then this method would surely blow that out right?

New header from FMF is $400 http://www.fmfracing.com/Products/BikeAsList/2005_KTM_525EXC

rover67
11-14-2012, 11:20 AM
Interesting report on the experiment Farnham. I may try it anyways.... With plugs.


A new one is $450 from KTM.

It looks like $129 for a used one with a dent on ebay

http://www.ebay.com/itm/KTM-Exhaust-Pipe-Header-OEM-400-450-525-Exc-Mxc-Xc-SX-2004-2005-2006-/110971026739?pt=Motorcycles_Parts_Accessories&hash=item19d6637d33&vxp=mtr

Then there is this:

http://www.piperepair.com/

Or I guess the FMF aftermarket route... I kinda don't want to spend a ton of money since I know it will happen again.

RicardoJM
11-14-2012, 11:25 AM
Interesting. I did this with my Klean Kanteen to remove a dent. It removed the dent just fine but also bowed out the bottom. I took a ball peen hammer to the bottom and put it back into shape.

nakman
11-14-2012, 11:32 AM
Interesting report on the experiment Farnham. I may try it anyways.... With plugs.


A new one is $450 from KTM.

It looks like $129 for a used one with a dent on ebay

http://www.ebay.com/itm/KTM-Exhaust-Pipe-Header-OEM-400-450-525-Exc-Mxc-Xc-SX-2004-2005-2006-/110971026739?pt=Motorcycles_Parts_Accessories&hash=item19d6637d33&vxp=mtr



According to their own Ebay ad, that one with the $129 used one sells a brand new one for $295. I'd probably go the used Ebay route, then you have a pretty decent backup if the freeze method fails.

Or hey, get another die for the bender and a stick of stainless? :D :weld:

rover67
11-25-2012, 06:35 PM
It worked well, I'll post up pics when I get my hands on a camera.

Squishy!
11-26-2012, 10:11 AM
Super :cool:

rover67
11-27-2012, 09:54 PM
pics of the ice fix.

this was after standing it up on end and filling it up till it poured out of the head ports.

i tried it a few times and it didn't work until i stuck it outside during a low 20's night. upper 20's to low 30's didn't do anything.

rover67
11-27-2012, 09:54 PM
holy **** the pictures are huge. I have to learn how to resize on a mac.

Squishy!
11-27-2012, 11:54 PM
Holy crap that's awesome :thumb:

Jacket
11-28-2012, 11:51 AM
Wow - that freezing process worked pretty well. And it cleaned the pipe too! ;)

rover67
12-10-2012, 07:38 PM
ok, lesson learned. don't try it a second time to get out all the small dents. It made it pretty smooth, but it also cracked it. $hit.

Squishy!
12-10-2012, 09:24 PM
Oooo... Dang :(

60wag
12-10-2012, 10:15 PM
It looks like its ready for a wrap now :)

rover67
12-10-2012, 10:36 PM
alright, mistake corrected.. it was actually pretty easy to just tap it back together and weld it. :) I'm done messing with it.

back to your normal programming :)

farnhamstj
12-11-2012, 09:06 AM
nice save. Marco, you the man!!

farnhamstj
03-05-2013, 09:22 AM
In an effort to reproduce Marco's results.

rover67
03-05-2013, 09:42 AM
poop, sorry man. I can weld it for you. We'll be in breck this weekend maybe I can make the trip over to see you guys and pick it up.