For the Suzuki TS250ER.

I've got one iffy exhaust and one good one (and two bikes...). The
problem on these dirt bikes is always the header pipe, which is made of
two steel pressings spot-welded together, with the manifold and section
leading to the siencer added.

The silencers never give up. The circular sections of pipe are always
solid. The problem is always with the bulging section made of the two
spot-welded halves. They corrode from the outside in, usually along the
welded seam. There's little point in trying to weld them up, because
you're trying to weld paper-thin metal which is mostly rust anyway.

Needless to say these are *utterly* unobtainable new, and nobody makes a
pattern. Pattern tailpipes, sure, but not the crucial bit that rusts.

I've tried a couple of people who advertise they make one-off expansion
chambers, but they're more interested in making race pipes for old
strokers. One guy reckoned it would cost £750 just to copy the part.

I can easily yield the not-so-good system as a pattern (as long as it
isn't destroyed and I get it back), but I need to find someone who can
do this sort of job. Open to the floor. Anyone got any ideas?


--
BMW K1100LT Ducati 750SS Honda CB400Fx2 Triumph Street Triple
Kawasaki GT550 Suzuki TS250ERx2 GN250 Back to nine bikes!
Try Googling before asking a damn silly question.
chateau dot murray at idnet dot com

On 2010-10-08 17:57:09 +0200, (E-Mail Removed) (The Older
Gentleman) said:

> For the Suzuki TS250ER.

Try Wolf Racing in Walters Ash (near High Wycombe).

--
Dnc

In communiqué <1jq1ypg.1yuzojqmz20dkN%(E-Mail Removed) o.uk>,
The Older Gentleman <(E-Mail Removed)> cast forth these
pearls of wisdom
>For the Suzuki TS250ER.
>
>I can easily yield the not-so-good system as a pattern (as long as it
>isn't destroyed and I get it back), but I need to find someone who can
>do this sort of job. Open to the floor. Anyone got any ideas?
>
>

These might be worth a bell. Not cheap though I suspect.
--
+-------------------------------------------------------------------+
| Pete Fisher at Home: (E-Mail Removed) |
| Voxan Roadster Yamaha WR250Z/Supermoto "Old Gimmer's Hillclimber" |
| Gilera GFR * 2 Moto Morini 2C/375 Morini 350 "Forgotten Error" |
+-------------------------------------------------------------------+

In communiqué <(E-Mail Removed)>, Pete Fisher
<(E-Mail Removed)> cast forth these pearls of wisdom
>In communiqué <1jq1ypg.1yuzojqmz20dkN%(E-Mail Removed) o.uk>,
>The Older Gentleman <(E-Mail Removed)> cast forth these
>pearls of wisdom
>>For the Suzuki TS250ER.
>>
>>I can easily yield the not-so-good system as a pattern (as long as it
>>isn't destroyed and I get it back), but I need to find someone who can
>>do this sort of job. Open to the floor. Anyone got any ideas?
>>
>>
>
>These might be worth a bell. Not cheap though I suspect.

D'oh:

http://www.gibsonexhausts.co.uk/page...pgenme=bespoke
--
+-------------------------------------------------------------------+
| Pete Fisher at Home: (E-Mail Removed) |
| Voxan Roadster Yamaha WR250Z/Supermoto "Old Gimmer's Hillclimber" |
| Gilera GFR * 2 Moto Morini 2C/375 Morini 350 "Forgotten Error" |
+-------------------------------------------------------------------+

On Fri, 8 Oct 2010 16:57:09 +0100, (E-Mail Removed) (The
Older Gentleman) wrote:

>For the Suzuki TS250ER.
>
snip>

>I can easily yield the not-so-good system as a pattern (as long as it
>isn't destroyed and I get it back), but I need to find someone who can
>do this sort of job. Open to the floor. Anyone got any ideas?

Try and find a small fabrication shop and ask them if they'll do it as
a 'fill in' job between other work. If you strike really lucky you'll
find one with an apprentice who they could give it to as a project.
The company I used to work for would always take on stuff like this
and leave it to the punter to pay the apprentice what he thought it
was worth, folding money with no receipt and no guarantee.

"The Older Gentleman" <(E-Mail Removed)> wrote in message
news:1jq1ypg.1yuzojqmz20dkN%totallydeadmailbox@yah oo.co.uk...
> For the Suzuki TS250ER.
>
> I've got one iffy exhaust and one good one (and two bikes...). The
> problem on these dirt bikes is always the header pipe, which is made of
> two steel pressings spot-welded together, with the manifold and section
> leading to the siencer added.
>
> The silencers never give up. The circular sections of pipe are always
> solid. The problem is always with the bulging section made of the two
> spot-welded halves. They corrode from the outside in, usually along the
> welded seam. There's little point in trying to weld them up, because
> you're trying to weld paper-thin metal which is mostly rust anyway.
>
> Needless to say these are *utterly* unobtainable new, and nobody makes a
> pattern. Pattern tailpipes, sure, but not the crucial bit that rusts.
>
> I've tried a couple of people who advertise they make one-off expansion
> chambers, but they're more interested in making race pipes for old
> strokers. One guy reckoned it would cost £750 just to copy the part.
>
> I can easily yield the not-so-good system as a pattern (as long as it
> isn't destroyed and I get it back), but I need to find someone who can
> do this sort of job. Open to the floor. Anyone got any ideas?

Bloke in Shipley, just down the road here did a brilliant job doing my
Transalp from sight!!

Zorstec, he's good & very reasonable.

On 8 Oct, 16:57, totallydeadmail...@yahoo.co.uk (The Older Gentleman)
wrote:
> For the Suzuki TS250ER.
>
> I've got one iffy exhaust and one good one (and two bikes...). The
> problem on these dirt bikes is always the header pipe, which is made of
> two steel pressings spot-welded together, with the manifold and section
> leading to the siencer added.
>
> The silencers never give up. The circular sections of pipe are always
> solid. The problem is always with the bulging section made of the two
> spot-welded halves. They corrode from the outside in, usually along the
> welded seam. There's little point in trying to weld them up, because
> you're trying to weld paper-thin metal which is mostly rust anyway.
>
> Needless to say these are *utterly* unobtainable new, and nobody makes a
> pattern. Pattern tailpipes, sure, but not the crucial bit that rusts.
>
> I've tried a couple of people who advertise they make one-off expansion
> chambers, but they're more interested in making race pipes for old
> strokers. One guy reckoned it would cost £750 just to copy the part.
>
> I can easily yield the not-so-good system as a pattern (as long as it
> isn't destroyed and I get it back), but I need to find someone who can
> do this sort of job. Open to the floor. Anyone got any ideas?
Daft as it sounds have you thought of using a custom bike shop?
If you can hand beat a petrol tank then i'm sure beating 2 sections
of steel into U shapes then welding them together is pretty easy.
http://beakysmotorcycles.com might be worth contacting?

Steve

Pete Fisher <(E-Mail Removed)> wrote:

> In communiqué <(E-Mail Removed)>, Pete Fisher
> <(E-Mail Removed)> cast forth these pearls of wisdom
> >In communiqué <1jq1ypg.1yuzojqmz20dkN%(E-Mail Removed) o.uk>,
> >The Older Gentleman <(E-Mail Removed)> cast forth these
> >pearls of wisdom
> >>For the Suzuki TS250ER.
> >>
> >>I can easily yield the not-so-good system as a pattern (as long as it
> >>isn't destroyed and I get it back), but I need to find someone who can
> >>do this sort of job. Open to the floor. Anyone got any ideas?
> >>
> >>
> >
> >These might be worth a bell. Not cheap though I suspect.
>
> D'oh:
>
> http://www.gibsonexhausts.co.uk/page...pgenme=bespoke

Tried them. No joy.


--
BMW K1100LT Ducati 750SS Honda CB400Fx2 Triumph Street Triple
Kawasaki GT550 Suzuki TS250ERx2 GN250 Back to nine bikes!
Try Googling before asking a damn silly question.
chateau dot murray at idnet dot com

Andy Bonwick <(E-Mail Removed)> wrote:

> On Fri, 8 Oct 2010 16:57:09 +0100, (E-Mail Removed) (The
> Older Gentleman) wrote:
>
> >For the Suzuki TS250ER.
> >
> snip>
>
> >I can easily yield the not-so-good system as a pattern (as long as it
> >isn't destroyed and I get it back), but I need to find someone who can
> >do this sort of job. Open to the floor. Anyone got any ideas?
>
> Try and find a small fabrication shop and ask them if they'll do it as
> a 'fill in' job between other work. If you strike really lucky you'll
> find one with an apprentice who they could give it to as a project.
> The company I used to work for would always take on stuff like this
> and leave it to the punter to pay the apprentice what he thought it
> was worth, folding money with no receipt and no guarantee.

That's not a bad idea.


--
BMW K1100LT Ducati 750SS Honda CB400Fx2 Triumph Street Triple
Kawasaki GT550 Suzuki TS250ERx2 GN250 Back to nine bikes!
Try Googling before asking a damn silly question.
chateau dot murray at idnet dot com

On 8 Oct, 16:57, totallydeadmail...@yahoo.co.uk (The Older Gentleman)
wrote:
> For the Suzuki TS250ER.
>
> I've got one iffy exhaust and one good one (and two bikes...). The
> problem on these dirt bikes is always the header pipe, which is made of
> two steel pressings spot-welded together, with the manifold and section
> leading to the siencer added.
>
> The silencers never give up. The circular sections of pipe are always
> solid. The problem is always with the bulging section made of the two
> spot-welded halves. They corrode from the outside in, usually along the
> welded seam. There's little point in trying to weld them up, because
> you're trying to weld paper-thin metal which is mostly rust anyway.
>
> Needless to say these are *utterly* unobtainable new, and nobody makes a
> pattern. Pattern tailpipes, sure, but not the crucial bit that rusts.
>
> I've tried a couple of people who advertise they make one-off expansion
> chambers, but they're more interested in making race pipes for old
> strokers. One guy reckoned it would cost £750 just to copy the part.
>
> I can easily yield the not-so-good system as a pattern (as long as it
> isn't destroyed and I get it back), but I need to find someone who can
> do this sort of job. Open to the floor. Anyone got any ideas?
>

I had exactly the same problem with a TS250C years ago, I made one
myself in the end. Sadly I don't have the facilities any more. This
lot look like they may help you out :

http://www.predatormotorsport.co.uk

--
Speedgazebo