I was planning on running a single fish tail at the rear of the pipe, but I’m a little concerned about all the back pressure. In addition, my mind started drifting away from those and I started to dream up other options.

I’ve always liked the looks to “bugle tipped” exhaust, as well as thick wall tubing. I figured I would try to make what looks like a thick walled flare tip. Here’s my process.

I scavenged the tips from an old set of pipes.

Next I ground it to fit an inner pipe, which matches my current exhaust diameter.

I welded an outer wall to the end of the inner pipe.

Weld, grind, file – here’s the tip. I still need to weld the bottom of the cone to the inner pipe, but you get the idea.

I think it has potential, but I’m not completely sold yet. I’m going to be making a second tip, to see how two-in-a-row look on the main pipe.

I’m looking for a new set of files (and instant gratification kicked in) so I hit eBay. One of the results was a small brochure produced by Nicholson regarding the types and usage of files. It looked interesting, but not $20 interesting.

Since the brochure was a free item from Nicholson, surely it’s scanned and online by now. A google later and boom…instant gratification in a pdf. Good reading.

Here’s a sample page:

Grinding and filing sucks, but it’s worth the effort.

Guess what the worst part of these pipes is…

As mentioned below – I had some concerns about the design for clearing the nose cone. I asked on Jockey Journal, and it seems everyone unanimously shares my concern. I really didn’t want to, but I pulled the pipe and worked out a concave indent for a replacement.

Here’s the new pipe followed by the side-by-side comparison of the new and old. Note the smooth, bullet-nosed protrusion into the pipe. Exhaust should flow a lot more smoothly around this than the shirt wall protruding into the pipe on the original.

I would have preferred it to be smoother, but 1) I tacked it down then peened it into shape/place and 2) you can’t really see it anyway. So I guess I’ll just have to let go of that little hang up.

I realized my pipe clearance solution was a poor choice. Somehow my mind was churning that over last night and I woke up at 4am thinking about it. Funny how the mind works. Anyway – I’m pretty bummed I need to go in and rework that section of the pipe, but it’s better that than a burned up exhaust valve.

Anyway – rather than work on that tonight, I decided to finish up my bracket for the exhaust (you can see the first part of this project below).

I decided it would be a bit more sanitary, and create some puzzled looks, if I boxed in the top of the bracket. I boxed it in with 1″ steel tube, coped to meet the exhaust pipe. Mostly a lot of filing to get it fit snugly between the bracket and the pipe. Since the width of the bracket was tight I had to hit it with the BFH once or twice to spread it a bit.

Some of the welds were a bit ugly since I was working around the rear pipe. As a result I ground them down and radius-ed a bit with a rat tail file.

Anyway – here are the pics. Hopefully I’ll resolve the clearance issue tomorrow and finish weld the exhaust.

Here’s the mount bolted to the frame, looking down from above: