Re-chroming Exhausts

[Baz1954]

As I stated before, I'm in the process of rebuilding my '78 GS1000. I'm trying to return her to original. For example I had to source foot-pegs, swingarm, brake hoses and other parts I ditched when young and dumb (instead of hanging onto them). Same with the exhaust system.

I shipped an original exhaust system from Houston TX as there nothing here in Oz. It needs re-chroming but the problem is the mufflers have to be removed or no-one will do it. My plan is to cut the ends of the mufflers off at about 20mm from the ends and withdraw mufflers, then weld tube to inside of the end with muffler attached. Now I should be able to push the muffler back in and drill four radial holes around the main muffler tube, withdraw the mufflers and weld nuts to the inside of the tube I welded in at the holes I drilled. Now I should be able to remove and replace at will.

Hope this makes sense and maybe someone has done a similar operation before. Thanks.

[johnr]

Don't bother. No chromer worth his salt will touch second hand exhausts cos they'll contaminate his baths. If you e found someone who will tackle rusty second hand motorcycle pipes, then he's probably not likely to do a good job.

[Toecutter]

Most good plating companies have dedicated tanks for dealing with the rough stuff. Good results can be achieved, however, it's expensive and worth assessing what you have and what you expect to receive back. If corrosion has eaten heavily into your parts, all you will get back is nicely plated puckered, uneven base material. It has always been an expensive process and even more so now. It's not an environmentally viable process and everyone is trying to shut these places down. As a rough idea, a Harris 4 into 1 system, including baffle was recently quoted at £550 for dip and rechrome. 

[Baz1954]

Thanks for replies. I have had the two removable headers done (they are double skinned). I have cut the baffles out, amazed that they are only about 150mm long. Wrapped with felt.

My guy has already sighted the system and will charge $AUD 1,500 to chrome. Going to go ahead with assembly process I described above.

[Joseph]

1500 should get you custom made stainless steel replicas by an exhaust specialist with removable baffles etc ?

I know polished stainless is not the same colour as chrome, so obviously it could show once on the bike, but at least durability is guaranteed, compared to chrome jobs these days

[Baz1954]

Hi all,

It's been a while since original post so an update regarding OEM exhaust. Could be useful to others trying to achieve what I am. I cut the ends of the mufflers off and welded a tube inside what is now an end cap. Then welded a nut inside the tube so I could use a single bolt to secure in place. Bolts are GS1000 headlight bolts because well...they are cute.

Result slightly modified exhaust and I'm happy. Chrome was carried out by Kustom Chrome here in Western Australia, possibly the best people in Oz . Apologies for the plug but after 7 months (they are flat out)I am totally rapt.

Now I'm waiting for the gas tank to be welded as I cut it in half to clean it properly then off to the paint shop. My last problem is the front master cylinder. I've tried other 16mm kits but no joy. So it looks like fitting a later model full assembly but hey what can you do.

Regards

Baz

[Baz1954]

Well good people, I just had to upload an image of my exhausts. It's taken four years to get to this point. Scouring the planet for original items that I threw away. Well when you're 25 years old you don't expect to see 30. I've bought an '82 GS850gl master cylinder (spares available) to replace the original but hey it's only 4 years younger than the original.

Baz