Repairing Header Pipes

If you have dinged up your titanium header pipe, or even your expansion chamber, don’t just chuck it away. They can be repaired with varying degrees of success.

I put a ding in my header on my first ride! The titanium is nice and light, but it is paper thin and doesn’t like smashing into rocks.

Following is a brief description and pics which describes how to go about removing dings.

You will need:

oxy set or propane torch
various clamps
rubber bung
air compressor
wire

Here is what I use to fix the header on the WR450

Make sure you are reading PSI on the gauge, in the picture it is set on 30 PSI

Tightening the nut right up expanded it enough so it wouldn’t fall in but don’t be afraid to be creative to hold it in place.

The assembled setup ready for ding removal

So on to the fixing part.
Set the regulator to around 20-30psi and plug the air in, you shouldn’t have too much of a leak. Once you’re sure everything is holding the pressure get the torch out and start heating around the ding, soon the whole area will be glowing red. You will notice that where you focus the flame of the torch a bright orange circle appears. Move this slowly around the ding moving inwards as it starts to come out, it will take a minute or two to start moving so just work slowly. If you do get a high spot just tap it back down. Some tinted goggles or sun glasses can help spot the lows, it glows very bright

The results were fantastic.

Before

After

Tips for success.

BE CAREFUL. The pressures involved are really not that great but that glowing steel will annihilate your skin.

Can’t be any holes in the pipe, any seams that look suspect need to be welded.(2 smokes only)

It needs to be hot, glowing bright orange.

If you have a really big dent or need to work on different spots the pipe can heat up too much and possibly warp so let it cool down occasionally, disconnect the air pressure when cooling.

This will also work for 2 smoke expansion chambers. Just figure out the best way to block off the ends and some sort of connection for the compressed air.

Before

After

The titanium headers can also be repaired by filling them with water and blocking the ends with wet rags. Simple place the header upright in the deep freeze overnight and the force of the water expanding when it freezes will also remove the dings. You may need to do this procedure a few times for ultimate success.