How to Build Exhaust Pipes for a Harley-Davidson Motorcycle

The exhaust system on a motorcycle is one of the most noticeable aspects of a bike. Motorcyclists can change how their bike looks and sounds by changing the exhaust pipes. One way to customize your motorcycle is to build your own exhaust pipes.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• Pipe or tube bender

Get Started

1. Create a design template for your exhaust pipes and outlet. You can draw the design on a sturdy piece of cardboard or template board. Make sure your template is the actual size you want your exhaust pipes.

2. Cut out the design from the template.

3. Secure the template to the motorcycle for a trial fit. This will allow you to see how your design will look on the motorcycle.

4. Modify the template as desired before proceeding.

5. Measure the length from the engine block to the first bend in your template.

6. Mark the measurement onto your exhaust pipe.

7. Repeat process as needed by measuring from the edge of one bend to the beginning of the next bend. Mark the measurements on your exhaust pipe for each bend you plan to make.

Bending the Pipe

8. Place the pipe into a pipe or tube bender at the point of your first mark.

9. Bend the pipe to match template. Make small adjustments to the pipe as needed.

10. Repeat the process for each additional bend.

Tips & Warnings

• Straight exhaust pipes generally have one bend and tend to be easier to build.
• Pre-bent elbows may be welded onto a straight exhaust pipe if you do not have a pipe or tube bender.
• Local law may have certain restrictions in regards to the level of noise an exhaust system can produce. Check your local laws before deciding on a exhaust system.

Resources

• Find pictures of Harley-Davidson exhaust pipes and exhaust system kits for sale
• Information on exhaust systems and motorcycle performance issues can be found at Harley Performance