Custom Stainless/Titanium Exhaust Headers

[Nope.]

Hi All,

I've got a 2011 XT660Z Tenere. It's a good all round adventure bike and I'm currently in the process of tidying it up a bit after some off road abuse.

One area that I've been struggling with a bit is the exhaust headers. They're mild steel (nickel plated out of the factory) and they're quite rusty. It's all surface rust, the pipes are still solid, but it looks awful. The clamps are so rusty that the bolts probably wouldn't come out in one piece.

Now, I could go out and get them ceramic coated and fit new (possibly stainless) clamps, but I'd much rather get a set of stainless or titanium headers for it; unfortunately it seems nobody makes a set of these for this bike (although it seems a company in Germany used to) and as such I'm forced to investigate having a set made.

Unfortunately the XT660Z exhaust is not exactly simple, the front bit being shaped like the attached picture plus some more out the back:

https://cdn.bcf.44bytes.net/files/f3a3a1c04fcb92ace5b16a3b5d4f.jpg

Can anybody recommend a company or person that could fabricate a decent set of headers given the original one as a template?

Cheers!
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2011 XT660Z Ténéré - 2003 YZR-R1 5PW (In Build)

[Easy-X]

Hey! Have an adventure: buy a welder and some pipe and make your own... how hard could it be?
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Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[Nope.]

[Bhud]

There's this company. No idea whether they're any good. I don't think it will be cheap.

https://www.gfmoto.com/

[Fisty]

Will these fit?

https://www.ebay.co.uk/itm/Manifold-Collector-DOMINATOR-Exhaust-Downpipes-Frontpipes-XT660-XT-660-R-04-14/273686446454?hash=item3fb8fbc176:g:O3AAAOSw~JFcWUYg
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Quietly and consistently taking the piss.
TL1000R | Hayabusa | ZXR400 | TL1000S | Bandit 400 V
Fatter and faster than Fret

[Riejufixing]

[Robby]

Expect to spend upwards of £500 to get that made in stainless.

[Easy-X]

Pah! Save all that money and just wrap it...

It'll give the bike character, trust me
____________________
Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[Baffler186]

It's possible to get everything off without snapping bolts as long as you're patient and use plenty of penetrating oil. If that fails, use heat. It's not even that bad if you snap off bolts, they can be drilled out. Why don't you try doing that, then you can clean the pipes up and either leave them or paint them?
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Current: 2009 SV650 S, 1990 Kawasaki GT550
Previous: 2009 CBF125, 1998 GSF600, 2004 FZ6 Fazer, 1978 CB400a Hondamatic

[A100man]

[stevo as b4]

Four stroke pipes should be cheaper in theory especially for a single and only a front pipe. I have no idea how much a top quality four stroke pipe builder like Race fit or Pipeworx would charge though? Don't you have a good stainless steel car exhaust place near by who could make you a set?

As for hydraulically formed pipes, good luck as most car exhaust places use mandrel bent pipes which works fine as long as the bore size is sufficient. The only hydraulic headers Ive ever heard of are the Micron serpent ones, and they disappeared soon after they came out.

My custom stainless steel two stroke exhaust was £320 so I'd expect your XT pipes to be cheaper than that!