Over exhaust restoration

[Rane850]

I managed to have full Over racing exhaust to my collection. It is from year 96-97 and 17 years of use has left some markings in it. I will clean, polish and repack it but I also will try it before winter in my blue 96 and do rest of work during dark months.
Those attachment flanges (to cyl head) have been bent for overtightening. Who remembers where are drawings for those two piece clamps?

[cobbadiggabuddyblooo]

The 2 piece ones from the kawasaki models wont fit because the header diameter is different so dont cut them off yet...

[emway]

Don't know if i can help you but here is the drawing for an original exhaust.

[Rane850]

OK, thank you for drawing, I will check dimensions with Over pipes. I now straighened those flanges with big hammer and wisebench (temporarily solution)

[Rane850]

I put this Over set to my bike and made very short test ride. When I started in garage it did not sound so loud, note is just what needed, deep and low. But when I turned bike to street I realized that this is way too loud. I did not have time to go to unmanned roads, just a small burst in motorway. Engine felt bit crispier even in lower rpm's what I wonder since those primary pipes are so much bigger than originals (od 38 mm vs 43 mm).
I will make my own db killers to silencers. Maybe dia 40mm, lenght 15 cm straight pipes like I have now in Micron cans.
I must try to straighten those clamps in hydraulic press since there is no room for thicker plates without changing longer studs.

By the way, are there spares available for Over in Europe?

[Rane850]

This hanger does not look very pro. In most Over's there is offset hanger so you dont need that 1" spacer. Does anybody know where to get tough clamps, dia is 115mm. Those "alibaba"-hangers seems to be 0,5 mm thick, so not good.

[Rich]

http://www.pjengineering.co.uk/categories.php?cat=9

they should suffice for your needs, but the bracket straps are not hard to make, I have done them from stainless and alloy before.

[Rane850]

Here it is in pieces, 50% of wool has burnt away from first 20 cm, thats why there are burning marks in outside core.

[Rane850]

Over Japan kindly answered to my parts inquiry, but those bits will become too expensive to get from Japan. So carbon tubes has been ordered from PJ Engineering and some sst- strips from local workshop. DIY

[Rane850]

Over restoration has been completed, core tubes and rivet bands are new, everything else is cleaned and polished. At the outlets i welded 15 cm long 35mm tubes for silencing. Now decibels are at acceptable level.
And I also put silencers to wrong sides

[M.V.]

Looks good mate, good job! I need to do that to my Omrae's soon...