New 5th/6th/8th gen performance header now in production in USA

[Duc2V4]

Hi All, looks like I didn't have to hold on to the headers I bought to get the build going. A few late comers to the party have relieved me of them, even before I took possession of them. So if anybody is or was looking to buy them, it would appear that it would be too late at this time.

 

On the topic of the actual build, all I can say is that we are getting closer and we hope to hear back from Wade real soon.

 

That said, I would like to thank everybody who were able to grab a set and for being so patient with this, we obviously didn't want to have everybody to wait this long, but sometimes we have no control over that.

 

Cheers,

D

[sfdownhill]

Greetings header gang - this update is to let everyone know that we will be able to pick up the current order of headers week after next, so Duc2V4 and I will be contacting all those who placed deposits with a balance due including shipping cost where applicable. Please feel free to contact either or both of us by PM with any questions.

[Ziffer]

12 hours ago, sfdownhill said:

Greetings header gang - this update is to let everyone know that we will be able to pick up the current order of headers week after next, so Duc2V4 and I will be contacting all those who placed deposits with a balance due including shipping cost where applicable. Please feel free to contact either or both of us by PM with any questions.

 

Woohoo!

[Duc2V4]

Hey all, I just sent out your totals with the balance due amount just a few minutes ago. Sorry it took me a while, doing 12-14 hour days at work last week and busy weekend catching up with the wife, kind of kept me a bit busy. On a positive note, I was finally able to get my FedEx account squared away, so I could finally get my discounted rates.

 

Cheers,

D

[RC51Nick]

Payment sent...   Thank you again for you guys doing these headers!!

[omgvfr]

All right, it's that time! I recently acquired my set from the latest run. The very good news is everything is working as it should! I've just finished with the install and I have some photos to share. 😁

 

Here is my pair. Right now the rear primaries are just balanced in the slip fittings. I have a Remus high mount can - the link pipe is balanced where it should be.

 

The Remus link pipe does not utilize the stock exhaust gasket. It has a built-in clamp. This is actually a very tight fit on the stock exhaust outlet. The diameter of these pipes are about the same. The muffler end of the remus link pipe would slip on as it should here. I knew this part would need to be addressed before the install.

 

The first welding shop I went by was a fabrication specialist, I showed them what I was working with. They didn't have expanders or tubing material there and I was referred to another local shop. The second shop has cars parked inside and custom turbo header projects everywhere. This was the right place. The first attempt was to just expand it as is - the metal promptly cracked and tore open. He confirmed I do have a clamp that would work. A moment later, the end is cut off and there is a new piece of pipe that slip fits being welded on. These now fit properly and everything is clean inside and out. This aspect of the project could have gone many ways. I am very glad it worked as well as it did. It's a pretty weld and is the most visible one so good there too.

 

Here is the starting point. The bike is a 1999 model. It hasn't been down before - the scrape on the stock header is from lean angle.

[omgvfr]

Removing the stock system is pretty straightforward. Remove tail plastic, remove rear wheel, remove Remus can and link pipe. Remove front fairings, loosen right foot stay, remove heat shield. Header bolts all loose, rear primaries disconnected, and the stock system shifts out just fine. Once the bike is back on the sidestand the centerstand can be removed. The bike certainly looks good with all of this stuff out of the way. I also cleaned up surfaces while the access was there. With everything ready, the first step was fitting the Delkevic copper gaskets. They're just a little big - but this is a good thing once all is assembled. You can see that the ring wouldn't just fit but needed a little manipulation to sit centered. My initial reaction was - oh no! Spend the time to make the entire gasket centered in the exhaust port. I noticed on the front ports there is some chipping of the external casting. Once fitted they stay in on their own and don't fall out unless disturbed.

 

 

Looking at the rear ports, here are the gaskets fitted.

 

I was told that the left rear primary slip joint was a tight fit. This is true - I had test fitted these before they went on the bike. The right slips on easily enough, while the left was quite tight. Wiggling and slightly twisting, it does slip on all the way though. Same thing removing the slip fitting. I put a marker dot on the slip fittings as an index, so I could tell when it was fitted all the way when on the bike.

 

With the rear primaries loosely fitted and the same in the front. Here is the view before joining the slip fittings. A bit of strength to align these while lifting the header up, both began their slip fit. A moment of manipulating by hand and they fit as much as they would go.

 

Out comes the ratchet strap with a piece of cloth to protect the surfaces. I squeezed the left joint first and then the right.

 

 

Once the strap was pulling, light taps on the slip joint pulled them right into place. This was surprisingly easy considering how tight this appeared while test fitting. After these joints were fitted, the remaining 4 points attaching to the bike all lined up where they should. Very nice!

 

[omgvfr]

Fitting the front primaries.

 

Fitting the midpipe. This lines up well after the welding work.

 

Stock exhaust clamp now in use. A big plus: The midpipe can now be removed without first removing the rear wheel.

 

Taking a look at how it all comes together. This is really nice.

 

I've ordered three M18x1.5 o2 plugs. Everything else goes back together as normal.

 

Note: Even if the rear primaries are slip fitted together and the header is in one piece. If you need to install or remove the centerstand it can be done by removing the header bolts at the engine. There is then enough flex to access the top right bolt for the centerstand. A parts diagram shows the assembly order of the spacers, flat and spring washers.

 

[Duc2V4]

Well, as you can see from omgvfr's post, the headers are here, he's just lucky that he lives in So Cal, so was able to stop by and pick his up first hand, rather than wait for shipping. On that topic, I'm flying solo right now as sfdownhill is away this week, so I'm trying to tag team this with my day job and doing the boxing up at night.

 

There's a few on here who have not responded to my last post yet, but rest assured, they'll be boxed up and ready to go along with the others. I was able to get them all boxed up last night but need to get the shipping labels done and then get the boxes dropped off, so they can get to their destination.

 

Here's what the front of my garage looks like at the moment. And a peek at what to expect once your box arrives (if you're one who has a set coming). Hoping to get all the labels printed and onto the boxes tonight. I know, I know, "Hurry up Duc, we've been waiting so long!"

[Duc2V4]

THEY'RE ON THEIR WAY!

 

I just have two left to deal with. These are the one's going outside the US, but I should have these out later today or tomorrow, different shipper and process along with a couple of I's to dot and T's to cross.

 

I just want to thank everyone for being so patient and understanding of the circumstances but we all persevered and the rewards will be received very soon!

 

Cheers,

D

[ioneater]

I have no doubt the wait will be worth it.  Thank you for your care and efforts following thru this endeavor!

[Ziffer]

Thank you to Duc2V4 and sfdownhill! We all have busy schedules and plenty of things to do, but you guys came through!

[RC51Nick]

Thanks Duc2V4.  Good things come to those who wait. 

 

[Oregonian]

Thanks for doing this and thanks for the good communication throughout the process. 

[Mohawk]

Well done the A-Team 👍

[Dazdiablo]

Hey I'm starting to look into building my 5th gen. I saw this first production run just went out not long ago. Is there any intention of doing a second run and if not could a custom order for a single be placed with the shop that made them in SoCal?

[Duc2V4]

8 hours ago, Dazdiablo said:

Hey I'm starting to look into building my 5th gen. I saw this first production run just went out not long ago. Is there any intention of doing a second run and if not could a custom order for a single be placed with the shop that made them in SoCal?

Bad news on a couple of fronts. After this last production run, our fourth run actually, the pipe builder handed off the welding jigs to sfdownhill, essentially ending our production runs with him. Unfortunately he and I never got to discuss what we wanted to do with them.

 

Here’s the really sad part, sfdownhill had a life ending accident this past week, he was was pronounced deceased a few days ago. Another unfortunate issue, I never got to meet the builder, I only knew him as Wade and sfdownhill did all the interfacing with him, including the only one of us to visit his shop, so I have no way of reaching him directly.

 

I am still in shock about what happened, let alone still in the dark about what’s going to happen with all of his stuff, all his equipment, motorcycles and even those welding jigs. He and I had plans to build up another 5 Gen using a set of headers from this last run and I don’t even know where that bike is at the moment. 

 

In all honesty, that is not my priority right now, mourning the loss of my friend and hopefully meeting with his family soon is. Here is a link to my post announcing this tragic loss.

 

 

[Dazdiablo]

10 hours ago, Duc2V4 said:

Bad news on a couple of fronts. After this last production run, our fourth run actually, the pipe builder handed off the welding jigs to sfdownhill, essentially ending our production runs with him. Unfortunately he and I never got to discuss what we wanted to do with them.

 

Here’s the really sad part, sfdownhill had a life ending accident this past week, he was was pronounced deceased a few days ago. Another unfortunate issue, I never got to meet the builder, I only knew him as Wade and sfdownhill did all the interfacing with him, including the only one of us to visit his shop, so I have no way of reaching him directly.

 

I am still in shock about what happened, let alone still in the dark about what’s going to happen with all of his stuff, all his equipment, motorcycles and even those welding jigs. He and I had plans to build up another 5 Gen using a set of headers from this last run and I don’t even know where that bike is at the moment. 

 

In all honesty, that is not my priority right now, mourning the loss of my friend and hopefully meeting with his family soon is. Here is a link to my post announcing this tragic loss.

 

 

OMFG I'm so sorry to hear this. Go ride for your friend, mourn his loss and see his family. If this pics back up it picks back up when the time is right. Now is not the time.

[flya750]

12 hours ago, Duc2V4 said:

Bad news on a couple of fronts. After this last production run, our fourth run actually, the pipe builder handed off the welding jigs to sfdownhill, essentially ending our production runs with him. Unfortunately he and I never got to discuss what we wanted to do with them.

 

Here’s the really sad part, sfdownhill had a life ending accident this past week, he was was pronounced deceased a few days ago. Another unfortunate issue, I never got to meet the builder, I only knew him as Wade and sfdownhill did all the interfacing with him, including the only one of us to visit his shop, so I have no way of reaching him directly.

 

I am still in shock about what happened, let alone still in the dark about what’s going to happen with all of his stuff, all his equipment, motorcycles and even those welding jigs. He and I had plans to build up another 5 Gen using a set of headers from this last run and I don’t even know where that bike is at the moment. 

 

In all honesty, that is not my priority right now, mourning the loss of my friend and hopefully meeting with his family soon is. Here is a link to my post announcing this tragic loss.

 

 

Just WOW! This is SAD news! 

[bmart]

Way too early, but how many Wades can there be that do this sort of work in that area? Maybe we can be an army when needed and find him for the benefit of the group. I'd chip in to assist. It might be as easy as using F-book or even a search on the two forums. 

[Duc2V4]

1 minute ago, bmart said:

Way too early, but how many Wades can there be that do this sort of work in that area? Maybe we can be an army when needed and find him for the benefit of the group. I'd chip in to assist. It might be as easy as using F-book or even a search on the two forums. 

I'm in contact with his cousin at the moment and we are looking at clearing out his place. I'm sure we can locate someone to perhaps build a set of "tribute" headers for the group, if not Wade himself. I'm hoping that he didn't toss out the welding jigs that Wade had given him and maybe we can do this again in his honor. Whether it's with Wade or someone else, the jigs would definitely be of great benefit.

 

I'll keep everyone up to date as best I can. His cousin said they were planning on going to his place soon to clear out his stuff, I'll see if I can join them and perhaps get a hold of the jigs Wade provided him. At the very least, they asked for my help with all his motorcycle stuff, as his family is not that keen on what he has or values of his bikes and gear.

[St. Stephen]

Hey Darryl, if you need help with grunt work moving Lance's things or just clearing stuff out let me know. I'm going back and forth often between here in the north bay and north county San Diego where we have family, so would be happy to stop and help. I think you have my contact info.

 

Rough year for you, hang in there.

[Duc2V4]

12 hours ago, St. Stephen said:

Hey Darryl, if you need help with grunt work moving Lance's things or just clearing stuff out let me know. I'm going back and forth often between here in the north bay and north county San Diego where we have family, so would be happy to stop and help. I think you have my contact info.

 

Rough year for you, hang in there.

Yeah, definitely a tough year for me and one of my biggest supporters and cheerleaders was Lance. He went to the hospital to visit me when I got out of surgery and was there when they released me. He would call or text me randomly to see how I was doing and to see the status of my DMV situation.

 

I have to credit to him for helping me get my license back, he gave me a number of a lawyer who works with drivers license issues, it was the lawyer who not only helped get the DMV appointment setup but to push it up by a month.

 

When talking on the phone I could hear his excitement in his voice on me getting the appointment sooner but even more so when we spoke after I got my license back. He was like a little kid getting his first bicycle for Christmas, he was so excited to hear this and I can remember him just planning for us to ride together. Not only because it had been so long since we had ridden together but I think it was he wanted to one of the first to ride with me again.

 

I’m waiting to hear back from his cousin and if I can be part of the crew to clear out his home, that would be great. If I have to wait until everything gets moved to Escondido, I’ll reach out to you.

[Dazdiablo]

This is probably still too soon but I'll just put it out there... I'm a custom metal fabricator. I've never done an exhaust but I'd love to have a look at the jigs and if I had access to a completed set I'm sure I could do something worth a shout. My shop is pretty comprehensive and anything I don't have I would get.

[boOZZIE]

6 hours ago, Dazdiablo said:

This is probably still too soon but I'll just put it out there... I'm a custom metal fabricator. I've never done an exhaust but I'd love to have a look at the jigs and if I had access to a completed set I'm sure I could do something worth a shout. My shop is pretty comprehensive and anything I don't have I would get.

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