im looking into my options on exhaust manifold for my 2008 R1, which are either an off the shelf manifold, or i make my own.


if i go for an off the shelf one, how much would i be looking at paying? and where is best to get it from?
my worry with this is, it might not fit great, or even the chassis bars might get in the way.


i think i could make one reasonably easily, by buying a R1 manifold, cutting the ends off, so ive got the flanges, then make some nice bends and weld it together. ive got a mig welder (although it is gasless) and can get hold of a big pipe bender, so if i take my time i think i could do it. and if it doesn't look very good i can always wrap it.


so anyone any advice?

cheers

Hi Matt.
I would enquire with MK. If you have used one of their engine cradles then they might be able to supply a manifold that will fit.
I would make my own though.
No need for a bender. Just buy another R1 manifold and cut both of them up into straights and bends.
Then its a 3D puzzle exercise. Lots of trial fitting, trimming etc.
We did ours using two standard blade 929 manifolds which are titanium. No wrapping required.
We made our own collector too. That was the most difficult bit as titanium springs back a lot. It won't be so difficult in steel.
Yes, I know we have deviated from standard configuration but the performance doesn't seem to have suffered.
As you say you could wrap the finished article if necessary.
More pics in my archive.
Geoff.

Thanks, ive now decided im going to make my own.

Can anyone tell me if the 2006 r1 has the same manifold flanges as the 2008?

Makesure you get the design right, the 2008 R1's are melting the head between cylinders 2 & 3, and so far the belief is that it is being caused by too restrictive exhaust designs and maybe not leaving the exup solenoid connected (using a resistor instead). This is why i am picking my car up from Tony Laws in Leeds tomorrow, properly designed custom built exhaust system for £540, its a bargain in my eyes!!

ive done some thinking about the design etc and think i will make it a 4-2-1 type.

one question though, im using 2 1/2" for the manifold, once its gone into 2 and 1 do i need to use some thicker pipe like 3" or is using 2 1/2" throughout fine?

2 1/2 seems rather big for a manifold, i'm making (trying) a manifold for my ZZR14 using the standard bike manifold cut up as like Geoff says, and that is 1 1/2 OD

i also have a 2005 R1 manifold made by mnr and the OD of that is the same as the ID of the ZZR14 so about 35mm

Damn im sure i read somewhere that the standard used 2 1/2. Although thinking about it it does seem a bit big.

And ive ordered 3m of the stuff.

Im still waiting for my donor manifold to turn up, so is it 1 1/2 i need for the mani then?

Cheers

the one just made for me by tony law is 41mm

Austen,

How do you manage the step between the exhaust port on the head and the manifold? I assume you are running stock head (no modifications here for RGB I think). Or does your new engine have 41mm i.d. exhaust ports as standard?

I have some ex-sidecar engine bits and they do the big exhaust header trick too, but in that case extreme engine modification was allowed so one engine I have has super big exhaust ports that match the header stubs.

Just interested.

Matt

quote:

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Originally posted by matt_gsxr
Austen,

How do you manage the step between the exhaust port on the head and the manifold? I assume you are running stock head (no modifications here for RGB I think). Or does your new engine have 41mm i.d. exhaust ports as standard?

I have some ex-sidecar engine bits and they do the big exhaust header trick too, but in that case extreme engine modification was allowed so one engine I have has super big exhaust ports that match the header stubs.

Just interested.

Matt

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