DIY: Exhaust Hanger (no welding)

Shift250R · August 17th, 2009, 05:51 PM

I decided to make my own exhaust hanger so I could get rid of my pass pegs. It dosnt look the best but it only came out to $5!

First I would just like to say I havn't had this long so Im not sure its bullet proof if you can afford it I would just buy Zartans. Anyway here are the things you will need.
1. Flat punched zinc plated metal brace which I bought at Home Depot for about $5. (size states 1-3/8" x 36")
2. Good Hacksaw
3.Original bolts and pegs (and paint if you want to paint it).

First you will need to remove your orignal pass pegs which has all ready been covered by Kelly in another DIY. I measured the pieces I wanted to cut but I didnt write down the measurements but all you have to do is using the hacksaw cut one strip with 10 holes and one strip with 11 holes. simple

Loosely bolt the bracket with 11 holes on the thread towards the front of the bike. You will also need to put 1 or 2 washers behind the bracket to bring it foward a little. I will discuss it later.

Next loosely bolt the bracket with 10 holes on the other side with washers.

Now this is the slightly tricky part. As you can see the brackets are flat and do not bend foward to the exhaust like most hanger do. Get your right pass peg (exhaust side) and pull out the bushings in side the bolt hole. we will use these as spacers.

Now the last holes of the bracket should line up. Place your long exhaust bolt through your clamp then place the bushing in between the clamp and bracket and loosely tighten. I used one original bushing (black) and the one that came with my exhaust (silver). The purpose is to keep the brackets and exhaust from being pulled together since the brackets are flat.

Once you have test fit it and tweaked it where it will fit just paint and your done. I used hi temp flat black.

Finished! Look mine has circles like Zartans!

Sorry for the blurry pics. Im not sure if this will work with the stock exhaust but the holes lined up very close the original but my exhaust bracket is movable. Like i said not the best but seems to hold fine so far and it was only 5 bucks.

Postiez · August 17th, 2009, 10:52 PM

Looks good! i wanted to get rid of my passenger pegs but I was worried about this

AnarchoMoltov · August 17th, 2009, 10:57 PM

Nice job man, it actually looks pretty decent when painted..

Did you use the same paint, to do the heat shield??

divingtigger · August 18th, 2009, 05:24 AM

WOW that looks great after it is painted, at first I thought that there is probably a lot nicer things you could have used, but that looks great once done.

The only thing I would have done differently was to cut them a little bit longer (extra 1/8" or at the bottom of the hole that is being cut off) and round the metal off so there is no sharp corners.

Once again, awesome mod, gonna have to do that to mine when I get it back

Shift250R · August 18th, 2009, 08:58 AM

Thanks guys but ya I used the same paint for my heat shield and that has lasted months with no fading or chips. I thought about cutting the corners and then grinding the edges but I got to carried away with how it was coming together and I forgot. Ill probably do it later.

divingtigger · August 18th, 2009, 09:49 AM

Quote:

Originally Posted by Shift250R

I thought about cutting the corners and then grinding the edges but I got to carried away with how it was coming together and I forgot. Ill probably do it later.

Sounds like something I'd do and have done countless times in the past

GreezMunky · August 18th, 2009, 03:12 PM

lmao, that is an awesome idea!

Very clever and doesn't look half bad at all for only $5. Cool stuff man.

08ninja250 · July 9th, 2010, 11:27 AM

I did this to my bike! Thanks alot!!! Great tutorial!

FerociousNINJA · September 8th, 2011, 05:12 PM

Nice work!

greatwhiteninja · September 8th, 2011, 07:02 PM

looks good black! nice.. i eliminated my rear foot peg bracket completely and just mounted the exhaust hanger off one of the rear set bolts then off the exhaust clamp were the slip on meets the head pipe, you look at my bike it doesnt even look like anything is supporting my exhaust.

FerociousNINJA · September 8th, 2011, 08:24 PM

Pic plz...

Quote:

Originally Posted by greatwhiteninja

looks good black! nice.. i eliminated my rear foot peg bracket completely and just mounted the exhaust hanger off one of the rear set bolts then off the exhaust clamp were the slip on meets the head pipe, you look at my bike it doesnt even look like anything is supporting my exhaust.

nickadolph · September 8th, 2011, 08:44 PM

Skippii · September 9th, 2011, 01:08 AM

I followed your instructions exactly, but it still doesn't work!!!

CZroe · September 9th, 2011, 04:28 AM

Jeff left me with some of this stuff after we used it to mount my plate but then I gave him my high-temp black paint XD

greatwhiteninja · September 10th, 2011, 08:33 PM

Quote:

Originally Posted by FerociousNINJA

Pic plz...

I'll take some tomorrow ..

ninjaknobs · September 10th, 2011, 09:08 PM

http://cgi.ebay.com/ebaymotors/_W0QQ...Q3aMESELXQ3aIT

check out my listing for a custom aluminum black anodized exhaust hanger

nickadolph · September 11th, 2011, 12:27 AM

Quote:

Originally Posted by ninjaknobs

http://cgi.ebay.com/ebaymotors/_W0QQ...Q3aMESELXQ3aIT

check out my listing for a custom aluminum black anodized exhaust hanger

No offense to you, the hanger looks really nice, but the point of this is to avoid spending $40 on a simple bracket.

greatwhiteninja · September 11th, 2011, 09:57 AM

mine was just a simple pc of steel i found at work..lol! i drilled 2 holes in each end, one mounts to the rear set bracket, the other on the end of the exhaust clamp. works perfect. painted it with wrinkle finish high heat paint. barely tell its there

cost..free basically !

CZroe · September 11th, 2011, 11:31 AM

It already has support there (the pipe). You need to support it farther back to lower the force on the pipe and your mount. It really isn't doing the same amount of stabilization and protection as the original mount.

greatwhiteninja · September 11th, 2011, 01:03 PM

well my pipe isnt stock.. its a area p with dan moto slip on .. so the original support doesnt work. so this bracket is the only support for the exhaust, trust me it works. would definitely work on stock exhaust with aftermarket slipon.. my exhaust doesnt move and ive had it installed for about 1k miles with no issues

DarC · September 12th, 2011, 07:29 AM

Nice work. I made one using barstock steel and I drilled it and bent it just like the ones you can buy. I then finally made one out of aluminum doing the same thing. Works great and I only needed one hanger.

xDapperx · August 26th, 2012, 06:09 PM

Quote:

Originally Posted by greatwhiteninja

mine was just a simple pc of steel i found at work..lol! i drilled 2 holes in each end, one mounts to the rear set bracket, the other on the end of the exhaust clamp. works perfect. painted it with wrinkle finish high heat paint. barely tell its there

cost..free basically !

What kind of exhaust is that? Looks awesome!

choneofakind · August 26th, 2012, 06:14 PM

Quote:

Originally Posted by xDapperx

What kind of exhaust is that? Looks awesome!

Dan Moto Jisu.

iNinja · September 4th, 2012, 06:18 PM

did this as well.

i can cut two more pieces with what i have leftover if anyone is interested.

Aufitt · September 5th, 2012, 04:28 AM

I made one up for my cbr from 3mm alloy.

Thread on making it here-
http://www.cbr250.net/forum/cbr250-a...bracket-3.html

93etgocart · September 5th, 2012, 04:49 AM

it looks like it was built using knex pieces. Not horrible when painted but not my cup of tea. As a metal fabricator I would have to make some extreme mount if i decided to make a new one but for now ive just got the rear pegs taken off.

Aufitt · September 5th, 2012, 04:58 AM

Quote:

Originally Posted by 93etgocart

it looks like it was built using knex pieces. Not horrible when painted but not my cup of tea. As a metal fabricator I would have to make some extreme mount if i decided to make a new one but for now ive just got the rear pegs taken off.

Mine is tidy.

choneofakind · September 6th, 2012, 12:00 PM

Quote:

Originally Posted by Aufitt

Mine is tidy.

Mmhmmm! It looks very nice

alex.s · September 6th, 2012, 12:34 PM

Quote:

Originally Posted by Aufitt

I made one up for my cbr from 3mm alloy.

Thread on making it here-
http://www.cbr250.net/forum/cbr250-a...bracket-3.html

now we're talking. nice work.

Aufitt · September 6th, 2012, 06:37 PM

I'll make one up for the 2013 Ninja when it arrives here and the Akrapovic goes on.

SnowMan777 · January 12th, 2013, 08:07 PM

Okay, This literally took me 30 minutes to cut/file/paint and install on the bike. Nothing better than saving 90% on a motorcycle part.

IMAG0324.jpg IMAG0323.jpg

SnowMan777 · January 12th, 2013, 08:09 PM

Just wanted to make sure it would fit. Now I am going to paint the screws, nuts, and washers flat Black. Should be just fine.

This will hold me over until I get a Two Bros. Exhaust

August 17th, 2009, 05:51 PM	#1
Shift250R ninjette.org member Name: Michael Location: Texas Join Date: Feb 2009 Motorcycle(s): 08 Ninja 250R Posts: 112	DIY: Exhaust Hanger (no welding) I decided to make my own exhaust hanger so I could get rid of my pass pegs. It dosnt look the best but it only came out to $5! First I would just like to say I havn't had this long so Im not sure its bullet proof if you can afford it I would just buy Zartans. Anyway here are the things you will need. 1. Flat punched zinc plated metal brace which I bought at Home Depot for about $5. (size states 1-3/8" x 36") 2. Good Hacksaw 3.Original bolts and pegs (and paint if you want to paint it). First you will need to remove your orignal pass pegs which has all ready been covered by Kelly in another DIY. I measured the pieces I wanted to cut but I didnt write down the measurements but all you have to do is using the hacksaw cut one strip with 10 holes and one strip with 11 holes. simple Loosely bolt the bracket with 11 holes on the thread towards the front of the bike. You will also need to put 1 or 2 washers behind the bracket to bring it foward a little. I will discuss it later. Next loosely bolt the bracket with 10 holes on the other side with washers. Now this is the slightly tricky part. As you can see the brackets are flat and do not bend foward to the exhaust like most hanger do. Get your right pass peg (exhaust side) and pull out the bushings in side the bolt hole. we will use these as spacers. Now the last holes of the bracket should line up. Place your long exhaust bolt through your clamp then place the bushing in between the clamp and bracket and loosely tighten. I used one original bushing (black) and the one that came with my exhaust (silver). The purpose is to keep the brackets and exhaust from being pulled together since the brackets are flat. Once you have test fit it and tweaked it where it will fit just paint and your done. I used hi temp flat black. Finished! Look mine has circles like Zartans! Sorry for the blurry pics. Im not sure if this will work with the stock exhaust but the holes lined up very close the original but my exhaust bracket is movable. Like i said not the best but seems to hold fine so far and it was only 5 bucks. Last futzed with by Shift250R; August 17th, 2009 at 10:36 PM.

August 18th, 2009, 05:24 AM	#4
divingtigger Pedal Power Name: Rob Location: Winterpeg (Winnipeg) Join Date: Jun 2009 Motorcycle(s): 2008 Ninja EX250R Posts: 401	WOW that looks great after it is painted, at first I thought that there is probably a lot nicer things you could have used, but that looks great once done. The only thing I would have done differently was to cut them a little bit longer (extra 1/8" or at the bottom of the hole that is being cut off) and round the metal off so there is no sharp corners. Once again, awesome mod, gonna have to do that to mine when I get it back __________________________________________________ Using Pedal Power

September 8th, 2011, 07:02 PM	#10
greatwhiteninja Ridin Dirty Name: Ed Location: Delaware Join Date: Jun 2011 Motorcycle(s): 2011 white se 250r , 2008 zx6R Posts: 921	looks good black! nice.. i eliminated my rear foot peg bracket completely and just mounted the exhaust hanger off one of the rear set bolts then off the exhaust clamp were the slip on meets the head pipe, you look at my bike it doesnt even look like anything is supporting my exhaust. __________________________________________________ #1

September 9th, 2011, 01:08 AM	#13
Skippii Milkshake Drinker Name: Skippii Location: Richmond, Va Join Date: Aug 2011 Motorcycle(s): 2007 Orange DRZ400-S, 2005 Ninja 250 & Custom Thundercunt Dirt Chopper Posts: A lot.	I followed your instructions exactly, but it still doesn't work!!! __________________________________________________ "What a sweetheart."- ninja_sleeper to me

September 10th, 2011, 09:08 PM	#16
ninjaknobs ninjaknobs Name: Lee Location: thousand oaks, california Join Date: Oct 2010 Motorcycle(s): 2010 Kawasaki Ninja 250r Posts: 34	exhaust hanger for sale on ebay http://cgi.ebay.com/ebaymotors/_W0QQ...Q3aMESELXQ3aIT check out my listing for a custom aluminum black anodized exhaust hanger

August 17th, 2009, 10:52 PM	#2
Postiez ninjette.org member Name: Nick Location: SALT LAKE CITY, UT Join Date: Jun 2009 Motorcycle(s): Red '08 250 Posts: 233	Looks good! i wanted to get rid of my passenger pegs but I was worried about this

August 17th, 2009, 10:57 PM	#3
AnarchoMoltov ninjette.org guru Name: Dan Location: Chicago, il.... Join Date: Jun 2009 Motorcycle(s): 2007 Suzuki GSX-R750 Posts: 378	Nice job man, it actually looks pretty decent when painted.. Did you use the same paint, to do the heat shield??

August 18th, 2009, 08:58 AM	#5
Shift250R ninjette.org member Name: Michael Location: Texas Join Date: Feb 2009 Motorcycle(s): 08 Ninja 250R Posts: 112	Thanks guys but ya I used the same paint for my heat shield and that has lasted months with no fading or chips. I thought about cutting the corners and then grinding the edges but I got to carried away with how it was coming together and I forgot. Ill probably do it later.

August 18th, 2009, 03:12 PM	#7
GreezMunky ninjette.org guru Name: Tor Location: TX Join Date: Dec 2008 Motorcycle(s): 09 250r (sold), 2010 Daytona 675 Posts: 301	lmao, that is an awesome idea! Very clever and doesn't look half bad at all for only $5. Cool stuff man.

July 9th, 2010, 11:27 AM	#8
08ninja250 ninjette.org member Name: Colin Location: Ottawa Join Date: Jun 2010 Motorcycle(s): 2008 ninja 250 Posts: 168	I did this to my bike! Thanks alot!!! Great tutorial!

September 8th, 2011, 05:12 PM	#9
FerociousNINJA ninjette.org member Name: Dave Location: DFW, US Join Date: Mar 2010 Motorcycle(s): 2008 Ninja TwoFiddy Posts: 160	Nice work!

September 8th, 2011, 08:44 PM	#12
nickadolph ninjette.org member Name: nick Location: Twin Cities, MN Join Date: Jun 2010 Motorcycle(s): ninja 250 Posts: 168

September 9th, 2011, 04:28 AM	#14
CZroe CPT Falcon Name: J.Emmett Turner Location: Newnan, GA Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.	Jeff left me with some of this stuff after we used it to mount my plate but then I gave him my high-temp black paint XD

September 11th, 2011, 09:57 AM	#18
greatwhiteninja Ridin Dirty Name: Ed Location: Delaware Join Date: Jun 2011 Motorcycle(s): 2011 white se 250r , 2008 zx6R Posts: 921	mine was just a simple pc of steel i found at work..lol! i drilled 2 holes in each end, one mounts to the rear set bracket, the other on the end of the exhaust clamp. works perfect. painted it with wrinkle finish high heat paint. barely tell its there cost..free basically ! __________________________________________________ #1

September 11th, 2011, 11:31 AM	#19
CZroe CPT Falcon Name: J.Emmett Turner Location: Newnan, GA Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.	It already has support there (the pipe). You need to support it farther back to lower the force on the pipe and your mount. It really isn't doing the same amount of stabilization and protection as the original mount.

September 11th, 2011, 01:03 PM	#20
greatwhiteninja Ridin Dirty Name: Ed Location: Delaware Join Date: Jun 2011 Motorcycle(s): 2011 white se 250r , 2008 zx6R Posts: 921	well my pipe isnt stock.. its a area p with dan moto slip on .. so the original support doesnt work. so this bracket is the only support for the exhaust, trust me it works. would definitely work on stock exhaust with aftermarket slipon.. my exhaust doesnt move and ive had it installed for about 1k miles with no issues __________________________________________________ #1

September 12th, 2011, 07:29 AM	#21
DarC DUCEATR Name: Dan Location: El Paso, Texas Join Date: Apr 2011 Motorcycle(s): RVT1000R Posts: 628	Nice work. I made one using barstock steel and I drilled it and bent it just like the ones you can buy. I then finally made one out of aluminum doing the same thing. Works great and I only needed one hanger. __________________________________________________ 2001 SP1 RC51- #62 -Akrapovic Ti, PCIII, Colin Edward's first baby tooth, Honda Racing sticker, some Japanese doods best attempt at Engrish scribbled on my engine block, little touch of soul.

September 4th, 2012, 06:18 PM	#24
iNinja ninjette.org member Name: Amy Location: PA Join Date: Mar 2012 Motorcycle(s): 2009 Ninja 250R EFI Posts: 58	did this as well. i can cut two more pieces with what i have leftover if anyone is interested.

September 5th, 2012, 04:28 AM	#25
Aufitt The A Team Name: Aufitt Location: Western Australia Join Date: Aug 2012 Motorcycle(s): Z50, CB125, RZ500, MC22, R3. Posts: 394	I made one up for my cbr from 3mm alloy. Thread on making it here- http://www.cbr250.net/forum/cbr250-a...bracket-3.html

September 5th, 2012, 04:49 AM	#26
93etgocart ninjette.org member Name: dennis Location: swmo Join Date: Mar 2012 Motorcycle(s): 2003 Honda Shadow, 2008 ninja 250 Posts: 237	it looks like it was built using knex pieces. Not horrible when painted but not my cup of tea. As a metal fabricator I would have to make some extreme mount if i decided to make a new one but for now ive just got the rear pegs taken off.

September 6th, 2012, 06:37 PM	#30
Aufitt The A Team Name: Aufitt Location: Western Australia Join Date: Aug 2012 Motorcycle(s): Z50, CB125, RZ500, MC22, R3. Posts: 394	I'll make one up for the 2013 Ninja when it arrives here and the Akrapovic goes on.

January 12th, 2013, 08:07 PM	#31
SnowMan777 ninjette.org newbie Name: Taylor Location: Yosemite Join Date: Jan 2013 Motorcycle(s): 2010 Ninja 250r Red and another 2010 Ninja 250r Red Posts: 6	I did it! Okay, This literally took me 30 minutes to cut/file/paint and install on the bike. Nothing better than saving 90% on a motorcycle part. IMAG0324.jpg IMAG0323.jpg

January 12th, 2013, 08:09 PM	#32
SnowMan777 ninjette.org newbie Name: Taylor Location: Yosemite Join Date: Jan 2013 Motorcycle(s): 2010 Ninja 250r Red and another 2010 Ninja 250r Red Posts: 6	Just wanted to make sure it would fit. Now I am going to paint the screws, nuts, and washers flat Black. Should be just fine. This will hold me over until I get a Two Bros. Exhaust

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