2 into 1 exhaust header options

[HoneyBadgerRy]

I contacted area p about buying a set and they said in order to be interested in selling a pair they would need a group buy of 25 or more. Being realistic, the only option I see is doing some math, getting some pipe, and making a pair myself. Does anybody know of any other options?

[csmith12]

Whoa! If Kerry would really do another run of pregen pipes then you just might get a GB order of 25. It is kinda understood around here that AreaP will not be making any more pregen pipes.

Can you confirm that he would in FACT do a production run and sale?

[HoneyBadgerRy]

Yeah, Kerry said he would be interested if we could get a confirmed order of 25.

[Yamahawk]

Originally Posted by HoneyBadgerRy

I contacted area p about buying a set and they said in order to be interested in selling a pair they would need a group buy of 25 or more. Being realistic, the only option I see is doing some math, getting some pipe, and making a pair myself. Does anybody know of any other options?

I am going to try and use the EX300 header with some mods to make it fit the pregen 1986 I have. There is a company called Woolf Products in Romulus, Mich that sells thin wall tubing, and also bent tube in 45, 90 and 180 degree bends, in aluminum, stainless and carbon steel. It is all .065 wall tube so it would make a great start to fab up a header from. I have a 2012 EX250J header, and I have a 2013 EX300 header coming from eBay. I plan on using the larger EX300 head pipes and the collector/rear pipe from the EX250 and weld up an exhaust for the Pregen. If you want them to bend up a header, they will, 5-6 bends would be about $75, and the pipe sells for $9-$12 per foot. HOWEVER, there is a $200 set up fee for their bender... :O So, I decided if I was going to do it, the 180 bends were $28 each, and the 90 ells were $20 or so each, I thought that around $100 worth of pre bent tube would get the two header pipes done, then use the collector off of a 08-12 EX250 for the rest. It's a little work, and some welding, but hey winter is here hehe...

[HoneyBadgerRy]

In my mind two 90s and seven 45s would do the trick, but four 90s and three 45s would be cheaper and still doable. I am not sure on where to best source the pipe, and I am not the best welder, but I can weld mild steel OK.

[Yamahawk]

Check out this page, 90 and 180 bends could be cut to make the bends you need, ( two 45 ells from a 90 bend cut in the middle) and be economical for that. The 1 1/4" od tube could be what you need, $9 a foot for straight lengths. Then add a few 90 ells and a couple 180's and poof, you have the necessary pre bent and straight tube. They always add about 6" to each end of the bends, i believe also...
http://catalog.woolfaircraft.com/vie...l-bent-elbows?

Here is the carbon steel elbows...

http://catalog.woolfaircraft.com/vie...l-bent-elbows?

[HoneyBadgerRy]

So far I'm looking at $140+ for the materials for the headers, and I need to touch up on my welding stainless pipe skills. Not bad, but I would prefer to order something dyno proven. Still an option though.

[Yamahawk]

I just picked up a 2013 EX300 header for $50 on eBay, and I was given a 2012 E250 header, so I will try that and see what I can make, and adapt from those two pieces. Being the EX300 header is 28.6mm, it should flow as well as the current size pipe used on the EX250 pre gen models. I will gut the cat also, as it isn't necessary for our bikes. if I need any pipe, I can order $20 worth from Woolf Aircraft Products. I believe both headers I am going to use are stainless, and should weigh considerably less when I get done than the current exhaust/muffler setup.

[HoneyBadgerRy]

Originally Posted by Yamahawk

Being the EX300 header is 28.6mm, it should flow as well as the current size pipe used on the EX250 pre gen model.

Wouldn't you want it to flow more? I am under the impression the stock headers are pretty narrow to give more torque at cost of top end.

[Yamahawk]

yeah, maybe... but the size is larger than the current postgen header, which is 1" id and that is definitely too small for top end. I think it should be ok.

[greg737]

Whoa! If Kerry would really do another run of pregen pipes then you just might get a GB order of 25. It is kinda understood around here that AreaP will not be making any more pregen pipes.

Can you confirm that he would in FACT do a production run and sale?

I can confirm that you'll love the AreaP pre-gen exhaust. I have one from their first pre-gen production run from about 7 or 8 years ago.

High quality product, perfect fit on the bike. Many miles with no problems and the stainless steel header, mid pipe and exhaust can are still clean and beautiful.

I like the sound of my AreaP stainless steel "long quiet" exhaust canister so much I'm currently talking to Kerry about a custom long quiet canister for my Suzuki GSF400 project bike.

[Yamahawk]

Originally Posted by greg737

I can confirm that you'll love the AreaP pre-gen exhaust. I have one from their first pre-gen production run from about 7 or 8 years ago.

High quality product, perfect fit on the bike. Many miles with no problems and the stainless steel header, mid pipe and exhaust can are still clean and beautiful.

I like the sound of my AreaP stainless steel "long quiet" exhaust canister so much I'm currently talking to Kerry about a custom long quiet canister for my Suzuki GSF400 project bike.

It sounds like a very nice exhaust system, to be sure!! I would love to have one. I am curious as to what size pipe he used to make up the header pipes? I just got my EX300 header, and they are larger in diameter than the EX250 Newgen, but they are still quite small at 1 1/8". I know the larger piping will flow more, up to a point, and then there are negative gains after a certain size as the velocity is lost in the exhaust gasses... I wonder what the optimum size would be for our Pregen Ex250 header pipes?

[csmith12]

I have a pregen areap system/header hanging in my garage Charlie. I will take some measures for you. Let me know if you need anything specific.

[HoneyBadgerRy]

If you would give me inner diameter, and the length from the merge point to the exhaust port for both sides it would be much appreciated Chris.

[csmith12]

This is an AreaP full race system for a pregen.

Cobwebs add .0001 inch. lol

[csmith12]

Originally Posted by HoneyBadgerRy

If you would give me inner diameter, and the length from the merge point to the exhaust port for both sides it would be much appreciated Chris.

K, give me till tomorrow please.

[Yamahawk]

Originally Posted by csmith12

This is an AreaP full race system for a pregen.

Cobwebs add .0001 inch. lol

Hehe they do add some... ya know, it looks like the exhaust port is 1 1/2" OD, but only for the collar where the flanges are. The pipe beyond the collar looks to be smaller than that. Is that correct, Chris? Is there any way you can measure the OD of the header pipes themselves, if they indeed are smaller than the part you are measuring in the picture? Thanks, brother!

[gokartmozart]

Looks like several people are puzzled over pipe sizes, don't know exactly what a "pre gen" is , might offer to help me here. My pipe OD on my 2004 is 1.25 (1 1/4) , just got an ebay 2 into 1 that was claimed to be a 2010 250 ninja , with a pipe OD of 1" !! . OK, is this a correct pipe size for a 2010 ? my intent was to buttweld my 2004 flange ends to the 2010 header to custom make a 2 into 1 to fit my kart. It's hard to see how a pipe that small goes on a 250.

[tfkrocks]

Originally Posted by gokartmozart

Looks like several people are puzzled over pipe sizes, don't know exactly what a "pre gen" is , might offer to help me here. My pipe OD on my 2004 is 1.25 (1 1/4) , just got an ebay 2 into 1 that was claimed to be a 2010 250 ninja , with a pipe OD of 1" !! . OK, is this a correct pipe size for a 2010 ? my intent was to buttweld my 2004 flange ends to the 2010 header to custom make a 2 into 1 to fit my kart. It's hard to see how a pipe that small goes on a 250.

Pregen = 1987-2007 ninja 250
New Gen = 2008-2012 ninja 250

[Somchai]

Some information about the best exhaust in case of the Ninja 250 FI ever.
It also was good for a big power gain for the US-Carb model also, watch the vid https://www.youtube.com/watch?v=wOGOyJyWrG4

And for more technical background read the technicals I attach...
(Italians know very well how to create a powerful exhaust)

[Yamahawk]

Originally Posted by Somchai

Some information about the best exhaust in case of the Ninja 250 FI ever.
It also was good for a big power gain for the US-Carb model also, watch the vid https://www.youtube.com/watch?v=wOGOyJyWrG4

And for more technical background read the technicals I attach...
(Italians know very well how to create a powerful exhaust)

I like it. I am looking at the different sizes that the exhaust expands up to, and it kind of reminds me of a tuned exhaust chamber for a two stroke. I can see why it would give a good power increase! It seems to start at the spigot at 25.5mm, then that goes into 28mm pipe, which expands up to 35mm then down at the long run increases to 42.4mm and then up to 50mm! It would definitely flow well and give a scavenge to the cylinder for maximum combustion! Two-strokes use this principle to get the most air-fuel into and out of the combustion chamber, and they tune with the sound pulse also.... convergent and divergent cones. A 4 stroke doesn't need that too much, so the back cone isn't as necessary.

[gokartmozart]

The photo of the areaP head pipe looks VERY similar to what I thought might work for my 2004 ex250 . Will the 1'' dia pipe flow OK ? Have you completed / tested your design yet Your '86 / ex300 build sounds very much like my '04 /'10.