BSA Gold Flash exhaust repairs

BSA Gold flash exhaust repairs. 

Nick came to me as his exhaust on his BSA gold flash has started to exhibit holes around the cross tube at the mounting points to the head.

We removed the old T and prepared a 2 new ones and a new cross pipe, and endeavoured to weld and tack in a temp jig using dimensions as Nick had the bike at home, this as we found did not ensure the correct geometry. As above we first tried to repair the T joints off the bike with a new cross tube, but we had to in the end due to the bike being at Nick and not in the workshop use some unorthodox methods.

We actual aligned and used strong tape and ensured the angles matched from the tubes across the front of the bike onto the other down pipe, and I took this back to the workshop.

We then set the exhaust up on the table and made a temp jig to hold them in the correct position were we then removed a small circle of tape and tacked the tube in 3 places to keep the required geometry of the down pipes, and T piece to the head.

We then checked the fit on the bike, and success, so we fully welded the pipes and cleaned up the welds and used chrome spray for this year to allow Nick to use the bike, success!