UPDATE-head pipe differences V1100 EV/Jackal tonti -- I know what to do!

[rodekyll]

I have several sets of head pipes from the tonti era.  I thought all the double-walled types were the same, but I find a small difference that is a hang-up on getting them installed.

The set that fits has a thick end where it goes into the head.  This acts as a 'collar'/clamping surface that the flange clamps against.  The set that does not fit looks identical, but the clamping collar is not nearly as thick.  I thought the half-circle keepers (like the half-rings on a valve stem) were supposed to make up the thickness, but after installing them with double gaskets I still can't make it clamp.  It looks like I need another 5mm or so.

Has anyone encountered this?  Is there a fix, or have I just powdercoated some pipes to waste time?

[fotoguzzi]

could there be 2 different clamps?.. the star type finned and the smooth later ones like you have..got a pic?

[Matt Story]

You could get a short length of the appropriate steel tube size and make your own to fit...

-edit-

I guess that was a bit incoherent.  What I meant was to make a longer set of keepers from the tubing.

[rodekyll]

could there be 2 different clamps?.. the star type finned and the smooth later ones like you have..got a pic?

I was trying finned ones because I like the look.  I'll take a look at my smooth ones and see if that helps.

[rodekyll]

OK -- after a little tinkering I discovered that stacking two sets of half-ring spacers fills the gap and still leaves enough head stud to properly nut down the clamp.  I have another pair of half spacers on the way, but I'm short one pair.  Does anyone have a spare pair kicking around?

[Orange Guzzi]

Last night, I was doing a little tinkering in the garage.  I found that there are two types of clamp spacers in my box of stuff.  One was about 1/2 inch and machined s.s. steel.  I think it came off a sport 1100, the others were about 3/4 inch and came off a square fin California, made from stamped carbon steel. 

One thing I noticed is the clamps, both sets would not fit inside the smooth clamp recess when mounted on the pipe.  They would fit inside the clamp when it was not mounted on the pipe.  Also, the recess inside the clamp was not round.  The spacers would fit when place in one location and not fit when move around 90 degrees.  I sanded the flanged area of the clamp spacers so they would fit into the recess at any position. 

What brought this to my attention was the lip on one of the clamp spacers was bent from previously mounting and not falling into the recess. 

You may try adding an extra exhaust gasket if the clamps do not pull up tight. 

[rodekyll]

Yes, I am seeing some differences in the spacer forms.  Neither of the two sizes are working for me (with finned clamps).  I had stuffed three crush rings into the exh port and still didn't like the clamping.  It looks like it would take maybe five to give the spacing.  Stacking the spacers seems like the way to go.  If anyone is looking -- it's the stainless machined half-round spacers.

[Orange Guzzi]

The s.s are to short.  Look in your box of stuff for the right ones.

[rodekyll]

I bought the pipes bare without any hardware as low-mile takeoffs.  So there never were compatible spacers.  I'm compounding the problem by using finned clamps instead of the smooth ones that probably fit.  My problem is that I did not anticpate the huge difference in flange thickness.

Part of my desire to use this stuff is that I've powdercoated the finned clamps and head/crossover pipes.  It's an experiment answer whether or not hi-temp powder is up to the job.