de-rusting a full exhaust (inside and out?)

[Rema1000]

I picked-up an almost-rustfree exhaust from a junkyard.  It had been removed, then put back on the frame, but not bolted-on.  About the only rust I can see is on the faces of the header-ends, where it would meet the block; this part was able to get rusty because it had been unscrewed from the block and left that way.

I'm wondering if there might be rust inside the exhaust pipe, from sitting open like that.  Do you think I should pour some phosphoric acid, or one of the one-step etching-solution/primer products like RustReformer/POR-15/Oxysolv/Coroless down the header and roll it around a bit?  I was planning to buy some anyways to use as a primer on the outside of the tube (I had great results on a car that way), and can't think of what would be any different between the outside and inside of the exhaust (except not wanting to clog the perforations inside the silencer can).  Anybody comment on the best phosphoric-acid product to use on an exhaust system?  And any problems using it also on the inside of the pipe?

Also, anybody tried using 1200 deg. aluminum paint to give a shiny look, instead of the usual flat-black 1200 deg. paint?

[Jared]

I wouldn't bother with the inside. If you etch it then coat it... I think the exhaust temps would just burn off whatever you used in there anyway.

Clean up the outside to your liking - bolt it on - and ride.

[Black Snowman]

I picked up a Yosh exhaust used that had been sitting outside for 3 years and was rusted inside and out, but fortunately, not throught. I sanded and wire-brushed it down, did a little sand-blasting on it and painted it with High-temp Rustolium silver and it hasn't given me grief yet.

[sprint_9]

I would bet that almost all exhausts out there have rust on the inside of them. As long as you cant see a hole bolt it on and ride.

[JamesG]

IF you have the dough, there are companies that will clean up and coat the insides and out with an insulating coating that both stops corrosion and inproves flow.

[Rashad]

ceramic coating inside and out would work. I have rusty orange pipes.. and i love them! :nana: Stupid V&H engineers....shoulda ceramic coated her.

[Black Snowman]

I was thinking about having Jet-Hot coat mine and I still may. It's about $100 or so I believe. They clean them off and do their magic. I only payed $100 for my exhaust and so for now settled on a $9 rattle can.

[Rema1000]

OK, sounds like I was being too concerned.  I'll do the rattle can for-now; I can always pull it off and redo at the next sign of rust (maybe when I'm bored in March, waiting for spring).  My main concern is that parts are getting a bit hard to find now, and I'd hate to have to go custom and rejet just 'cause I let my stock exhaust rust away.

Now, about the gaskets between the pipe header and block (part number 1 on http://www.bikebandit.com/partsbandit/showschematic.asp?dept_id=137706): my Haynes says to replace 'em, but BikeBandit lists them as out-of-production and out-of-stock.  

I was thinking of trying to keep the old gaskets, but put some exhaust sealant putty inside the flanges to try and stop leaks (it's a putty that hardens like sandstone once iit's been heat-cured).  Anybody guess if that's doomed to failure, or of some current-production bike with the same size exhaust header gaskets?

[Black Snowman]

They replaced that gasket with a new part # I think. I was able to pick up the exhaust gaskets from the local shop.

[yamahonkawazuki]

go to any suzuki shop. around here i was quoted 2.84/ea. after tax.  

[JamesG]

Get new exhaust seals they aren't that expensive. IF you HAVE to be a cheapskate, use ultra hi temp RTV rubber. Don't use anything that cures hard.
Not only will it make removing the header a PITA, but the heat contraction and expansion has the potential to  crack the head around the exhaust ports.  And that would suck...

[yamahonkawazuki]

yeah, i ordered those along with headlight ring/s, tires, front brake lever, and a whole bunch of other stuff today. i went ahead and got two seals, cause if i am goin to pull the exhaust, i might as well replace them both, besides they are inexpensive anyhoo.  

[yamahonkawazuki]

part number for exhaust gaskets are 09280-40010

[The Buddha]

Jet hot or ceramic etc cracks and chips easy and then the rust spreads under it like a subterranean fungus. Sand and paint every other year or as needed (which I think in NC means every 2 months). Stainless steel pipes are the only kind that dont rust. Chrome peels, paint wears off...Insides will not have much rust if the bike is ridden. If storing it get it running nice and hot and as soon as you shut it off stuff a rag into the pipe.
Cool.
Srinath.