DIY Network

'48 Indian Motorcycle: Headers and Exhaust From "Classic Rides" episode DCLR-307

The headers and exhaust components for the '48 Indian Chief, along with all the support and trim pieces, were sent off earlier to be re-chromed. Now that the pieces are back, it's time to re-install them.

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	Fender struts and new running boards, as seen on the fully restored Indian.
	Chris and Craig install the rear fender struts on the '48 Indian.

Materials and tools:

re-chromed header, exhaust and trim
complete set of wrenches, SAE or metric
masking tape
permanent marker
hand drill

Note: This is a summary of steps included in the restoration procedures shown in this episode of Classic Rides. These are general guidelines for restoration procedures on this particular make and model of motorcycle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

Figure A
Figure B

Installing the Header, Exhaust and Fender Trim Pieces

The first step, installing the header, is actually the most difficult, so it will be good to get it out of the way. Having a helper for this part of the project is a good idea.

• The header is a compression fit into the cylinder heads, and its only securing point is a bracket down on the running board. The upper pipes of the header slide into the cylinder heads and often are a tight fit.

• Set the header in position on the right side of the bike. Push up on the two collector pipes while positioning them so they can slide into the cylinder heads.

• Once the pipes have begun to enter the cylinder heads, the nuts on the securing bracket can be put on. Tightening the nuts will push the collector pipes up and seat them in the cylinder heads.

• With the header set in place, we can move on to the exhaust pipe and the fender trim pieces.

• Since the rear fender is brand new, the first step in this process is to mark and drill the holes for the bracket in the rear fender (figures A nd B).
  

  	Installing the rear-fender strut.

• If your helper from the header pipe is still around, don't let them leave, because they'll be useful here.

• Set the lower bolt in the fender strut. (This is the piece that runs from the suspension trailing arm up to the fender.) Leave it a little loose so the strut can be moved.

• Have your helper hold the strut in its up position, and hold in place the fender surround piece. (This piece sits around the rear of the fender, essentially looking like bumper.)

• With both pieces held in place, use the sharpie to mark on both side of the rear fender where to drill the mounting hole. Once the hole is marked, the strut and surround can be set down.

• Use the drill to drill hole in the marked area of the fender, be very careful to not drill into the tire. Once the holes are drilled, we can bolt in all the struts and exhaust.

• Re-position the fender struts and surround, and on the right side, the exhaust pipe mounting bracket. With everything in place, install a bolt, lock washer, and nut on each side.

• Check that everything sits evenly and then torque the nuts.

RESOURCES :

Welders
Lincoln Electric
Website: www.lincolnelectric.com

Kiwi Indian
Website: www.kiwi-indian.com

V-Twin Mfg.
Rims, Spokes, Hubs, Tire Irons and Truing Stand
Website: www.vtwinmfg.com

Motorcycle Lift
Handy Lift
Website: www.handy-lift.com

Various Tools
Eastwood
Website: www.eastwoodco.com

Hepavac Asbestos Vacuum
Bullseye
Website: www.bullseyecorp.com

Parts Washer
Safety Kleen
Website: www.safety-kleen.com

Chrome Polish
G & H Metal Finishers
282 Dakota St.
Paterson, NJ 07503

Belt Grinder
Ellis Manufacturing
Website: www.ellissaw.com

Powder Coating Shop
Best Signs
Phone: 865-922-5247
E-mail: bestsigns@tds.net

Coker Classic White Wall Tires, Tubes and Spoke Covers
Coker Tires
Website: www.coker.com

Gaskets/Headers
James Gaskets
Website: www.jamesgaskets.com