Bobber Rebuild: Panhead Exhaust Install

Kevin Baas has the oil lines wrapped up and is ready to install the front and rear Panhead exhaust pipes. Before doing so, he will install the clutch release lever while he can still easily access the area. The clutch release arm is mounted onto the shaft that extends out through the top of the clutch/transmission end cover. Kevin secures it with a chrome flat washer and a nylock-style locking nut.

Both front and rear Panhead exhaust head pipes fit snugly over the exhaust output ports on their corresponding heads. Exhaust gaskets are not used. This is meant to be a snug fit. The head pipes are secured with circular squeeze style clamps which are tightened with a 5/16″ bolt and locking nut. The front head pipe is fitted over what is most commonly known as the squish pipe. This pipe section has an area which is narrow and flat. Hence its name; squish pipe. This pipe needs to be narrow in order to fit in between the motorcycle’s frame and the bottom, right side of the motor case and cam cover.

There is a midpoint mounting bracket on the squish pipe that mounts to a frame tab near the crossover tube for the rear brake. This is also the mounting point for the mechanical rear brake switch. The rearmost section of pipe, for both front and rear Panhead exhaust, is mounted to a frame welded bracket. It is best to loosely install all exhaust mounting hardware prior to tightening any one area.

Once all hardware is correctly installed, tightening should begin at the heads and continue on to the rearmost mounting point. Always tighten Panhead exhaust systems from front to rear. With the Panhead exhaust system wrapped up, Kevin will be able to install the kicker arm.

Next up, Kevin will move to the left side of the Bobber and begin installing the primary drive and clutch assemblies.

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