Hi, nearing the stage of cutting the hole in my side panel for my R1 exhaust. I have made a template out of card and just wondered what others have
done and your opinions on what i have so far
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Also to save starting a new topic, What nuts should i use to attach the exhaust to the engine studs? Do i just use normal nuts and threadlock as im
thinking nylocs will just melt with the heat.
Also should the nuts in the pic below be tightend until the two surfaces meet flush?
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Thanks and sorry for all the questions
no need for thread lock on the exhaust bolts, i replaced my std exhaust stds with stainless ones, i just used a split washer and stainless nut to
attach my exhaust,
your hole looks neat and tidy, remember to leave plenty of room to fit some rubber edging to finish it off.
just my 2p's worth
[Edited on 26/10/09 by omega0684]
Looks good to me.
On my car, I chose to cut a large rectangle out and use a piece of ali sheet to panel it back in, trimmed close to the exhaust similar to yours.
That means I now have an access panel to the engine and can remove the manifold the easy way if needed.
Hi
You may wish to see if the manifold can be removed through the hole.
I did some work on a cross flow locost once and the hole looked ample.
Could I get the damn thing out? Twisted it one way, then the other, could I hell.
I think the phrase is "O for another half inch." 
Paul G
Have you put ali panels in the inside of the engine bay?
ETA - and on a bec! Think of the extra weight
[Edited on 27-10-09 by speedyxjs]
Looks OK to me... for the edge of the hole, you could do what I did: make a template out of plywood, with the hole the same size as you want it to end
up. The cut a hole in the ali a cm or so smaller all round. Place it on the plywood, clamp in place, and tap over the edge with a rubber mallet. Once
the hammered edge isd at 90 degrees, removed the wood and tap over a bit more to make a slight return.
Hey presto, no rubber trim to potentially melt, and nice curved edge safely out of the way of IVA man's ball
I agree with 907 ^^^ checking if you can remove manifold through hole.
On the subjecyt of :-
Also should the nuts in the pic below be tightend until the two surfaces meet flush?
The answer is no just keep them parallel to the face when tight.
If you can get the hole in the Ali panel as neat as the one in card the should look really good.
RD 
Iv'e used the standard nuts from Yamaha only cost a few quid.
Hole looks OK.
For the nuts get some Exhaust specific copper coated lock nuts. They have the end slightly piened over to stop then coming undone. A good motor factor
should have them, but if you get stuck, I keep a bag in stock and I'll stick some in the post.
adrian
Cheers guys just what i needed to hear to pluck up the courage to make a big hole in my side panel!!
quote:
Have you put ali panels in the inside of the engine bay?