Having done the deed....
- Drop the header off the bike. When you do this you will need new gaskets for the head attachment.
- Sand off the obvious bad areas and rusty junk with rough sand paper or a sanding spong works good.
- Coat the "cleaned" up header with this stuff ----
http://www.thermotec...at-coating.html
- An alternate may be the "jet hot" coating approach, but I dont have experience with it.
- The coating air dries but optimum would be to bake it a about 350 degrees.
- Themotec has a wide variaty of wraps to use. -- I think I used this stuff ---
http://www.thermotec...hite-black.html
- I thought the clips I bought from thermo tec were junk - I just hauled down to AutoZone and bought a bunch of radiator clamps.
- The wrap is supposed to be damp when you wrap it around the pipes, I found the easiest way was to lay out a strip on the floor and hand spray water on it with a left over spray bottle.
- Once you have the thing all wrapped up, you need to let completely dry out for a couple days, warm and indoors prefered.
- Once the wrap is dry, you have to go another round with the super coating stuff ----
http://www.thermotec...at-coating.html
- Do a few light coats and let dry, and then go for a nasty heavy coat with the stuff and maybe 2. - I wouldnt do the wrap thing without the coating step.
- If you can do another oven bake, (maybe a powder coat guy would have one?) you will be ahead of the game.
- When you get it reassembled on the bike, it will first smoke to high heaven. I did quite a few, start up, warm up, shut down, wait 20 minute cycles.
- When you have had enuff of that and get on the road, its still gonna stink. I just takes time for it to go to a final cure. Jeez, I did mine 4 years ago and once in a while I still get a whiff.
Well thats the poop. I'm not saying this is the optimum, but just my experience. -- Some here will throw out concerns of pipe rusting early or metal fatique on the header material. That is totally possible, but if it happens, just replace the pipe. If it happens to me, I'm fine with it.
-So far so good, I like it.
Good luck