Moto Guzzi 850 Café Racer – Custom Exhaust Fabrication

The Moto Guzzi 850 café racer build continues with a custom exhaust fabrication project, transforming the original exhaust system into a simpler, cleaner setup while retaining the original down pipes and H-pipe.

The large original mufflers are removed and replaced with new tail pipe sections to give the classic Moto Guzzi a more purposeful custom motorcycle appearance.

This stage of the build covers cleaning and preparing the original exhaust down pipes, removing surface rust and grime, painting the pipes matte black and preparing the original H-pipe for reassembly. New tail pipes and finned exhaust clamp connectors are then fitted to create the rear section of the custom exhaust.

I originally planned to wrap the final section of the exhaust, but instead used flexible exhaust sleeve material to join and clamp the various pieces together. The episode also covers cleaning parts with a sonic parts cleaner, using a wire brush drill attachment to remove stubborn grime and corrosion, and painting the finned exhaust clamps with red engine enamel.

The result is a substantially simpler custom exhaust system ready to go back onto the Moto Guzzi 850 café racer. The original mufflers and other unwanted parts will be sold on eBay as part of the ongoing strategy of recovering some of the cost of this custom motorcycle build.

This Moto Guzzi 850T project is being built from the ground up as a distinctive café racer, with each stage covering a different part of the motorcycle's transformation — from frame modifications and controls to the fuel system, oil lines, exhaust and eventually the finishing details.