How to Build a Custom Motorcycle Exhaust

A custom exhaust can completely change the look, sound and character of a cafe racer or custom motorcycle. But building one doesn't necessarily mean starting from scratch with a welder. There are plenty of ways to modify an existing system, combine aftermarket components or create a custom exhaust using readily available parts.

In this Workshop guide, we look at several approaches to custom motorcycle exhausts, from fitting an aftermarket Delkevic system to a Honda CB750 through to modifying exhausts on motorcycles including MV Agusta and Ducati. We also look at creating custom exhaust systems for Kawasaki and Moto Guzzi cafe racer projects.

Planning the exhaust route is particularly important on a custom motorcycle. Clearance around the frame, foot controls, suspension, engine and bodywork all needs to be considered, along with pipe diameter, muffler placement, mounting points and heat management.

You don't necessarily need a fully fabricated exhaust to get a custom result either. Combining existing components, modifying mufflers and using flexible exhaust sections can provide practical alternatives to welding an entire system. The right approach depends on the motorcycle, the desired appearance and sound, your fabrication skills and your budget.

Whether you're building a cafe racer from scratch or simply looking to improve the exhaust on an existing motorcycle, this guide covers some of the options and considerations involved in creating a custom exhaust.