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Thread: Exhaust rust removal and coating

  1. #1
    Rusted Vijay1911's Avatar
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    Default Karizma R's Rusted Silencer/Exhaust Pipe - Sanding, Repaint

    About four years back, the rust in the silencer pipe of my ZMA near the bends started to surface. It had just started then, later over the years it grew significantly no matter how much I take care to limit its expansion (by that I meant not to drive in watery area as much as possible). I did not like it at all, as it was screwing ZMA's look. I have noticed in many ZMA's (and on many other manufacturer motorcycles too), that this problem was there and nobody was willing to give a damn.
    So, my aim was to clear it and repaint it and look good. It can be helpful to someone if that person can spare few hours. After completing it, I can say that it's not that much tedious as it looks, just a little effort.

    PRECATIONS: This work must be done in water free environment, little ventilated area.

    TOOLS:

    1. T Spanners/T Handle wrench. [Sizes: 10, 12 and 14] It can be obtain from the machinery hardware tools shops. These shops are located near the shops which sell the submersible motors, motors for deep wells/bore wells.
    2. Open End Spanner/Wrench [Sizes: 08 and 10]. It also can be obtained from the machinery hardware tools shops.
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    3. Sandpapers. These can be obtained from the wall paint shops. They have many variety and are very less expensive.
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    4. Spray Colour Can a.k.a. Stove paint. It is very much important that one should buy the paint that is HIGH HEAT RESISTANCE spray colour. I bought it from online retailer Amazon.in for ₹ 385 of colour matt black (400 ml can).
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    5. Allen key [Size: 4], to remove the golden / silver cover of silencer.
    6. Some old newspapers.

    PROCEDURE:

    NOTE: The picture shown were not taken according to the steps explained in the order below. Many pictures were taken after finishing the paint-job and refitting of the silencer pipe was done. I request to ignore this error of pictures.

    STEPS:

    I have preferred to use T handle Wrench/ T spanner for easy access where open end spanners are tough to operate in less spaced places..

    I. REMOVAL OF ENGINE COWL:

    Since the screws on the cowl were not coming out easily and in fear of damaging them, I decided to remove the engine cowl completely. Here are the steps.

    1. Loose and Remove the bolts completely shown in the picture using T Spanner (Size:12).
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    2. Only Loose the yellow circled bolt using Open End Spanner/Wrench (Size:10). Do not remove this bolt completely, it should be loose only that much, so that the curved plate (highlighted in RED) can be suspended freely with the help of the bolt and will not affect the removal of cowl.
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    3. Here, I had used Open end spanner (Size:10) to loose the bolt. After it gets loosen up, I used T spanner (Size:10) to remove it completely.
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    4. Same procedure as Step 3.
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    After these 4 steps the engine cowl comes out easily, one just have to pull it appropriately.

    II. REMOVAL OF SILENCER/EXHAUST PIPE:

    1. Firstly, Only Loose the bolts shown in yellow circles using T Spanner (Size:10).
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    2. Same as step 1, Only Loose the bolt for now. Do not remove the bolts completely.
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    3. Remove the bolt completely using the T Spanner (Size:14).
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    4. Then, remove the bolt completely above the silencer cover/muffler using T Spanner (Size:14).
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    5. Now, remove the bolts completely from steps 1 and 2. The Silencer will sit there without any bolts need to hold in its position. Few shaking and hand pushes at the rear end of the silencer can loosen it up and push the silencer from the back to the direction shown, it will come out. Taking someone's help for hand push from the rear of silencer in this step will ease this step.
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    The silencer will be removed after these steps.

    IMPORTANT NOTE: Using a cloth piece, close/cover the exhaust hole in the cylinder head of engine, so that nothing goes inside the cylinder through that exhaust hole.

    III. REMOVAL OF CHROME/GOLDEN EXHAUST COVER/MUFFLER:

    I was able to remove outer muffler easily using the Open End spanner (Size:8) on the yellow circled nuts shown in the picture.

    1. Remove the 5 Allen bolts using Allen key (Size:4). Pull out the rear cover
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    2. To remove the inner muffler, I had to open the two Allen bolts. I tried to remove the Allen bolts using the Allen Keys (Size: 4).
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    The Allen nuts were so tight, may be they rusted from inside and jammed up, I broke an Allen key by putting too much pressure. After too many failure attempts, I decided to let the inner muffler be there. I will cover it up with plastic before spray painting.

    Need to clean the silencer, so that all the dust gets removed.

    After cleaning it looks like as shown in picture. One can see the rusted part along the bends and in some new areas too.
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    Above picture is brighten to show the rusted portion.

    IV. SANDING OF SILENCER/EXHAUST:

    Before buying the sandpapers, there are two thing to remember:
    1. Lower the sandpaper number, Rougher the grits will be.
    2. Higher the sandpaper number, Smoother the grits will be.

    This means lower number sandpapers are best suited for removing the paint from the surface with lesser efforts. And higher number sandpapers are best suited for polishing/smoothing the surface that was made uneven by lower number sandpapers.

    I used sandpaper number 100 to remove paint from silencer. Then, sandpaper number 150 to smother the surface. Then, I used sandpaper number 320 to smooth even more. And finally, I used sandpaper number 600 to finalize the super smoothing the surface.

    One more thing, Sanding must be done in one direction, either vertical or horizontal for proper sanding from the surface. I chose to vertical method as the pipe was cylindrical and with this method I used lesser effort to remove the paint from more area. In corners or closed places, one can select any method. This is for proper finishing on the pipe.
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    1. Place a newspaper below the silencer, so that it the place surrounding the sanding are does not get dirty. Put cloth inside the Exhaust inlet of exhaust pipe.

    2. Cut a small piece from the leaflet of sandpaper. Start Rubbing that piece of sandpaper on the metal surface by decided method and keep rubbing until the bare metal past the rust is seen. Do not just rub on the rusted part cover area around the rusted part. Keep even pressure on the sand paper for both rusted and non rusted part as one would want an even surface.
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    3. The scratches vertical on the metal surface can be seen.
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    This how the exhaust pipe looks after all sanding and polishing.
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    IMPORTANT NOTE: After polishing, care must be taken that, water does not come in contact with the polished surface, as it will lead possibility of rust formation again.

    V. SPRAY PANTING:

    Since I was not able to remove the inner muffler, I covered it with the plastic bags and stick it with duct tapes. (This is the first time I am using the spray paint, being cautious I used papers on walls. But it was not necessary to use it if we control the flow of spray.)
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    Before spraying the paint to polished surface, it is better to use Primer coat as it provides proper base to the paint. But I decided to skip this step as I did not find High Temperature Primer coat at that time.

    Now for spraying the paint, I would suggest to look at this video as it provides basic idea regarding getting a even coating of spray paint.



    One simple way is to use multiple light coats than single heavy coat.

    I did a single coat three times. Time between every spray coats was 30 minutes. Single coat of spray takes about five minutes to dry. This is the silencer after 3 coats of spray painting.
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    It is not necessary to hang the Silencer like I did, I did it for completer access to everyplace. It can be done by placing it on few newspapers on ground.

    Just to show how rusting has affected the metal surface, surface above line was affected by rust than polished surface below the line.
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    Let it dry for about an hour, and then fit it again as removed from the ZMA.

    Follow these steps to fit it again on the bike.
    1. SECTION III : Step 2 > Step 1.
    2. SECTION II : Step 5 > Step 4 > Step 3 > Step 2 > Step1.
    3. SECTION I : Step 4 > Step 3 > Step 2 > Step1.

    After fitting the silencer on ZMA looks like this.
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    FOLLOW UP NOTE: I will update the condition of the paint after few months, till then it will be tested.

    PS: This is my first post in DIY section, I tried it to be as simple as possible. Some pictures got rotated here, I took those in portrait mode here they are shown in landscape mode.
    Last edited by The Monk; 4 Weeks Ago at 06:05 PM. Reason: Video Format settled in post

  2. #2
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    Default Re: Karizma R's Rusted Silencer/Exhaust Pipe - Sanding, Repaint

    DIY Approved
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    Default Re: Karizma R's Rusted Silencer/Exhaust Pipe - Sanding, Repaint

    Good work mate

    For removing bolts/nuts which are rusted. Please spray with WD40 and allow it to seep in fully. Let it rest for about 5-10 mins and slightly tap the bolt with a small hammer. Then try opening the bolt with a ring/ box spanner.

    Cheers

    Mathews
    srikany and Vijay1911 like this.

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    Default Re: Karizma R's Rusted Silencer/Exhaust Pipe - Sanding, Repaint

    Primer coating is highly recommended as Paint wont stick to metal so perfectly and will come out very easily. Primer coating will prevent the metal from rusting and paint finishing and quality will be good.
    Vijay1911 and accuengineer like this.
    Happy & Safe Riding to All

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    Default Re: Karizma R's Rusted Silencer/Exhaust Pipe - Sanding, Repaint

    Quote Originally Posted by accuengineer View Post
    Good work mate

    For removing bolts/nuts which are rusted. Please spray with WD40 and allow it to seep in fully. Let it rest for about 5-10 mins and slightly tap the bolt with a small hammer. Then try opening the bolt with a ring/ box spanner.

    Cheers

    Mathews
    Quote Originally Posted by vimalnair4u View Post
    Primer coating is highly recommended as Paint wont stick to metal so perfectly and will come out very easily. Primer coating will prevent the metal from rusting and paint finishing and quality will be good.
    I will keep both things in mind for future works.

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    Default Re: Karizma R's Rusted Silencer/Exhaust Pipe - Sanding, Repaint

    No updates of the aftermath of use... Waiting for an update.

  7. #7
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    Default Exhaust rust removal and coating

    Hi frnds, good morning. I wanted to share this but there are many of you who may have faced this issue often. Motorcycle exhausts getting rusty. It is really annoying to see motorcycle exhaust pipe rusted and it ruins the looks of your bike. I own karizma r 2014 and even my exhaust was rusted as bike emits lot of heat.

    I looked for many options available in market, e.g. chrome plating, ceramic coating.
    Option 1: Chrome plating certainly dont really work well with a metal pipe unDer high heat, and also dosnt suit with modern bikes which have engine in black colour.
    Option 2 : Ceramic coating, which i find very helpfull but skills and materials used specially for exhaust pipes will cost you a lot and it is very rare to find some one who will actually do it for a single purpose as generally these are the small/medium size factories who have there fixed buisness working on boilers on industrial appliances, so they wont entertain.
    Local painter dont have any clue what should be used for ceramic coating and how heat treatmemt needs to be done. When i painted my exhaust with ceeamic coatin through a local painter, paint was just vanished in the air as I started engine on ideal only in 5 miniutes, while some others where managed to hold on for atleast a day or two.
    So coming to the point, this is all you need.
    1. Rusted exhaust

    2. Sand paper (80grit, 140 grit)

    3. Rust removing chemical (Rustoleum) 120rs per litre

    4. Bosney high temp paint (HI1200,matt black,1200 fahrenheit) 350 rs

    【NOTE : DO NOT USE WATER ANYWHERE】
    Procedure :
    1. Use 80 grit sand paper to remove rust on large surface. Use 140 grit sand paper to get rusts in corners and joints. Objective is to remove surface rust anyhow. Do not use water to clean the pipe, just wipe it with dry cloth which will clean remaing red colour dust. Be patient, take time to clean pipe thoroughly.
    2. Take a cloth and and deep it in rustolem chemical and wipe the exhaust clean, dont worry it will not cause any damage to skin(confirm this from the store you will purchase, generally available at local paint supplier)
    3. Once exhaust is cleaned just to remove complete rust take a big cloth soked in chemical and use it to completely wrap the exhaust, and keep it as it is for atleast 1 hour.

    After one hour use scotch bright to rub the exhaust with chemical and then wipe off all chemical.
    4. Keep the exhaust to dry in sunlight just hanging in air (keeping on floor can case dust partical to stick on it, and keeping inside a closed room will not let it dry quickly)

    5. Time to test your painting skills
    Hold spray can atleast 1 foot away and start painting exhaust in single direction. Dont apply too thick coat in first attempt

    Let the first coat dry for atleast 20 miniutes. If you miss out any spot dont worry you have 2 more coats to do with 20 miniutes interval each time. I did it in broad daylight so paint was dry enough in 10 miniutes but yet waited for 20 miniutes each time.
    【NOTE: DO NOT APPLY ANY PRIMER】
    6. CURING PAINT :
    Now attach your exhaust on bike and start the engine, and keep it running on ideal for 10 miniutes. As the heat builds up paint will start giving some white smoke and smell of burning. Do not tempt to rev engine. After 10 miniute stop the engine amd let the pipe cool off for 20 miniutes. Follow same pattern for two more times.

    You are now good to go if you follow curing procedure correctly. Its also important that dont let any oil drops fall on exhaust while doing services to your bike, if there is any oil just clean it with cloth before starting engine.
    Please let me know if this helped you. Its been now almost 1 month and my paint is not fading away.

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    Default Re: Exhaust rust removal and coating

    Quote Originally Posted by Abhi303 View Post
    Hi frnds, good morning. I wanted to share this but there are many of you who may have faced this issue often. Motorcycle exhausts getting rusty. It is really annoying to see motorcycle exhaust pipe rusted and it ruins the looks of your bike. I own karizma r 2014 and even my exhaust was rusted as bike emits lot of heat.



    .....
    Please let me know if this helped you. Its been now almost 1 month and my paint is not fading away.
    Hi Abhi,

    Thanks a lot for detailed step by step rust removal technique. My Unicorn's exhaust has started to rust(very small area as of now), I shall try your technique to prevent rust protruding to other areas.

    Can you post the link for Bosny paint( if its a online purchase)?

    Cheers!
    Last edited by The Monk; 4 Weeks Ago at 06:01 PM. Reason: Please don't quote all the pictures. Thanks

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    Default Re: Exhaust rust removal and coating

    Quote Originally Posted by Abhi303 View Post
    Hi frnds, good morning. I wanted to share this but there are many of you who may have faced this issue often. Motorcycle exhausts getting rusty. It is really annoying to see motorcycle exhaust pipe rusted and it ruins the looks of your bike. I own karizma r 2014 and even my exhaust was rusted as bike emits lot of heat.

    I looked for many options available in market, e.g. chrome plating, ceramic coating.
    Option 1: Chrome plating certainly dont really work well with a metal pipe unDer high heat, and also dosnt suit with modern bikes which have engine in black colour.
    Option 2 : Ceramic coating, which i find very helpfull but skills and materials used specially for exhaust pipes will cost you a lot and it is very rare to find some one who will actually do it for a single purpose as generally these are the small/medium size factories who have there fixed buisness working on boilers on industrial appliances, so they wont entertain.
    Local painter dont have any clue what should be used for ceramic coating and how heat treatmemt needs to be done. When i painted my exhaust with ceeamic coatin through a local painter, paint was just vanished in the air as I started engine on ideal only in 5 miniutes, while some others where managed to hold on for atleast a day or two.
    So coming to the point, this is all you need.
    1. Rusted exhaust

    2. Sand paper (80grit, 140 grit)

    3. Rust removing chemical (Rustoleum) 120rs per litre

    4. Bosney high temp paint (HI1200,matt black,1200 fahrenheit) 350 rs

    【NOTE : DO NOT USE WATER ANYWHERE】
    Procedure :
    1. Use 80 grit sand paper to remove rust on large surface. Use 140 grit sand paper to get rusts in corners and joints. Objective is to remove surface rust anyhow. Do not use water to clean the pipe, just wipe it with dry cloth which will clean remaing red colour dust. Be patient, take time to clean pipe thoroughly.
    2. Take a cloth and and deep it in rustolem chemical and wipe the exhaust clean, dont worry it will not cause any damage to skin(confirm this from the store you will purchase, generally available at local paint supplier)
    3. Once exhaust is cleaned just to remove complete rust take a big cloth soked in chemical and use it to completely wrap the exhaust, and keep it as it is for atleast 1 hour.

    After one hour use scotch bright to rub the exhaust with chemical and then wipe off all chemical.
    4. Keep the exhaust to dry in sunlight just hanging in air (keeping on floor can case dust partical to stick on it, and keeping inside a closed room will not let it dry quickly)

    5. Time to test your painting skills
    Hold spray can atleast 1 foot away and start painting exhaust in single direction. Dont apply too thick coat in first attempt

    Let the first coat dry for atleast 20 miniutes. If you miss out any spot dont worry you have 2 more coats to do with 20 miniutes interval each time. I did it in broad daylight so paint was dry enough in 10 miniutes but yet waited for 20 miniutes each time.
    【NOTE: DO NOT APPLY ANY PRIMER】
    6. CURING PAINT :
    Now attach your exhaust on bike and start the engine, and keep it running on ideal for 10 miniutes. As the heat builds up paint will start giving some white smoke and smell of burning. Do not tempt to rev engine. After 10 miniute stop the engine amd let the pipe cool off for 20 miniutes. Follow same pattern for two more times.

    You are now good to go if you follow curing procedure correctly. Its also important that dont let any oil drops fall on exhaust while doing services to your bike, if there is any oil just clean it with cloth before starting engine.
    Please let me know if this helped you. Its been now almost 1 month and my paint is not fading away.
    Any online link for that "Rustoleum" product ?

  10. #10
    Rookie Abhi303's Avatar
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    Default

    Quote Originally Posted by bobisbacktorock View Post
    Any online link for that "Rustoleum" product ?
    I dont know about online link, but i found it at a local industrial paint dealer who had it and it was his suggestion. Its generally sold in minimum 1 litre plastic container without any brandname. They pronounced it as "rustoleum"

    Quote Originally Posted by bobisbacktorock View Post
    No updates of the aftermath of use... Waiting for an update.
    I did not read the original thread before posting my

    Quote Originally Posted by vdarshan View Post
    Hi Abhi,

    Thanks a lot for detailed step by step rust removal technique. My Unicorn's exhaust has started to rust(very small area as of now), I shall try your technique to prevent rust protruding to other areas.

    Can you post the link for Bosny paint( if its a online purchase)?

    Cheers!
    Check for bosney hi1200, thats the matt black paint, i got it from a local stationary shop who keep all types of spray paints, but he ordered it for me on my request. They will have catlougue but they wont disclose dealer. You may get this on amazon directly but its sold for 550 rs approx online, and in shop u will get for less than 350 rs

    Quote Originally Posted by bobisbacktorock View Post
    Any online link for that "Rustoleum" product ?
    Its is available in local paint dealers/wholesalers. They usually order it in bulk and sell in minimum 1 litre pack. There was no branding on it. Its makes foam like handwash when rubbed on rusted metal. And it does not effect your skin so directly apply it using cloath.
    I will provide you more detail if required only if i get time from office work 😅
    Last edited by The Monk; 4 Weeks Ago at 06:02 PM. Reason: Consecutive posts

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