D.G. header

After 3 years of procrastination I finally broke down and bought a new D.G. header, to replace my original 33yr old one. Should go without saying, I was "fairly" excited as I removed all the gleaming Chrome from the box. First thing I did was treat the inside of the 6 pipes with "Eastwood Internal Ceramic Coating". (Another topic)This coating dries FAST, so was soon starting to install the pipes. This is where the shit started and never stopped ! None of the header pipes would fit into the cylinder-head. The flanges diameter were too large ! Now at this point some would have sent the whole system back to D.G.I on the other hand decided I could reduce the flange diameter with a Dremel and stone.....so I did and got them all to fit. I'll estimate the flange diameter was reduced approx. .025" to .030". Problem solved. A note here: With 33 yrs. of previous experience re & re'ing my original D.G. numerous times I found an easier way of installing the system. With all six pipes in the head and the collar nuts "snugged", I grouped the 6 pipes together as they would be in the Collector. I slid the Collector/Muffler assembly thru the center-stand and got down on the floor to insert the pipes. Another W.T. F. moment when I discovered the pipes were different lengths ! ? All 6 pipes should insert into the Collector a measured 1.375". The varying lengths meant that the longest ones would seat before the shortest, leaving the shortest inserted by a mere 1/2". Again: Most would have sent the entire system back to D. G. however the solution was simple enough so after buying an appropriate size tubing cutter I trimmed the longest 3 pipes to match the remaining 3 which were the same length. Another issue solved ! With the pipes back on, now loose at the collars, I started to install them into the Collector. A trick I use to aid in this is to suspend the muffler at it's approximate height with a bungee cord. This gives lots of movement at the Collector-end to make the pipe insertion significantly easier. I got 3 pipes installed and everything came to a halt. I could not get a 4th pipe installed and realized that there was virtually no movement from the suspended muffler. The muffler was jammed against the differential. There was nothing I could do to resolve this. I then took my old collector/muffler and slid it thru the center-stand and - guess what ? It fit perfectly ! I put the both muffler assemblies on the bench and the issue was a no-brainer. The NEW assembly was assembled and welded out of the correct orientation. As if no jig had been used !I sent an email with photos and got a quick response.

---

So we are going to send you a new rear section with no hassle on sending the one you currently　back, you can keep it, disregard it whatever may be. Thing is we will need to make this rear section since we are out of stock of the kz1300 pipes. So it will be ready in a week but we will take it to get it chromed and that usually takes 1-2 weeks,　the rear section should be ready by the end of March and beginning　of April.　Hopefully this is okay and you do not mind the wait. We will try to get this done ASAP!　

---

　2 weeks goes by and nothing from D.G. so send an other email requesting an update. And I wait...........In the mean time, I decide to remove the finger-prints from the pipes and see a flaw in the chrome on #6 pipe. It's so obvious as to how this occurred, its PAINFULL. At some point in the production this pipe has been dropped on a rough surface a received pitting. In someone's infinite wisdom they attempted to sand-out these pits. THEN; instead of polishing-out the sanding marks they simply chromed over them. Now, realizing the sanding marks and pits were now "highlighted" they attempted to polish them out and in doing so polished thru the chrome down to the base layer of Nickel ! ANOTHER email; this time requesting a new #6 pipe. And I wait. I sent another email a week later asking for an update and received a response.

---

Hey Bob,We have your muffler done but it just at the moment we do not have a platter, the one we hadrecently　just closed. My production manager is trying to get a new local platter since a lot of them are not very local. I will　email or call you when I get a better update next week!-DG Performance Sales

---

And I wait. 10 days later I send another email requesting an update.

---

Hi Bob,I sincerely apologize for the delay in response. My name is Abigail and I'll be taking care of your order from now　on. We recently had changes in staffing and had to let go of the employee that was previously　handling your order due to　errors like this.I just caught up with your past emails and I'll be speaking with our team today about this. I'll get an updated shipping date estimate to you　ASAP.　Once again, we are truly sorry for the delay and we greatly appreciate your patience. Customer satisfaction is our highest priority.　Please let me know if there's anything else　I can do for you.Thank you,Abigail-DG Performance Sales

---

And I wait. Then receive this

---

Hi BobI have an update. Our chrome platter went out　of business and because of new California environmental　laws, hexavalent chrome plating is no longer accessible for us. We are switching to a new chrome platter, but they only do trivalent plating. There will be a slight difference in tint between the replacement parts we send and what you already have. Is this okay with you?Let me know and we can proceed from there. Once　again, thank you for your patience and apologies　for any confusion.Best,　Abigail-DG Performance Sales

---

My response to this is:Abigail,Boy…..This just keeps getting better 　! !The whole point of a new system was because of that very fact.　 The pipes and muffler had all taken on different heat related tints and looked like crap.So, No. Two tints of chrome; 　on one pipe and the muffler assembly is not OK with me.　 "Slight Difference" is subjective and I’m not taking that chance.　 Not on top of everything else.You can have it all back and I’ll expect a refund including the taxes paid.　 You’ll be paying for the return shipping !Or: credit my PayPal 50% of my original purchase price; I’ll have a plating shop here deal with #6 pipe and I’ll see if a muffler shop can "Tweak" the muffler assembly 　to get it to clear the differential/suspension and that will be the last you hear from me.My refund option through PayPal is still a viable option.The ball is in your court.Bob.　(And again I wait ! I send another email)

---

D.G.'s reponse:Hello,We were trying to figure out the best solution before moving forward.We can send you a shipping label and upon return of the items we will send you a refund. Due to the changes with our chrome plating, we have decided to discontinue manufacturing　that exhaust system for the　time being.　Thank you-DG Performance Sales

---

D.G. and I came to a resolution. After 3 months of fucking nonsense, I have the "Chrome Exhaust" I wanted. I managed to get the muffler/collector to fit without and re-bending required. Only after I trimmed the pipes another 3" in order to get the muffler supports to line up and have the "exit bend" align with my modified center-stand. I called the only "plater" in my area (They nickel plated my frame 41 years ago) and asked what the turn around time would be. "7 to 8 weeks" FUCK ME...will this shit ever end ? So: I am currently using the #6 pipe and will have it re chromed next winter !If you're considering a Header it looks like the only option now is a S/S Delkevic !
 

 

Hi Scotch!

If you decide to go with a Delkevic, I have a couple of options to suggest.

I love my Delkevic system, but I wanted a different look for the muffler.  I ended up using a short resonator (Cherry Bomb style) polished stainless muffler (built-in 90 degree turn down outlet) with a wide polished SS band clamp to connect to the mid-pipe.  Not too loud--the rush of wind over my helmet drowns it out at cruise, but a nice bark under acceleration.  I can provide a picture and further details if you're interested.

That left me with a brand new megaphone-style muffler with its included three baffle options and all the associated mounting hardware.  I only ever test fitted the muffler, and it's never had exhaust through it.  If you were to buy this, it would give you two options: 1) see if Delkevic would sell you just the primary pipes and collector/mid-pipe and use my muffler, 2) buy a complete straight muffler system AND buy my megaphone for comparison.

And of course if Delkevic would sell you just the primaries and the mid-pipe you could choose your own muffler like I did.

I'm in Oregon and I see you're in B.C., so the shipping would hopefully be reasonable.

This story is absolutely criminal. All DG Performance makes is exhaust systems and I can appreciate that they had a change to their chroming process because of California environmental changes. Timing in this case got Scotch caught in the middle and that's unfortunate. The criminal part is the lack of communication and leaving the customer hanging while they tried to figure out what to do. They should have picked up the phone and talked to Scotch and told him they were in the middle of changing their chrome plating service and that there were issues to work out and a time delay would be involved. Then they should have offered Scotch some options to resolve his issue. rather than 10 weeks of bullshit emailing.

There was also a number of issues with the manufacturing of the pipes. Every pipe was too long, a weld on the muffler was wrong, all of the pipe flanges were too big in diameter and to top it off, one pipe had been damaged and an attempted repair to the pipe removed the chrome from the pipe. WTF !!. DG should have insisted on a full return just to figure out what happened there. If it was one pipe that was a problem, deal with the single problem, but in this case, every pipe was wrong. Somebody really screwed up here and if your only product is exhaust systems, then you better get your shit together or you will lose your business.

When I was a working stiff, communication was always one of the highest issues in a problem that needed to be rectified. I made it a commitment to reply to any email or voicemail with a response to the fact that I received the email or voicemail and a commitment to do A,B,C and how long before they would hear from me again.

Shame on DG for putting Scotch through a shit show. A new DG exhaust system is $1000 USD. Not cheap for 6 pipes and one muffler, considering they are a manufacturing facility for exhaust systems. 

On the flip side, looking forward to hearing about the test results on the Eastman Internal Exhaust Coating.

I'd be remiss if I didn't also add this "Tid-bit".  Initially, with the 3 pipes installed (partially) and jamming the muffler up against the differential I also discovered this:

 
 

Digitally measured @ 5 degrees off vertical !


Initially, the pipe was hard against the Radiator mount.  I was able to "drift-over" the mount to achieve the "whopping" .024" clearance.
I did end-up with about 1/4" clearance.  This was a result of both the final shortening of the pipes and reducing the pipe-flange diameters.  The original flange diameter reduction (minimal) was done per pipe and only enough to get them to fit into the cylinder head.  The final reduction was done by reducing the diameter to match the O/S dia. of the split-collars.  And No.....there are no exhaust leaks !   This resulted ( somewhat mysteriously)  in achieving the final position of the muffler and adequate clearance of the pipe to frame gap.  The irony here is that my original D.G. had the same "off vertical" angle and 1/4" clearance to the frame, on the #1 and #6 pipes.
In the end (no pun intended) I was able to get adequate (?) clearance.  If not for having the former D.G. I'd be none-the-wiser.  And honestly, I prefer the closer fit to that of the previous.

 

I should point out that I have nothing against Delkevic, parse. I simply had a "boner" for the Chrome look as opposed to that of S/S,  that in my mind was more in keeping with the "theme" (?)  of the bike.

I'll comment on the "Eastwood" when there's been some significant mileage (and heat) put on the pipes. 
I can report however that the exposed base layer of nickel on that #6 pipe has darkened somewhat but  I expected this and I don't believe it's a negative reflection ( There's a PUN ) on the product, itself.