chopping stock pipes

So if you have ever tried to chop stock pipes, they can be less than a joy to work with. about 3 years ago i chopped my pipes and using the stock headers welded on some dump outs and they looked and sounded great. however the past month or so ive noticed a random clunk or metalli crattle at higher speeds... not too safe feeling!

i bumped my front pipe the other day and heard a rattle, and so i pulled the front pipe off, the inner pipe ( honda saw fit to build the pipe within a heat shield to prevent bluing) had broken off and was rattleing around for god only knows how long.
it had rubbed a hole in the bottom of my pipe and was acting as a sort of baffle im sure.
I ended up having to chop the pipe in 3 pieces due to the bends, just to pull the pipe out.

i was able to weld everything back together and patch the holes and thin spots that the broken pipe had created, and i put some new wrap on the pipes so i got to enjoy a ghost rider-ish smoke filled ride home =D

im working on a friends sportster right now ( i dont normally do harleys but i felt bad hat the guy was getting raped at the HD dealership. $700 bucks for rewiring bars and a new set of bars? Thats what i call rape. so i also chopped his pipes up and wrapped them, but he wants black header wrap instead of the cream color so im going to have to order some black header wrap and re-do them.

Shop is almost done, im able to work around things as half the 110 power is not working, but the welder and air tools are up so im back in full swing.

on the bench currently -
Duffs Bars for his xs650
Custom Gas tank for Youngkhong from the VLXRCCC forum
Lic plate relocation on clifs sporty
Solo Seat and custom Pan on Clifs Sporty.
Tonys Bike- Wiring and battery box
Tonys Bike- Headlight and Tail light

DO FUN SHIT!!