Dream exhaust options.

[Muddy]

By the way, when I clicked on your website, there appeared to be some sort of a virus telling me to call a number because my Apple account was violated. I could not get out of the loop.

Thanks, this is probably some sort of website bug.

[Gene1000]

Thank you, Muddy.
I appreciate your time you spent with me on this issue.
With the help you have provided, today I think I’ve made some progress. But first, I need to confirm one thing:

First, when everything is assembled and installed, the “joint” does not directly come into contact with the engine exhaust port (see photo). Instead, it is about a quarter of an inch away. Is this correct? Was this the intended design?


Second, you were right about the exhaust headers being somewhat different. The exhaust headers are different in overall size and as a result, the “joints” on both sides of the bike are different in diameter, thickness and overall size. It therefore follows that the collars on both sides of the bike are also different in size.
The collar-halves with the raised flanges are installed on the left side of the bike. The collar-halves that do not have the stepped flanges are on the right side. Otherwise, they will not fit. This is the case with my 1965 CA 77 Dream. I don’t know about other years.

[Muddy]

G'day Again Gene1000

That is great that you are making progress.

The joints do not usually tighten right up to the head. What you've shown in the last photo is normal and the intended design.

From the photos you have provided, it is now easy to see you have parts from 2 different serial number bikes. Both joints should be the same and all 4 split collars should be the same if all from the same bike. Because of this, it is possible that the headers and mufflers are also different. That may not be a problem is you are not looking for "authentic" and can get both sides to work.

The joint with the larger internal diameter should be fitted with the 2 split collars with the flanges. The joint with the smaller internal diameter should be fitted with the 2 split collars with no flanges.

Good luck and keep going.

Muddy

[Muddy]

On reflection and re-examination of your photos, I am concerned about the large internal diameter of the larger joint. The internal diameter looks way too big. Anyway see how you go.

[Gene1000]

Thanks for all of your guidance, Muddy. Very much appreciated.

I had no idea that the bike has parts from two different serial number bikes. Now the schematics make sense.

I bought the bike from a police officer in January 1966 and as such it was literally brand new. Minimal mileage. It is very strange that components of the exhaust system are from different bikes. I never made any changes in all the years that I owned it and the police officer that I bought it from only owned it for a few months. Perhaps an exhaust header was damaged and the previous owner ordered an incorrect header that had to be retrofitted with parts made specifically for it.

I’ve been restoring this.bike on and off for three years. Attached is a current photo. The only things it needs are new exhaust pipes. Finding originals is next to impossible.