I have a 94 Road King with stock pipes my front header pipe is broke At the weld where the bottom clamp is. Can this pipe be welded or is the metal too thin. I'm sure it's thinner than when it was 22 years ago

 

I just did it on my Shovelhead. Went to the auto parts store and got a 1 7/8" section about 2" long and modified it to use as a sleeve. You need a good TIG welder and some skills, go slow. When it was done, it's about twice as strong as original, and the chrome heat shields hide it.

Disclaimer: Remove the pipe so you don't fry any electrics or blow up your gas tank.

 

Like RHPAW said, you'll need to use something as a sleeve, and you will need to TIG it. Go slow, weld 1/4" at the most at a time and let it cool.

 

Won't the warranty cover it? You should be screaming bloody murder about the poor quality of Harley exhaust pipes!

 

Warranty on a 22 year old bike? Ok...

 

they all come with lifetime warranty. Just ask your salesman, He will promise it!

 

A very common problem.
My 2000 Ultra was 13 years old when the crack in mine was discovered.
Fortunately (for me) the "indy" had a used pipe on hand and I got it at a great prce.
If I had not been planning on buying a new bike I would have opted for either a new pipe, or a set of "true duals".


Your bike should be a bit quieter and it may even idle a little smoother.

 

I know a set of pipes are expensive, but it just may be time. you are going to start patching them. a new set of pipes will change the whole look of your bike

 

Charlie makes good sense here ... once you start patching you're usually doing it regularly

 

I can tell you from personal experience once you patch it it will crack inches from where you patched. It could take a few months or a year but it will crack again.