Changing exhaust without a torque wrench
The covers with gaskets and multiple bolts require more care in tightening than the exhaust bolts.
Like has been said before in this and many other threads on this subject, tighten, ride, cool and check again.
The threads are not as week as some on here have suggested, the 1/4" ratchet idea is a good one, hold it near the head and tighten it down.
Screwing a bolt into aluminum threads is far more prone top stripping than threading a nut on a stud in aluminum.
Is it any wonder the exhaust studs are one of the most popular fasteners that need drilling, extracting, tapping and or heli coils. The spec is 60 to 80 inch pounds. at the tight end of that spec you are only talking 6.6 foot pounds most 3/8 drive torque wrenches go as low as 10 foot pounds. Ever heard of the word finesse? When you are talking inch pounds being ham fisted won't cut it. It really is just tight enough to slighly crush the woven gasket in the exhaust port to form the seal to the head pipe. Over tighten these nuts they will snap off the studs given time. I am almost certain these nuts do not get tightened as tight as the screws in the handlebar switch housings to give you an idea of how gently they need to be tightened!.
You can add any length extension to a torque wrench to gain access to the fastener with no change in the accuracy.. The only things that will throw off the torque reading is changing the length of the torque wrench handle, or I should say adding overall length of the wrench at either end with either a pipe on the handle or something like a box end wrench (on one end) with a 1/4, 3/8. or 1/2 square drive (on the other end...what ever the case may be) unless it's positioned 90 degrees to the handle and does not change the overall length of the torque wrench. The other things that will give false torque wrench readings are rusty fasteners and factory pre applied thread locking agent, or self locking nuts. It is best to clean and apply anti seize compound for the most accurate torque...especially on an exhaust stud.
Most technicians will have an inch pound torque wrench with a range of 40-200 inch pounds in either 1/4 or 3/8 drive, a 3/8 torque wrench with a range of 5-75 foot pounds, and a 1/2 inch torque wrench with a range of 40 foot pounds to as high as you can find.
Tech23
The Best of Harley-Davidson for Lifelong Riders







