I am going to fabricate my own manifold but i don't have a donor manifold

can anybody tell me the pipe diameter for a 2002 R1 5pw motor and is it possible to make the flanges that fit to the exhaust ports?

Any suggestions gratefully received!!

Heres the flange dimensions from a manifold I had which fitted 4XV/5JJ/5PW. They were cut out of 6mm thick flat bar.


Description

Hi Tony.
Here's my suggestion FWIW.
Get hold of two standard manifolds and cut them up into straights and bends. You won't need to make any flanges or worry about tube diameters.
Use the aforementioned bits to make up your manifold. It needn't look too much like a patchwork quilt if you take your tie to minimise the number of joins. You will have to make, or buy, a collector or three, depending on your design.
You could measure up a standard jobbie for primary lengths etc
This is basically what we did on our Phoenix 929 'blade. The 929 is Titanium as standard. Not sure about R1.
We also used a Titanium can from a ZX9.
I'll post some pics if you are interested.
If you have bending gear etc. and are determined to build from scratch it could still be worth getting hold of a standard manifold to measure up and cut the flanges off.
Geoff

are the flanges flat?

are there any gaskets or sealing rings needed between flanges and exhaust ports?

and would it be a good idea to make my pipes a little oversize

And yes any photos would be very useful!!

Pics as requested. There are no gaskets or sealing rings. Flanges are flat.

thankyou for the photos

Nice job !!

Have just bought pipe bender today with 38mm mandrills so I'II have a go!!