Rusted headers - How much metal is left?

So these are the headers on my '83 XJ650. Super rusted.




I'm wondering what my options are. I'm thinking of sanding them back and painting them black? I'm worried that sanding them will take heaps of the metal off?

Also, how do I remove the headers from the engine?

I have taken the collars off but then the pipes fit into a silver sleeve and it appears they are held in place by some sort of filler? You can kind of see it in the pics.

Does the sleeve come out of the engine? How is it held in there?

 

I disconnected them from my bike and they just wiggled out. Some spring-like gasket material also came out. I assume I'll have to replace them after I paint the headers. They look like they're about in the same shape as yours.

 

Plenty of good metal to work with in those pipes, basically surface rust from th pics. Have you undone th rear mount for th pipe, surely y can jiggle it around a bit, maybe need to give it a few firm taps with a hammer at th head but not heavy handed.
Looks like 3 and 4 cylinders run hotter than 1 and 2. ?

 

If you don't have access to a beadblaster then buy some muratic acid (swimming pool supply or hdward store) it will remove the rust but you must neutralizm it asap with baking soda or copious spraying with WD 40

 

Have them bead blasted and then powercoated or send to jet hot. You will love the look.

MN

 

Most likely surface rust, but untill you start removing it
you won't know.
Like Bushy noted these pipes have a good amount of metal
to work with, but like any type of corrosion it's going to
depend on the original quility of the pipes. If the metal has
a thin spot or flaw then rust can eat through much deeper.
Muffler paint will look good for about a year or so. Header
wrapes also look nice on some models.
Please post your results so we can see the results.

 

Cheers for all the tips guys.

But i'm still not 100% on getting the headers off. That silver collar that is in the engine block, does that come out? Is it separate or attached to the header? Do the headers just sit in there with pressure from the collar or is there some sort of gap filler that is used on installation?

The plan is to sand it then paint it with high-heat paint. I'm going to look into getting them blasted. The corners on the connectors would be a PITA.

So this is the muffler,



I'm not going to paint it black, want to keep it raw, how will it come out if i sand and buff it? Would it be worth getting it sand blasted as well?

 

I'd give them "The Treatment"
Media Blasting with a Medium that will take them right down to Bare Metal.
Grinding:
Hit the rough spots with a Body Shop Type Grinder and get everything smoothed-out and prepped.
Sanding:
Like the Grinding. Go-over the whole System with 320 on a Dual-Action Sander. Prep them for a NICE L@@K after Treatment.
Dress:
Grind and Dress anything Funky that will look worse Painted, Coated or Plated.

Power Coat 2010 -- Not like before.
You have a multitude of Color choices.

The part between the Header and the Cylinder Head is a round Flange Donut.
It's a Gasket. Round. With a hole in the middle. Donut.

 

Thanks Rick,

So this DONUT you speak of. Where can I get some, for when I have to re-install? Are they a standard size from an auto-parts store? or are they specific?