I just got done gutting my exhaust.
Actually, mine is still intact. I used exhaust graciously donated by bluedragon. Thanks for a smooth transaction
I did not gut mine because I was not sure whether I would F it up (I did not http://www.vfrdiscus...tyle_emoticons/default/+1.gif ) or whether I would hate the sound once I'm done.
Having read all the related posts, I still did not have a clear picture of what exactly needs to be done and how to do it.
So, here is my definitive guide to gutting a 6th Gen. exhaust
I did it with out cutting it in the middle and with out a welding machine.
The whole job took me a little over 3 hours. This includes the time that I took to figure out what exactly needs to be done and what tools to use No beer brakes Hopefully, this write-up will save an hour for those of you who come in my "glorious" footsteps. (You can tell I'm pretty proud [read full] of myself).
- Heavy duty work gloves. After reading prior posts
- Goggles (not pictured). Use your imagination.
- Wise Grip
- Channel Lock
- 12 inch chisel. A shorter one will not work
- File (rough grain)
- Large screwdriver
- Disassemble the tail section plastics, fender, all chrome heat shields, etc...
- Leave the exhaust on the bike. I looked in vein for something else sturdy enough to place the exhaust on for cutting, hammering and pulling. It turned out that the bike is the best platform for all the work, so I hooked it up and the rest happens while exhaust is installed on the bike.
- Cut the end caps off with a sawzal. This will take some time, but it is not too difficult. Use the edge of the file to start the cut in the middle of the weld and continue with the sawzal all the way through.
- Now, comes the fun part. Remove the outer baffle. Some explanation is in order here. Look at this diagram:
- The most important thing to notice is what I refer to as the "middle pipe". This pipe connects the two baffles. It must be dislodged from the outer baffle by chiseling around it until it is free of the welds.
- Cave in the middle of the outer baffle with the chisel. This does two things: First, it makes the three tabs with the spot welds move away from the muffler wall, which makes it easy to insert chisel and knock the welds off. Second, it deforms the baffle and makes it easier to pull out.
- Attach Wise Grip to any pipe (other than the "middle pipe"), grab the end bolt of the Wise Grip with Channel Lock and hammer the s!@#$%t out of it until the outer baffle comes out.
- The inner baffle comes out by following the same procedure. No need to dislodge the middle pipe you will be using it to pull the baffle out.
- Repeat on the other side. Here is the picture of baffles out. I actually got the outer baffle up side down here. OOPS.
- Step away and admire the view. Now is a good time to take pictures. I love that totally naked look of the tail section with open exhaust:
- Now, remove the exhaust and turn it up side down to get rid of the metal shavings. I actually used my trusty shop vac. to get everything out.
- Use JB Weld to glue the end caps back on. This stuff hardens to become as durable as steel. No bull. I have not done this yet. It's on my to do list for tomorrow.
Thanks to everyone who did it before me and took the time to share your experience. It saved me time and helped to avoid possible bodily injury :thumbsup: