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A New Way To Gut Your 6th Gen Exhaust


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#1 JTG

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Posted 03 April 2008 - 01:53 AM

Here's the bike that will receive the exhaust I have modified. I bought a spare exhaust off of VFRD member "jabandsnort" from further north in California in case I didn't like the modifications so it could be returned to stock. I believe the exhaust came off an 02 and it's going on an 07 RWB.

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Unfortunately I didnít notice until after I had done the work on the 02 exhaust that the stock exhaust on my 07 has additional heat shields on the outside of the cans. Iím not really sure how much these help with heat dissipation, but I do use soft Cortech saddlebags on a regular basis and I wouldnít want to melt them. At any rate if there is a noticeable difference in heat, the 07 exhaust may require surgery as well. Which means Iíll have an extra gutted exhaust for sale.

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The concept behind this was to bypass the baffles without removing them or cutting the end off the cans. (I had much grander plans to begin with but ultimately decided I was too lazy for any of them.) Essentially the gasses pass from the front of the muffler to the rear through a large tube, then they are circulated towards the front again through a smaller tube and finally towards the rear through the 2 smaller exhaust outlets. Someone drew a decent diagram of the inside of the muffler somewhere on this forum if you need a visual. This mod will bypass the extra routing and just travel straight from the front to the back of the exhaust through the one large tube.

So without further ado, here it is!

I'm going to assume that everyone either knows how to remove the exhaust and heat shields or can figure out how to do it by searching around this forum. So I will skip the removal and installation and just deal with the hack and slash part of it.

The first step was to take a hole saw with an inner diameter that just fits over the outlet pipe on the exhaust. Hole saws typically require some material for the center drill bit to go through that keeps the hole saw from ďwanderingĒ. However because the exhaust outlet fits inside the hole saw this is not necessary. That being said drill through the end cap around each exhaust outlet as shown. As long as you have a new sharp hole saw this should be fairly easy.

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The second step is to cut off the exhaust outlets as close as possible, it is not necessary to be flush with the end cap of the can however the next step is easier if these are a little shorter.

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The third step is by far the most tedious and will require some patience and a steady hand. I used a Dremel tool with a shaft extension and small cutoff wheels. Make sure to buy wheels that are small enough to fit inside the exhaust outlets. If they arenít small enough, just wear them down on a scrap piece of steel until they fit inside. I went through about 5 for each outlet or 20 total, fortunately they are really cheap! I cut off the exhaust outlets about 1Ē into the cans but you could change this as Iím sure it would affect the sound quality in some way (not really sure what it would do?) One of the outlets is curved so it would probably be difficult to cut it off any further than 1Ē inside the can.


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Here is the finished product all deburred and ready to have the heat shields reinstalled.

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Iíve ridden back and forth to work a few times with them on, and I think I love the sound! Itís taking a little adjusting of my senses because over the last 12,000 miles Iíve become accustomed to the sewing machine quality of noise emitting from the machine beneath me. Iíd be curious to hear the difference between what Iíve done and a fully gutted exhaust, so if thereís anyone in SoCal with a gutted exhaust send me a PM and letís compare and contrast. From the sound clips Iíve heard of a gutted exhaust it certainly seems very similar, but itís really hard to tell from an inexpensive video recording. In the meantime Iíll work on getting a video and sound clip.

Thanks for indulging me,
Jon


HERE'S THE CRAPPY VIDEO CLIP!! Pay no attention to the hideous Pontiac Aztec in the background, that belongs to my neighbor. I don't think I'm going to quit my job to become a videographer, but this gives an idea of what it sounds like. After living with this for about a week, I'm LOVIN IT! :blush: Staintunes may sound better, but for the price I'm not willing to find out.

http://video.google....929474949107971

Edited by JTG, 07 April 2008 - 08:50 PM.


#2 Go4ord

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Posted 03 April 2008 - 03:19 AM

Hi Jon,

Nice looking concept. I have had a 'spare' set of pipes in the garage for a few months now.. just waiting to do a Gut job on them.. now this makes 3 different ways to do it.

I like your idea for the fact it requires no welding after the mod !! now I best go looking for an extension for my dremel... ;-)

looking forward to the sound clip..

cheers

matt

#3 marid2apterbilt

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Posted 03 April 2008 - 07:45 AM

Got any pics from after the reinstall on the bike..??

Im no welder either so it sounds like a great alternative...

Do you think it would be possible using the long dremel shaft to cut the internal pipe then using Really long needle nose twist n pull out the section of tubing to keep a completly stock look..

#4 soichiro

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Posted 03 April 2008 - 10:49 AM

Got any pics from after the reinstall on the bike..??

Im no welder either so it sounds like a great alternative...

Do you think it would be possible using the long dremel shaft to cut the internal pipe then using Really long needle nose twist n pull out the section of tubing to keep a completly stock look..



IMO, it would be easier to just cut the end off and remove the baffles. I'm no welder either but it is a simple job for a good welder. I got a set of pipes, had the welder cut the ends of and weld them back on.

Does the exhaust whistle? It seems like the exhaust would hit the the end of the can or the heat shield and make noise.

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#5 Baileyrock

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Posted 03 April 2008 - 11:05 AM

I like the idea and the fact that most of the baffling is still in place so it will hopefully be a deeper/ throatier sound w/o being too loud! :unsure:

You may be able to play with sound quality if you added tube/ sleeve inserts into the larger holes so that they stick out past the end caps. Changing the length of how far the tube go into the muffler will allow you to custom tune the sound. Having them go in past the interior tubes may greatly improve the sound(or worsen it). :rolleyes:

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#6 JTG

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Posted 03 April 2008 - 12:40 PM

Got any pics from after the reinstall on the bike..??

Im no welder either so it sounds like a great alternative...

Do you think it would be possible using the long dremel shaft to cut the internal pipe then using Really long needle nose twist n pull out the section of tubing to keep a completly stock look..



IMO, it would be easier to just cut the end off and remove the baffles. I'm no welder either but it is a simple job for a good welder. I got a set of pipes, had the welder cut the ends of and weld them back on.

Does the exhaust whistle? It seems like the exhaust would hit the the end of the can or the heat shield and make noise.



No, there is no whistling. Just the same throaty sound I believe you'll get from a full gutting. I am thinking that the end caps may blue a little from the heat however. I was mostly concerned that the full gutting would be too loud for my liking, and there's no reversing that procedure. This way if it's not loud enough, the next step will be to cut the ends off and perform the full gutting.

Baileyrock, yes I was planning on welding in some insert sleeves to play with the sound. I'm just waiting to buy a new Miller TIG welder, I sold my metal fab shop and all the equipment about 6 months ago and now I'm missing the luxury of having all that equipment sitting around whenever I want to build something.

As for doing this but keeping the stock look... I'm not sure, maybe? You'd have to see if there's a hole saw that fits in between the exhaust outlet and the short piece of pipe that acts as a shield around the exhaust outlet.

I'll take some more pictures of the exhaust on the bike and post that video this weekend.

Edited by JTG, 03 April 2008 - 12:46 PM.


#7 Baileyrock

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Posted 03 April 2008 - 12:47 PM

Baileyrock, yes I was planning on welding in some insert sleeves to play with the sound. I'm just waiting to buy a new Miller TIG welder, I sold my metal fab shop and all the equipment about 6 months ago and now I'm missing the luxury of having all that equipment sitting around whenever I want to build something.

I'll take some more pictures of the exhaust on the bike and post that video this weekend.



Cool, I have a Miller MIG welder, but wish I had a TIG too. :rolleyes: :unsure: :fing02:

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#8 FotoMoto

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Posted 03 April 2008 - 12:55 PM

I am thinking that the end caps may blue a little from the heat however.


There is no "may" to it rather how much. :rolleyes:

#9 JTG

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Posted 03 April 2008 - 10:10 PM

I am thinking that the end caps may blue a little from the heat however.


There is no "may" to it rather how much. http://www.vfrdiscus...tyle_emoticons/default/+1.gif


True, I'm not really worried about it as the exhaust gasses really aren't carrying all that much heat by the time they reach the end of the cans. If they do turn blue... oh well, it will match the paint http://www.vfrdiscus...tyle_emoticons/default/+1.gif

#10 JTG

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Posted 05 April 2008 - 05:28 PM

Apparently my video camera is smarter than I am, I made a recording but I can't get it onto my computer :blink:

Anyway, until I figure that out here's another picture with the exhaust mounted on the bike.

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