Member Contributer magellan Posted November 22, 2005 Member Contributer Share Posted November 22, 2005 http://www.vfrdiscussion.com/uploads/1139666809/gallery_5128_669_217749.jpg[/img] Well, I?m well into the first of my winter projects. I ?bought? a 6th gen pipe and mufflers from a buddy here in town (a case of good local microbrew made it happen) and eyeballed the potential for fitment on my 5th gen. As you?d guess, a great deal of tail sub-frame and plastic modding would be necessary to make such a wide exhaust system fit, besides the fact that the stock 6th gen system is pretty heavy. I looked a bit harder and lo and behold, the 6th gen mufflers are symmetrical. So I cut them both free and started grinding the mounting and heat shield bracketry off, allowing me a better idea of what might be possible. border='0' alt='user posted image' /> 2000_0302_103411AA.JPG The up-pipe from the headers was a no-brainer to use, going up and under the seat as on the 6th gen. The ?only? thing I had to do to proceed was reassure myself that the muffler would fit under the seat and leave compression clearance for the tire with my pillion aboard (this proved to be a major difficulty). After a quick test-fit it was apparent that a single 6th gen muffler exiting just under the trailing edge of the taillights would look extremely cool. Time to go to work. border='0' alt='user posted image' /> 2000_0302_131641AA.JPG I started by pulling everything out from under the seat, including the ecm. Then I went after the undertray with a bare hacksaw blade (works better than anything else I?ve tried), removing bits and pieces to allow the muffler to ride as high as possible. border='0' alt='user posted image' /> 2000_0302_103434AA.JPG With a solder gun I plastic-welded the undertray back together as neatly as possible, creating a very flat bottom surface along with two mounting recesses for the pre-existing heat-shield mounting tabs to slide into. This provided a good way to locate (but not permanently secure) the muffler while I continued to eyeball things. The ecm now resides where the tool kit was and the tool kit gets scrunched in beside it. border='0' alt='user posted image' /> 2000_0302_131733AA.JPG I was a bit concerned about flow restriction and power loss through just one 6th gen muffler, so I drilled out the two inner chamber walls in a honeycomb pattern and opened the entry hole wider to free up breathing. So far so good. It was obvious early on that I wasn?t going to like the look of the license plate tacked on beneath the muffler, so I thought, ?Why not use some of the waste undertray plastic to make mounting tabs for the plate and stick it out at a 45 degree angle just past the muffler exits?? The plate now partially hides the muffler but I like the way it came together and I?m still able to use the Lite N? Boltz I bought for my fenderectomy. border='0' alt='user posted image' /> 2000_0304_082220AA.JPG border='0' alt='user posted image' /> 2000_0304_050110AA.JPG Then trouble struck. I needed a shakedown ride to check tire clearance and decided to go to my favorite muffler shop and have my buddy Kasey look at my work and see about welding in the connection from the up-pipe to the muffler. (You should?ve seen the looks on the faces of everyone around the shop when they heard the viffer with no muffler; even Kasey?s jaw dropped? and he owns the shop!) I was tempted to forget the whole muffler idea and go straight-pipe, and it sure didn?t help my resolve to use the 6th gen muffler that even the short ride to the shop had left scuff marks from the tire on the muffler... riding solo. Crap! So I went back home and cut the muffler in half to see if I could still use it. Turns out most of the sound deadening takes place in the back end of the muffler, which is good. I went ahead and shortened up the works by about six inches and stuffed the front chamber full of stainless steel wool. border='0' alt='user posted image' /> 2000_0309_153147AA.JPG border='0' alt='user posted image' /> 2000_0309_153300AA.JPG Then I re-welded the end-cap (entry end) to the muffler, at the same time flattening the bottom front end to match the contour of the tire for even more clearance. At this point I was out of welding rod and my wire-feed welder is terrible on thin pipe, but I used it anyway so the welds are pretty ugly where no one will ever see them. Oh well? border='0' alt='user posted image' /> 2000_0309_153420AA.JPG Tomorrow I?ll get the connector pipe welded in, then I?ll pull the completed system off and paint just the muffler with flat red Flame-Proof paint. I?ll post up pictures of the completed project in a day or two after the paint cures. :beer: Quote Link to comment Share on other sites More sharing options...
Veefer800Canuck Posted November 22, 2005 Share Posted November 22, 2005 Wow, you don't have any fear at all, do you? :thumbsup: I was sort of wondering the same thing these past few weeks, but I was kinda leaning toward more of the ENTIRE 6th gen rear subframe/plastic/exhaust-onto-a-5th-gen kind of mod. I've got to eyeball a 6th gen next to mine and see what would be the potential hangups or brick walls to such a thing. What are you going to do about the plate being in the way of the end of the can? Make a couple of 45' turndown exits or something? Quote Link to comment Share on other sites More sharing options...
Member Contributer magellan Posted November 22, 2005 Author Member Contributer Share Posted November 22, 2005 What are you going to do about the plate being in the way of the end of the can? Make a couple of 45' turndown exits or something? <{POST_SNAPBACK}> Thanks for the support! Oddly enough it was precisely the idea of using the whole 6th gen rear end that got me started. But when I started looking at subframe mounting locations and seat-to-tank fit I realized just how insane that project would be. Pre-kudos to you if you tackle that one!! (Besides, I'll only have about $70 into this whole project when I'm done!) As far as the license plate, I think I'll just ride it without the turndowns for a few short trips and see how much heat develops under the plate and tail lens assembly at idle. I could either protect the underside with a bit more heat-shield mat or go with the turndowns. We'll see. There's plenty of room between the exits and the plate right now for unrestricted exit (about 1 1/2"), so no problem there. Quote Link to comment Share on other sites More sharing options...
Member Contributer johne Posted November 22, 2005 Member Contributer Share Posted November 22, 2005 Good stuff Magellan :beer: Just curious, did you ever consider a CBR exhaust? Either 1000 or 600? Quote Link to comment Share on other sites More sharing options...
Guest ratfink Posted November 22, 2005 Share Posted November 22, 2005 Sweet! That's pretty similar to what I did with my V&H can. I ended up fabbing the up-pipe as well. I like the outcome. Good job. :thumbsup: border='0' alt='user posted image' /> rightside.JPG Quote Link to comment Share on other sites More sharing options...
Member Contributer VolatileVFR Posted November 22, 2005 Member Contributer Share Posted November 22, 2005 Good work Magellan.. This may be one of those 2 AM "drunken guy at the bar" questions, but in the close-up of your half cut exhaust and the tag mounted, why is the exhaust that white color? I notice the welding marks, so I know this is the undercover of the exhaust with chrome pieces uninstalled. Can you enlighten such a confused soul?? heh.. Thanks.. Michael ...wasn't sure if it had something to do with the welding process and how the "sheet of white" was obtained... or....was it some type of primer you applied since you are planning on repainting, that is, to keep from rusting... <My guess> :beer: Quote Link to comment Share on other sites More sharing options...
Guest imortlfool Posted November 22, 2005 Share Posted November 22, 2005 Looks like you're losing some suspension travel there (?). Will the rear wheel strike the exhaust given a good bump and a pillion? Quote Link to comment Share on other sites More sharing options...
Member Contributer magellan Posted November 22, 2005 Author Member Contributer Share Posted November 22, 2005 Good stuff Magellan Just curious, did you ever consider a CBR exhaust? Either 1000 or 600?<{POST_SNAPBACK}> No, actually... I was fixated on the 6th gen VFR pipe (a friend offered his unused stocker cheap). Maybe I should have looked at other options, but I'm really happy with the result. Ratfink, you were one of my inspirations, bro. Thanks! VolatileVFR, the white is FlameProof primer (handles 1200 degrees F!), which I'll follow with flat red. Awesome stuff, but you really have to make sure it cures well. Looks like you're losing some suspension travel there (?). Will the rear wheel strike the exhaust given a good bump and a pillion? <{POST_SNAPBACK}> At the exhaust shop this morning I had a 200 Lb guy on back with me while we bounced the bike. Still had 1/2" clearance to the muffler, and that's with minimal rear preload. It was a major concern for me too... :beer: Update to follow. Quote Link to comment Share on other sites More sharing options...
Member Contributer oyama Posted November 22, 2005 Member Contributer Share Posted November 22, 2005 magellan The exaust looks awesome, but can you post sound as well? Quote Link to comment Share on other sites More sharing options...
Member Contributer magellan Posted November 22, 2005 Author Member Contributer Share Posted November 22, 2005 I went to the exhaust shop this morning and had the connection from the up-pipe to the muffler welded in and clearances ckecked. Less than an hour and I was out the door. For good reason, Kasey at the shop was worried about heat damage to the plate and maybe the light assembly above the outlet, so when I got home I cut another hunk of stainless sheeting from the 6th gen heat shields and used it behind and above the plate. Should do the trick. border='0' alt='user posted image' /> 2000_0310_050718AA.JPG Then I pulled the whole system off (so easy with the rear wheel off!!) and applied another coat of primer to the muffler. border='0' alt='user posted image' /> 2000_0310_050650AA.JPG I don't have a kiln for curing this paint, so I'm using engine heat to do it. Maybe I'll just leave it this way! :beer: Later today I'll finish with the red and hopefully get some pics of the finished product posted tomorrow. Oh yeah, the sound? It sounds magnificent! No louder than my Staintune was, but with a tone that's slightly more "raw", as though the exhaust pulses bounce around less in the muffler before exit (sounds better than ever IMHO). Because the outlet is further removed from my ears than before, the bike is quieter at cruise too. Total labor hours: about 20. Total cost: approx. $110 (exhaust shop charged $70) No complaints! :thumbsup: Quote Link to comment Share on other sites More sharing options...
Guest ratfink Posted November 22, 2005 Share Posted November 22, 2005 I too had some rubbing until I tweaked things a bit. It's cool to see so many 5th gen getting the mod itch. Monkey gave me the inspiration for mine. LOL Quote Link to comment Share on other sites More sharing options...
Member Contributer magellan Posted November 22, 2005 Author Member Contributer Share Posted November 22, 2005 magellan The exaust looks awesome, but can you post sound as well? <{POST_SNAPBACK}> Here's a sound file, but it comes off a little thin. The actual sound has more bass. At least you'll be able to tell how surprisingly well such a tiny muffler damps an otherwise bowel-emptying shreik... :D Quote Link to comment Share on other sites More sharing options...
Member Contributer VolatileVFR Posted November 22, 2005 Member Contributer Share Posted November 22, 2005 I like the custom "Really Fast Chopper" look.... the heck with it...cut the mufler off and just leave your pipes as is... Biker Build off... here comes Magellan!!! :beer: Quote Link to comment Share on other sites More sharing options...
theoxmole Posted November 23, 2005 Share Posted November 23, 2005 Fess up Magellan, you liked the sound with the muffler off! :P I had to start my old one before I got the new mufflers put on. The neighbors couldn't wait to see what I had in my garage! Quote Link to comment Share on other sites More sharing options...
Member Contributer VolatileVFR Posted November 23, 2005 Member Contributer Share Posted November 23, 2005 (edited) Surely everybody has had the extreme experience of cranking without the muffler... WOW!! What a sound!!! I strongly urge you to go out to the garage, pull the muffler, and crank up your solid VFR if you have never done this... Be ready... May need a beer on hand... :beer: And yes, it will push you to take your now muffler-less VFR to the drag races next Sunday... :beer: Edited November 23, 2005 by VolatileVFR Quote Link to comment Share on other sites More sharing options...
Member Contributer magellan Posted November 23, 2005 Author Member Contributer Share Posted November 23, 2005 And yes, it will push you to take your now muffler-less VFR to the drag races next Sunday... :beer: <{POST_SNAPBACK}> At the muffler shop the guys agreed that it sounds like a small block with gear-driven cams on nitrous... and steroids... and maybe even methamphetamine :D Bloody awesome for sure. They offered to just run the pipe out the back, but I was pretty sure my wife might take issue with that... I used to have a Yammie FZR400 with a track-only Yosh on it, and man did it wail. But when I opened up the VFR on the way to the shop, it sounded far better than any inline 4. Quote Link to comment Share on other sites More sharing options...
Member Contributer magellan Posted November 23, 2005 Author Member Contributer Share Posted November 23, 2005 All done! Here are the pics: border='0' alt='user posted image' /> 2000_0310_130448AA.JPG border='0' alt='user posted image' /> 2000_0310_130422AA.JPG border='0' alt='user posted image' /> 2000_0310_130401AA.JPG Quote Link to comment Share on other sites More sharing options...
Member Contributer Avid One Posted November 23, 2005 Member Contributer Share Posted November 23, 2005 border='0' alt='user posted image' /> A great way to warm up the morning cup of coffee! Quote Link to comment Share on other sites More sharing options...
The Phantom Posted November 23, 2005 Share Posted November 23, 2005 All done! Here are the pics Very sharp Magellan. I'm all for recycling :lol: I've also been wrestling with where/how to mount the licence tag under the Wolf system. I like your solution but it does hide what you've done, also I imagine it mutes the sound a little? Which probably would be a good thing with my system... Can you post some daylight pics, with the seatcowl fitted? (I'm assuming you have one). I'm thinking the red canister + seatcowl will give a nice symmetrical look to the rear end of your bike (and perhaps you could consider losing the rear peg brackets just for the pic B) ) Gee, I wish I'd finished my Wolf installation already, underseat exhausts are becoming so passe :beer: Quote Link to comment Share on other sites More sharing options...
Member Contributer dude Posted November 23, 2005 Member Contributer Share Posted November 23, 2005 Megellan Excellent write up and a cool project. You did a great job :beer: I do agree for anyone who hasnt heard their viffer with muffler off go do it now!!!!!!!!!!!! :beer: Quote Link to comment Share on other sites More sharing options...
Guest SilVFR Posted November 23, 2005 Share Posted November 23, 2005 Very nice. 5th Gens look great with underseat exhaust. My hat is off to you :thumbsup: Quote Link to comment Share on other sites More sharing options...
Member Contributer vfrqqq Posted November 23, 2005 Member Contributer Share Posted November 23, 2005 You know, ever since I heard my 03 without pipes I didn't even feel like installing the new Lazer Xtremes I'd just bought cause I that was the sound I wanted. My dilemma is that a Harley with straight pipes or even just some other custom job rollin' down the road can't be that much louder than a VFR with straight pipes. Why are they allowed to get away with it but if we did it we'd get pulled over in a second? Or perhaps this isn't the case and I should just try my luck cause DAMN how sweet it sounds without a muffler!!!! :beer: Quote Link to comment Share on other sites More sharing options...
Member Contributer magellan Posted November 23, 2005 Author Member Contributer Share Posted November 23, 2005 Just for the Phantom. Thanks for the suggestion. Now how do I keep it this way without making my wife feel excluded? Guess I have to buy her that 636 she wants... :joystick: border='0' alt='user posted image' /> 2000_0311_011020AA.JPG border='0' alt='user posted image' /> 2000_0311_011059AA.JPG border='0' alt='user posted image' /> 2000_0311_011117AA.JPG border='0' alt='user posted image' /> 2000_0311_011214AA.JPG Quote Link to comment Share on other sites More sharing options...
Member Contributer bjf Posted November 23, 2005 Member Contributer Share Posted November 23, 2005 All done! Here are the pics: That is just plain amazing. Quote Link to comment Share on other sites More sharing options...
Veefer800Canuck Posted November 23, 2005 Share Posted November 23, 2005 Cool, too bad about the license plate obstructing the view of the muffler. I hope the hi-temp red paint stands up after time. Quote Link to comment Share on other sites More sharing options...
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