Gotama

On 4/23/2023 at 9:30 AM, Oregonian said:

I just sent my deposit.

 

I saw a set of these in the flesh at EDR Performance in Beaverton Oregon.  They will be doing the install and tune for me.  They have done multiple sets and report great results and happy owners. 

Yeah great results that Eric isn’t willing to share 

I’m seeing a lot of posts about what exhaust cans to get for the system. Here’s my two. Cents.
Long time ago FMF racing made a dual can system for these bikes, those days are long gone.

  What I was able to do and research is that any exhaust system off of a similar year Yamaha R1 can be fitted up to a custom splitter pipe. Which sfdownhill fabricated for my particular project 

I wasn’t expecting him to knock this completely out of the park with such an awesome fabricated job.

20 hours ago, VFR4Me said:

Any 8th gen folks mount one of these without the dyno tune?  What are the impressions. How does it run without a tune? 

It all depends. Before I removed the 02 pair system We had to add a bunch of fuel to  get a proper AF. After I remove the pair system We had to take a shit ton of fuel out. You can run the bike with the stock tune on these headers, and it will probably run just fine. But I get the full benefits of the performance exhaust I would highly suggest removing the o2 pair  system

and getting a custom tune 

On 7/14/2021 at 6:57 PM, Ziffer said:

So...I have a couple questions...

How much are/were these headers going for? I read thru a lot of posts, and it seems like they were going to run around the $800 mark. What did they come out to? Also, what makes these headers better than Delkevics or Lexteks? Seriously, I have no experience with any of these.

The difference is these actually make power 

All these attempts to achieve what is simple 

stock cans are crap lol plain and simple 

R1 cans from corresponding years can and will work beautifully .

32 minutes ago, ShipFixer said:

The wood shims and hammer were the only tools required to make up for the front end misalignment.  I think I could get them in place without them but it was a lot easier that way.  I'd assume all of these experiences will be a little different, but I got the right one in first, then the shims pushed the left one out a bit where i could get it more forward and between the stud holes, then when i took the shims out it was pretty easy to line up the last centimeter or so of movement in the left one.

 

If it were a bit harder for me and I didnt have the shims, I would consider removing the front wheel and fender so I could really get in and pull it a part and line them up by hand.

 

Meanwhile, no luck on the studs and nuts coming apart.  I may try a torch if I can find one, but meanwhile, if you haven't installed yet and you have an older bike like mine, you may want to order a few of the studs and nuts for the front cylinder ports just in case.

I had one stud that was like that up front too 

Sheesh I just physically moved the front pipes in place by hand 

fit perfectly 

no fancy tools needed except muscle 

Today was Dyno day

so back in 2009 I had the bike tuned with a PC3 and I cut the tips on the stock exhaust that was the only mod I did on my Dads bike 

sadly he passed away last January and never got to see this completed 

basically he didn’t want me messing with it to much lol

after new plugs O2 block off plates 

VFRD headers and custom mid pipe to a pair of FMF apex cans 

I have got to say these headers are legit !!!!

blue line is what I started with in 09 

red line is after the stated mods I did 

and 

green line is where we are at 

mom currently running the Michlen road 5’s and if I switched to the power 5’s you’d see a 2 to 3 hp increase 

33 minutes ago, MadDoc said:

Page 11 of this thread talks about the gaskets. I followed those (and from discussions with a buddy) and ordered a set of 42mm washers from Delkevic. I got on the phone with them yesterday and they said they just had some come in. You might want to hurry up if you want that as they are almost always not in stock (this particular size, no idea why). Been checking for the past 2 weeks before I finally contacted them.

https://delkevic.com/copper-gasket-42-mm/

Perfect timing just ordered a set 

On 4/16/2021 at 3:34 PM, fattiresire said:

Anyone taken a swing at putting on a set of the new batch of 8th Gen headers? My shop is having trouble getting a good fit of the gaskets. They used the gaskets that were available with the headers. Any feedback or advice on getting these installed leak free?

Wait you all had gaskets with your new headers ?

Now who’s got that thread link to whoever was making that center stand stop for these things ??

Just received mine today but I have to wait since I’m getting the mid pipe too coupled to some fmf cans 

gives me some time to source some header gaskets in the mean time and some O2 bung block offs .

Just got my shipping notification 

On 2/1/2021 at 12:45 PM, sfdownhill said:

Further update. Got hold of Wade today - he received the long-awaited tubing merges last week and is currently building our order of headers. After all this time, this is grounds for serious woo and hoo.

 

Duc2V4 and I will be going over the list of purchasers during the next few days so we can get shipping estimates together for everyone, order gaskets for those who have requested them, and arrange to drop off the pipes at the passivators when Wade is done with them.

Awesome 

8 hours ago, sfdownhill said:

FMF canisters?!?! I thought we agreed on Graves Motorsports mufflers!!

(Just kidding)

I was looking at a set of graves 

but the FMF just spoke to me lol

On 1/1/2021 at 6:29 PM, sfdownhill said:

Yep, Wade is building. I spoke with him yesterday to ask him to notify us when he is getting close to completing our order so we can contact everyone who has placed orders for headers.
 

As an aside here, I also let him know how many 5 gen vs how many 6 gen orders we have. To us VFR owners, the only difference between 5 and 6 gen headers is that 6 gens have a 5/8” shorter collector exit pipe, but, to the builder, there is more to it than simply chopping off 5/8” from the finished assembly. Because the mandrel bending machine clamps so hard on the tubing to bend it accurately, the tubes suffer slight deformation at their ends. So Wade uses a hydraulic machine to expand the ends of tubes to the correct diameter. What this means for the collector exit tube is that he needs to cut off the 6 gen’s 5/8” prior to expanding the tube in order to provide a long enough expanded section to provide the proper length of clamping area for the midpipe to be fastened. I like that our fabricator builds our headers with this amount of foresight and experience.

 

Back to the topic at hand - Wade has all the tubing back from the mandrel bender and is ready to start welding, but his supplier of tubing merges is backordered - one of the ways he keeps our cost so far below other fabricators we contacted is by using pre-manufactured tubing merges made from the same quality 304 stainless steel as the tubing used for the headers. The supplier told Wade he will have the merges for our headers by January 18.

I and Duc2V4 both apologize for the delay - it certainly has taken much, much longer than expected to get to this point.

 

We will stay in contact with Wade and, as we get them, will post more updates here.

Awesome I’ll get the fmf cans mailed down this week for the mid pipe fabrication on my 6th gen 

can’t wait till the final product is here and installed 🙂  

Are we building yet ?

On 12/18/2020 at 2:29 PM, boOZZIE said:

No rapidbike any more, so probably a few ponies left unaccounted for

I got these same numbers with just a gutted stock can and stock headers . PC3 tuned on the dyno 

10 hours ago, sfdownhill said:

 

There is a definite theme to everyone’s curiosity, and the timing couldn’t be better.

 

We have been negotiating with Wade the fabricator, attempting to buy our way past or navigate around his 15 unit minimum order. Last week we finally got a commitment from him to build 12 headers for 5/6 gen VFRs and 3 headers for 8 gen VFRs. These are a couple more units than we have deposits for, but the iron was finally hot, so we had to strike. As fast as we could get down to the post office, we used Priority Express to send him deposits for all 15 headers, so:

 

WE ARE NOW IN BUILD PHASE! WOOHOO!

It will be 6 weeks to get the finished headers in our hands, and about a week after that to get them all to the passivators and picked back up. Then we’ll be shipping all those shiny new pipes out to all you extraordinarily patient folks who placed deposits.
 

One person dropped out a few days ago, so there will be an extra set of 5/6 gen headers available.

Yes finally 

I can’t wait to send you the cans I need made to the mid pipe also 

should sound sick afterwards 

Okay back on topic 

are we in production phase yet ?

On 12/29/2018 at 8:39 PM, sfdownhill said:

A pre-production prototype header assembly with specifications nearly identical to the Two Brothers Racing [TBR] 5th gen VFR 800 header is now being constructed in southern California.

 

This is a new thread duplicating a post on the VFRD '5th & 6th VFR 800 Header build' thread. The objective of this new thread is to give the project described below an opportunity to stand on its own four cylinders. There is a metric ton of valuable data and opinion on the old thread, so if you're new to VFR headers and curious about the gestation of this project, don't deny yourself the pleasure of reviewing it.

 

Here is photographic evidence of the work in progress. This photo shows the jig that has been fabricated in order to get the proper layout of the performance headers. Photos taken 12/26/2018:

 

 

*Acknowledgements:

 

From the start of this project, we knew we'd need help, and so sought assistance from some very well respected, long time VFRD members.

 

Special thanks to VFRD member Cornercarver for the generous and trusting loan of his prized, irreplaceable [Until now!] set of original TBR headers.

 

We also would like to thank VFRD member RVFR for his support of this effort through contributions from the 2017 gofundme header fund.

 

Contributing members - all massively experienced and extremely helpful - include but are not limited to: Sebspeed, Cornercarver, TimmytheCop, MiniCarver, BusyLittleShop, BuzznerSuntrusts, RVFR, Mohawk, Mello Dude, CandyRedRC46, Stray, keef, voided76, and 3dcycle. Our sincere thanks to all these individuals and others for their wise counsel. Without you, we could neither be getting a prototype built, nor could we have established a path to a production version of this performance header.

 

 

*General information / major bullet points:

 

[1] The production version of the performance header assembly described here will be hand built in southern California and cost $790.00 plus shipping from the manufacturer. California residents need to add 7.75% state sales tax.

 

[2] The header will fit 5th and 6th gen VFR800s. [8th gen owners, see Note 'a' below]

 

[3] The header will go into production when orders for 15 units are received with a $200 deposit per unit.

 

[4] The prototype header is scheduled to be completed by 1/11/2019.

 

[5] A baseline dyno run of a VFR fitted with 98/99 headers and same day/same dyno full tune of the same VFR with prototype header installed is scheduled for the week of 1/14/2019. [Dyno testing methodology is detailed under 'Dyno testing procedure']

 

[6] The list below of deposits received will be kept updated, and we will be adding a second list of individuals interested in seeing the dyno results before placing a deposit.

 

If you are interested, PM us and let us know the following:

a] which gen VFR [5th, 6th, or 8th] you would like a header for

b] which fueling management system you use or intend to use

c] which slipon muffler/midpipe you have or will use

d] if you intend to have your exhaust system dyno tuned

e] if more than one unit, how many headers you are interested in purchasing

f] if you are placing a deposit

 

*A LIST - 5th gen/6th gen header orders with deposits received:

1-Duc2V4           5th gen          Rapid Bike                                TBR slipon                               yes dyno tune        1  5/6th [maybe 2nd header for 6th gen]

2-VFR7503        6th gen          PC3                                           has TBR and Leo Vince          maybe dyno            1  5/6th

3-WackenSS      5th gen          PC3 [RB in future]                     Leo Vince                               yes dyno                  1  5/6th

4-jim v                6th gen          PC3 [maybe RB in future]          Micron                                    yes dyno                  1  5/6th [maybe full system]

5-MadScientist   5th gen          PCV w autotune                        Micron low, MIG high               autotune [maybe dyno]  1  5/6th

6-bornes            6th gen          Rapid Bike                                SC Project CR-T                      yes dyno                 1  5/6th

7-Airisom           5th gen          PC3 or PCV                               Delkevic                                  yes dyno                  1   5/6th

8-CornerCarver 5th gen          PC2 or better                             Wolf [sweet!]                               yes dyno                  3   5/6th

9-CC                  5 eng in 6 chassis PCV                                    Staintune                                yes dyno

10-CC                6th gen           Rapid Bike                                 OEM                                       

11-Sebspeed      5th gen                                                                                                                                             1  5/6th

12-Mbrane          5th gen          PC [which PC TBD]                    miscellaneous                         yes dyno                    2  5/6th

13-MBrane

14-interceptor69 5th                PC3                                                 Vance & Hines                           no dyno                        1 5/6th

15-3Dcycle         6th gen                                                                                                                                          1 5/6th

16-moosemoose 5th gen          RB                                             Delkevic                                                                   1 5/6th

17-sfdownhill       5th gen          PC3                                           Staintune                                 yes dyno                   1 5/6th

18-EX-XX            5th gen           PC2                                             Custom midpipe/slipon                 yes dyno                     1 5/6th

19-GreginDenver 5th gen         TBD                                                                                                                                             1 5/6th

20-Funkatron     5th gen          PC3                                                 TBR                                            maybe dyno                    1 5/6th

21-Tirso              5th gen          PC3/PCV w auto                           Staintune                                        no dyno                     1 5/6th

22-8th gen prototype

 

LIST 8 - 8th gen headers with deposits received

1-HighSideNZ  8th gen header  6 chassis /825cc 5eng/front rad  Rapid Bike Leo Vince                                                  1  8th

2-Fz6wja                                                                                                                                                                                           1  8th

3-samuelx                                 PCV                                                  Yoshimura                                      yes dyno                     1  8th

 

*B LIST - parties interested in purchasing a 5th/6th gen and/or 8th gen header who prefer to wait before placing a deposit:

-Samuelx        8th gen          RB or PCV                                  current Delk, Yosh, OEM         maybe dyno            1  8th

-Voided76      8th gen           Rapid Bike                                 Assorted slipons                                                       1  8th

-Stray              8th gen header front rad 5th                                                                                                                1  8th                                                                               

-boOZZIE        6th gen          Rapid Bike                                  Micron                                        yes dyno                  1  5/6th

-RC51Nick      6th gen          Rapid Bike/autotune                Staintune                                    autotune                  1 5/6th

-carlgustav     6th gen          Rapid Bike                                  M4                                               no dyno                   1  5/6th

-CornerCarver  8th gen header front rad 5 eng in 6 chassis PCV Staintune                        yes dyno                  2  8th

                         8th gen header front rad Torocharged 6 gen Rapid Bike  Staintune            looking for a dyno capable of handling it

-Sebspeed      8th gen                                                                                                                                                      1 8th

-MooseMoose 5th gen       Rapid Bike/MyBikeTunig          Delkevic                                                                         1 5/6th     

-adkfinn          5 gen              PC3                                             Black Widow                             yes dyno                    1 5/6th

-fly750            8th gen                                                                                                                                                       1 8th

-neo2122        6th gen         OEM/PC3                                    Delkevic                                     yes dyno                    1  5/6th

-wholepailofwater 5th gen     OEM/TBD                                   Staintune                                                           1 5/6th

 

 

 

*Background:

 

Over the past year, VFRD member Duc2V4 and I have made an exhaustive [ouch!] search for a manufacturer/fabricator qualified and willing to produce a reasonably-priced, high quality "replica" of the Two Brothers Racing 5th gen header assembly. The TBR is the accepted standard in production VFR performance exhaust systems. After unproductive efforts with several fabricators, in August of this year we were referred to and contacted a gentleman named Wade, founder of an established southern California exhaust manufacturing firm. Wade expressed interest in taking on this project. Communications about and development of this project have continued with Wade since August and resulted in the construction of the fixture pictured above, along with a pre-production prototype header, a dyno testing schedule, and a commitment to build a production run of 15 units.

 

 

*Dyno testing procedure:

 

Testing will consist of a baseline dyno run of a 5th gen VFR with OEM 98/99 headers installed [See Note b below]. After the baseline run, the test VFR's 98/99 headers will be removed and replaced with the prototype performance header assembly. On the same day as the baseline run, a full dyno tune will be performed on the subject VFR with performance header installed. The dyno tune will be performed on the same dyno by the same dyno technician, with the same air filter, same fuel management system, and same midpipe/muffler.

[Test subject VFR is described in 'Test bike']

 

 

*Some dimensions, features, and specifications of the header will be taken from the TBR.

The new header will incorporate the following specifications from the original TBR header design:

-header construction will be from 18 gauge 304 stainless steel tubing, [0.049"/1.24mm wall thickness]

-header will have 38mm od primary tubes [1.5" od]

-header will have 41.5mm od secondary tubes [1 5/8" od]

-header will have 51mm od collector tubing [2" od]

-header's rear primary tube junctions will be fastened by spring tension fittings

-header's left front and left rear primary tubes will merge

-header's right front and right rear primary tubes will merge

-header will have no crossover of front or rear primary tubes

-header's collector exit tube will have a 51mm od [See Note c below]

-header's tubing will be mandrel bent

 

 

*Some specifications will be changed from original TBR header design.

To align with the VFR community's objectives and improve durability, the header will incorporate the following changes to the original TBR header design:

-header's collector exit pipe will be modified to match position and angle of OEM collector exit pipe

-midpipe/muffler/clamp to be supplied by customer [See Note c below]

-midpipe/muffler to be fastened to header collector exit pipe by clamp

[Clamp not supplied with header]

-header will have two O2 sensor bosses at 2000-2009 OEM header's O2 sensor locations: one O2 sensor boss on secondary tube after left front/left rear primary merge, one O2 sensor boss on secondary tube after right front/right rear primary merge

-right rear primary tube of all headers will be mandrel bent to provide 1/16" clearance from rear head cam chain tensioner when installed on 6th gen VFRs

-header's stud nut tension flanges will be 1/4" thick stainless steel [See Note d below]

-header's collars at head end of primary tubes will be reinforced and length adjusted for 1/4" head stud fixing flanges

-header's internal flow surfaces at head end collar joints of primary tubes will be finished smooth/flush [See Note e below]

 

 

*Wade's credentials:

Wade designed and built exhausts for Kerker Exhaust Systems from 1980-1988. Since founding his own exhaust fabrication business in 1989, he has produced custom, prototype, and production exhaust systems and components for numerous individuals and manufacturers, including Two Brothers Racing. He builds a production aftermarket full exhaust system for a current non-Honda V4-powered motorcycle. Here are two of his current projects. Photos taken 12/27/2018 and 12/28/2018 :

 

 

 

*Test bike:

 

For initial testing, we will use this motorcycle [Or possibly our 6th gen - see Note b below]:

2001 California 5th gen with 60,000 miles

K&N big mouth air filter [See Note f below]

PC III USB, map dyno tuned in 2013 with OEM California ECU, no O2 sensors installed

Dynojet O2 sensor resistor terminations installed on OEM O2 sensor leads

OEM 49 state ECU now installed, PC III not retuned, no O2 sensors installed

OEM 98/99 VFR headers ceramic coated with Staintune high mount slipon.

Maintenance performed before dyno testing:

New air filter, new Denso iridium IUH27#4 plugs, valve clearance adjustment, injectors professionally calibrated, starter valves synched, new thermostat, new silicon coolant hoses, new Engine Ice coolant, oil and filter changed w Mobil 1 0w-30 and Purolator PBL14610 filter

 

 

*Notes:

 

Note a - an 8th gen version of the performance header with 'widely spaced' front primaries is in the works for a production run to follow the initial production run of 5th/6th gen headers.

 

Note b - If there is significantly greater interest in proving the prototype header on a 6th gen, we have a 6th gen standing by and can use it for the dyno baseline run and test/tuning instead of the 5th gen. For 6th gen test/tuning, we will use the same dyno testing procedure at the same test/tune facility as described for the initial 5th gen test/tune. The 6th gen available for testing currently has ceramic coated 98/99 headers installed with gutted OEM mufflers and a PCV. We would obtain open flowing aftermarket 6th gen slipon mufflers to optimize testing of the prototype header.

 

Note c - Wade recommends keeping the the 51mm od collector exit pipe instead of reducing it to the OEM exit pipe's 49mm od for the following reasons:

1 - it is probable that reducing the collector diameter will have a [small] negative effect on top end performance

2 - Wade uses premanufactured tubing merges of very high quality. Reducing the collector diameter would mean that the collector merge exit diameter would be too large for the 49mm od exit pipe, and the labor required to adapt the two components would raise the cost.

3 - purchasers of a replica header who want to use aftermarket slipons can have the collector end of their slipon expanded to fit the 51mm od exit pipe by any competent exhaust/muffler shop. Two Brothers slipons  and OEM mufflers will require exhaust wrap to function as a gasket in place of the OEM 'donut' gasket.

4 - the collector joint of all slipon midpipes we could think of except TBR are 2" od and slotted at the clamping end. Wade was concerned that a 2" od midpipe that has been slotted to clamp onto the OEM collector pipe is likely to tear at the base of the slots when expanded.

IMPORTANT - when having a slipon's midpipe expanded to fit this performance header, make certain the muffler shop expands it gradually in two or more small steps. Wade recommends drilling a relief hole at the muffler side ends of the midpipe's slots to distribute stress and reduce the possibility of tearing. Wade tested the viability of expanded slotted 304 stainless steel 18 gauge 2" od tubing by slotting a piece of 2" tubing while I was at his facility. He then expanded the slotted end of the tube in two steps to fit over the 51mm od collector exit pipe with no tearing at the slots.

 

Note d - Here is Wade's 1/4" thick stainless steel head stud nut tension flange:

 

Here is the original TBR head stud nut tension flange [Note that flange is bent from tension]:

 

Note e - Original TBR has rough, unfinished joints in the internal flow surfaces at head end collars of primary tubes

 

Note f - See RVFR's June 8 2017 post on page 5 of vfrd thread '5th & 6th VFR 800 header build' for photos of standard vs big mouth K&N air filters. Both filters have K&N part number HA-8098

 

Note g - Significant improvement can be achieved over OEM gas flow through the exhaust port into the header primaries by using crush gaskets that do not intrude into the gas flow path when installed. The id of OEM VFR crush gaskets reduces to around 30.41mm when installed with header stud nuts torqued to spec. The exhaust port id is 32.45mm - that's a 2mm reduction in gas flow passage diameter. To solve this, we will be confirming Mohawk's recommendation to use GSXR750 crush gaskets between the performance header primaries and the VFR's head.

 

Note h - Wade has expressed a modest willingness to build complete exhaust systems in high or low mount configurations for 5th gen VFRs. These full systems would have the same specs as the full systems that were the only configuration in which TBR sold the VFR headers - the TBR headers were only available with a matching midpipe and muffler/canister. Mufflers built by Wade would be available in metal or carbon fiber. We neglected to ask Wade which metals he uses for muffler/canisters or what a full system would cost, but soon will ask him to specify materials and pricing. We have not yet introduced the possibility of Wade building a 6th gen full system, but will ask him if he'd consider it.

Just reposting the original topic so that someone just tuning in to this thread can catch up 

4 hours ago, Alvinvfr800 said:

What about the supercharger for the vfr? Dose that still around

I’m sure if you do a search you can find it 

the super charger is driven off the timing pully and isn’t a turbo driven off the exhaust .

On 9/25/2020 at 8:35 AM, ducnut said:

Rare stuff!

I found a pair of R1 fmf apex cans and just modified the hanger .

should bolt right up 

I’m just sitting here dreaming of the day I can slap these headers on with the new mid pipe to the fmf apex cans I have sitting on the garage floor .