| Author | Message | ||
     D_adams |
Just documenting what I am using and how I'm doing my own exhaust. 3.5"x8"x12" oval SS case body, 2.5" midpipe, 1.875" collector pipes, Megs collector, 23% open perforated SS internal tubing, SS wool and fiberglass packing, SS end plates and various bits of tubing. Hangers and clamps are also SS. Eventually I'll polish the whole thing.                | ||
| Arcticcr |
Nice post! I'll be looking forward to the updates. Do you plan to dyno the bike, before and after? Jay | ||
| D_adams |
It's already been dyno'd and was at 123 hp with only a k&n filter. I have some cuts to make tonight and hopefully I'll get some of this welded up after work or first thing tomorrow. I'm guessing there's maybe 4-5 hours of fitting and welding to do. This is a first for me, so I'll try to take plenty of pics as I go along. I probably could have bought the race ecm and buell race pipe by now with what I've thrown at this project and I'm still not done yet. Of course, the TIG welder was the high dollar item at about $1500 and I ended up getting a foot pedal for it a couple of weeks ago. I'll finally get to use it tomorrow. | ||
| Justa4banger |
I like that simple yet sharp looking. I dunno if its going to really muffle much, but we will see. Now if someone would just mass produce them. | ||
| D_adams |
If this works as I anticipate, yep, it could be mass produced. The parts are "off the shelf" and easy to get. Some cutting and each would be hand crafted, but I'd like to think it will be special. Parts cost at the moment is about $350-400 including the stainless steel wool and fiberglass packing stuff. | ||
| Ccryder |
Just color me curious, what are you basing your design on: Something that fits, something I can get components to fabricate, something that looks better than stock, some calculations for wave flow or, what? I do wish I had the time and $'s just for the equipment you have. Best I could do was a el-cheapo flux core "Mig" welder. Hey it works but, a nice TIG welder sure would be nice. We will all be interested in the outcome of your project. BTW nice picts. | ||
| 1_mike |
Looks a bit like the Buell race muffler..along with the basic dimensions... Nice work. Mike | ||
| D_adams |
The design is just something I wanted to try. It's similar to the Buell race pipe, but the can is longer, the primaries are shorter and the midpipe is shorter as well. I want it to fit where the stock pipe does, not hang too low, sound good and look at least halfway decent. I know I can fabricate it, it's just coming up with the time to get it done. Everything keeps getting pushed back on my schedule. I did some basic calculations a while back and I don't remember the exact numbers, but I think the industry standard for this size header is 2" or therabouts. I came up with some slightly larger numbers and just arbitrarily picked 2.5" It's a volume vs. velocity thing. I just wanted to try this and see if it works. Modifying it to a smaller size is just a matter of slipping in a smaller diameter tube temporarily to change the velocity. I think HD sells them as "torque tubes". As far as being close in the basic dimensions to the Buell pipe, I just looked around to find a can that would fit what I wanted. This one is longer than the race can by a couple of inches I think. Magnaflow came close for buying an off the shelf muffler in polished stainless, but the inlet/outlet option just wasn't there. I found what I wanted with these parts, so I'll give it a go and see what happens. The equipment is nice to have, but you can probably buy used on ebay for less than 1/2 what I paid. I wanted a warranty, so I bought new instead. | ||
| Bob_thompson |
Dean, is your muffler going to be a straight through with packing like the Buell race unit or will you use a turbo type (baffles) system? If straight through your choice of perforated tube seems like it might not kill much noise and the oval seems un-necessary. Just wondering? I chose the turbo type to have a high flow baffle type to reduce as much noise and still have good flow. Great job though, looking forward to your finished product. Bob | ||
| Blackflash |
It does look nice adams .You are a true die hard worker.I like that.Looking forward to a finished product and some sound clips.Any possibilities of a x pipe downpipe then into a 2 into 1 before the muffler?Whats your thoughts on that?I'm pondering myself on improvements.I have the tone I want just thinking about improvements. | ||
| D_adams |
No, it's not going to be straight through design, although it's close. It will be 2 chambers, the 2nd one will only be about 2.5" long though. I'll post pics as I get farther along. I am planning on starting with welding tomorrow morning. I have the new collector pipes cut and slotted. I need to mount them on the bike to have a good frame of reference first. They'll get tack welded while on the bike, pulled off and then complete the welding on a bench. It's not the easiest thing to describe, so I'll take pics of it so you can see what I've done. I don't know how far along I'll get, but with a bit of luck, I'll have a good prototype by noon or a bit after. It's supposed to be nice out tomorrow and I really want to go ride. | ||
| Hdwrenchtx |
looks great | ||
| D_adams |
Some more pics as I go along.      Tacked together here for a rough fit, double checked, it's within 1/8" of where I wanted it, maybe less.        Internals of the muffler.        This one is special, we all know why.      This is it for a short bit, need to weld on the end cap and then mount it up to see where the hangers need to go and how long to make them. Btw, it's loud. Video later also. | ||
| 99buellx1 |
Thought you wern't going to do a straight through? | ||
| Ccryder |
I can only imagine how LOUD it really is! How are you going to repack it? | ||
| Bob_thompson |
Nicely executed Dean! I agree it just might be kind of loud but if it is a small amount of back pressure with one of my favorite baffles might be in order if you wish. Might just add some better bottom end also. I really like the fully under the engine placement. Great job my friend. Bob | ||
| Ottobotz |
-Is there any clearance issues, like speed bumps? -Looks good, though, cant wait for the video..... | ||
| D_adams |
First run, throttle stuck near the end when I blipped it. Not sure why, but it's not doing it now. Bike was cold, not sure if it was an off idle thing or not. Took it out on the service road and it's got more balls on the bottom end than before, according to my sotp dyno. HOLY COW this thing snarls! At any rate, I won't get a chance to run it on a dyno for at least a week or two. It definitely feels stronger and runs considerably smoother, pulls hard from 2500 rpm without chugging or anything. This was FUN! (Message edited by d_adams on January 18, 2010) | ||
| T_man |
It doesn't sound too loud - but then again = hard to tell online. Nice and deep though. Good work. | ||
| D_adams |
Finished pics    | ||
| Ravnna431 |
That looks great...good job! | ||
| Ccryder |
VERY nice job! Should be real interesting what the dyno thinks. | ||
| Blackflash |
I agree nice job!! | ||
| Mountainstorm |
It's got the look and the sound. Great work. | ||
| Thefleshrocket |
Are you gonna build these? If the dyno shows no loss in power compared to stock (more power would be great) and you can produce them for a dollar amount I can get past my wife, I want one! (Also can't wait for more sound files.) | ||
| D_adams |
I need to take it back off and weigh it. I forgot to do that earlier. Thanks for all the positive comments. I'll work on getting a flyby sometime soon, weather permitting. | ||
| Arcticcr |
I'd like to place an order  Looks good and sounds even better!!! Jay | ||
| D_adams |
No current plans for repacking, I want to see how long this will last as is. I figure at least 4-5 years. It's stainless steel wool and FMF fiberglass strand packing. It will be tough to take it apart. Both ends would need to be ground off or cut. I guess you'd lose maybe a 1/4" doing that, but it would still work. Just need to re-weld it when done. I doubt that it's going to get much louder than it is. Roughly it's the same as a Jardine, but deeper and without the sharp bark or hard edge to the sound. I just posted this so everyone who wanted to could see how it's done. I guess it took me 7 hours total, but I had to hand grind out the collector to slip fit, which blew about 2 hours of time messing with that. The headers are NOT exactly 1.75" OD. Mine measured 1.775" so I had to do a bit of hand grinding on it to slip them on. No tubing expander, so that's why. I'll order one if I really need it, the cheapie ones are about $35 and the Lyle brand is about $80 or so. | ||
| Nillaice |
i like it. sounds throaty but not raspy.  | ||
| Green1 |
Great sound from it,now you've got me thinking |
