As requested, how I cut my Yosh, with pics. : Suzuki GSX-R Motorcycle Forums: Gixxer.com

**BuzzinHornets** · 03-26-2007, 08:32 PM

So a few people requested in my "2 new pipes" thread that I post a write up of how I did it. I was wise enough to document the process in pictures so here it is.

**Disclaimer**
I do not profess to be an expert at pipe cutting, therefore this is only the process that I used. Some may have other ways, or done things a little different. I can not make any claims of performance gains or loss with a cut pipe. I can only say that this process worked for me and I am very pleased with the results. Now on to the show!

Here is the pipe right off the bike.

I then drilled out the rivet heads on the collector side and removed the steel band. After about 30 min of trying to remove the end cap from the pipe It hit me, why not make a practice cut below my final cut line. This cut was made with a hacksaw and allowed me to not only easily remove the end cap, but also practice cutting te stainless sleve. (I would recomend this aproach as the end cap is a BITCH to get off! Cuttting it here allowed me to pry the end cap off without damaging any part of the stainless sleve that I was keeping.)

Here is a pic with the first cut done.

The internals finally exposed.

At this point I still could not seperate the sleeve from the end cap, the sleeve is on there tight. So i whipped out my trusty rotary tool and applied a cutoff wheel to the sleeve. To my surprise this baby cut through like a hot knife through butter! With the cut made I finally had the end cap free.

Now things get serious as you can see by the frosty beverage I have prepared for myself!

Now on to marking the final cut line (notice that the head on my frosty beer has frozen due to the ultra cold glass!) I used the blue 3m painters tape to mark my line. By lining the tape up around the can I was left with a straight line to cut from. Also ditched the hacksaw at this point in favor of the rotary.

Cut complete.

Baffle exposed. There is a ton of fibreglass inside this sum beotch!

I cut the baffle off so that it would just fill in the end cap and started to reinstall the end cap. Again this end cap proved to be a pain. A little persuasion from the old malet an the whole piece came together like a charm.

Here is where I re-riveted the can. This was much easier than I thought. I just lined up the band in the same mannor as the outlet side and drilled my first hole where the two ends of the band came together. I placed the first rivet here and worked my way around the can in the same fasion. (notice that I am still enjoying my frosty beverage!)

Here is the final product! A short can and an empty beer mug!

The final product mounted on my baby!

There you have it. I hope this post can provide help to those who need it. I know I enjoyed making it. Don't be afriad to try this. Just go in prepared and have fun!

**NoXi0uS** · 03-26-2007, 08:54 PM

excellent job on your project!

**smoothgixxer** · 03-26-2007, 08:56 PM

damn it took you a while to finish that cold beverage. i just did the same thing on my ROUND pipe. if your can is ROUND make sure you line it up right so the exaust tip and badge is positioned how it should be. i put it all back together and re-riveted it only to find out the badge was facing the inside of the bike and the tip was facing inward. i had to drill out the rivets and re-cut it to get it right but man it looks hot now. sounds great too. hope that makes sence im about 10 beers deep at the moment. if you have a triangle shaped pipe, this would not be a problem of course

**jakasaurus25** · 03-26-2007, 08:58 PM

well done...Thanks....

**icup 05_750** · 03-26-2007, 09:01 PM

Thanks for the write-up!

**GixxerKOE** · 03-26-2007, 09:05 PM

do you think it sounds better than before?

**BuzzinHornets** · 03-26-2007, 09:30 PM

Quote:

Originally Posted by GixxerKOE

do you think it sounds better than before?

Better is a little subjective. I have not had the chance to ride much after I did this. It is louder but as far as better it's hard to tell at this point because to me it sounds killer either way!

**URnotyourSN** · 03-26-2007, 09:55 PM

Has anyone ever made a mod that lowers the support ring. I like the looks of it but hate how that ring covers the Yosh plate.

**toezter** · 03-26-2007, 09:55 PM

you know...if you're steady enough with the dremel, you could "trim" up the area where the Yosh logo is covered by the bracket.

honestly, you don't need a full ring to support the can.

**blackstar** · 03-26-2007, 10:45 PM

nice write up!! final result looks awesome

**zjbarnes** · 03-26-2007, 11:27 PM

I have that same exact beer mug. What size are those rivets?

**BuzzinHornets** · 03-26-2007, 11:34 PM

Quote:

Originally Posted by zjbarnes

I have that same exact beer mug. What size are those rivets?

I used aluminum 3/16 long rivets.

**Cheez5000** · 03-26-2007, 11:41 PM

sweet write-up! do you think it would be any different to do this on a carbon fiber pipe? and when you refer to "rotary tool," similair to a dremel? :confused

**zjbarnes** · 03-27-2007, 12:07 AM

Quote:

Originally Posted by BuzzinHornets

I used aluminum 3/16 long rivets.

Thanks

**BuzzinHornets** · 03-27-2007, 07:21 AM

Quote:

Originally Posted by Cheez5000

sweet write-up! do you think it would be any different to do this on a carbon fiber pipe? and when you refer to "rotary tool," similair to a dremel? :confused

Can't se why carbon would need a different process, although I would be more careful when cuting the sleeve and re-iserting the end cap. And yes, by rotary tool I mean my Black and Decker Dremel knock off

**.:1k:.** · 03-27-2007, 04:38 PM

Excellent write up, very descriptive. I just wish there was a super short exit mod that more resembles the k6 and k7s. For some reason I really like that, but a job well done!