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Open Wide For Chunky: Chopping and Gutting \'05 muffler

I actually like the look of the '05 muffler on my bike, but it could be smaller, stronger-sounding, and lighter. So, I got a take-off (thanks, Paul), sliced it in thirds and used a shortened Yosh race baffle to build a GP-like, cheap pipe bolt-on. I did keep the valve to control around town sound and save some low and mid range.
The stock muffler is incredibly well made. Each section is many layers thick w/ Ti and sheets of stainless steelwool and foil-backed fiberglass. Internally, it routes the exhaust thru three chambers ( the end cap is a hollow cap). I don't see how the baffles could be replaced or drilled out as someone suggested. Pics to follow, hopefully.
The end cap is spot-welded to the first third with the race baffle and harvested packing.
I haven't installed it yet. I waiting to get a good remap. Any suggestions? Also, I haven't installed the hanger because I have to fab a strap or weld the stock one on.
It should be be quieter than the Racefit but louder than the Yosh TRC shorty at full open.






 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

Looking forward to the photos Doug, glad the stock pipe is going to good use.
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

I am tempted to just get it powder coated black till I get the Yosh I really want.. lol (Could that even be done?)
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

for the future please do your posting like i have done for you here.. no sense having 6 threads on the step by step. it makes it much harder for anyone to follow.

nice job by the way.. lets see some pics of it on the bike.
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

nice work man!
i like it!!!
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

Is there anything in the pipe that would be destroyed if I did powder coat it?
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

I just dont think i like the look of the final result. Sorry
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

He needs to paint it to look like a fish..
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

i'd really like to see it on the bike, hurry up!!!!
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

Question: the second picture from the top, does the middle slice of tthe pipe face right or left? I.e., do the two pipes face the endcap or the engine?
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

From the looks of the way the hanger is on there, they face towards the endcap, not the engine.
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS PICS

on the bike!!! Everyone is waiting.....
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

you are crazy!!!! (and talented)

good job, i couldnt imagine doing that work!
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

you are crazy!!!! (and talented)

good job, i couldnt imagine doing that work!
I agree.......nice cutting and welding.
 

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Re: Open Wide For Chunky: Chopping and Gutting \'05 muffler

Did yu attempt to start the bike without the exhaust? How loud is the engine on its own?
 
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