Exhaust system build.
I mocked up a pipe for the right side, welding together some exhaust pipe at the appropriate angles with the right amount of twist, fitted it to make sure it looked right, then took it to an exhaust centre and asked them to mandrel bend four bends from 42mm pipe to match the angles, so I could weld them together later.
I got the bends home and welded them together with the right amount of twist, but I didn’t like the angle of the tail pipe, so made a V cut in the pipe a few inches after the bend, bent the tail section up a little and welded the two pieces together. Repeating the process for the other side. ground them smooth, then painted them with exhaust black paint.
For the clamps I mounted some 10mm thick ally in the four jaw, turned up the 42 mm hole, then marked the position of the 10mm exhaust stud holes drilled them through, shaped the clamps and polished them.
For the lower mount, I bent up some 3mm steel plate in a half circle with short returns either side, shaped another 3 mm piece of steel to affix to the frame and welded it to the half circle clamp, then painted it exhaust black paint. Next I bent some 3mm ally plate in a half circle with returns each end, stuck it together with the steel half circle and drilled through four holes for stainless allen heads, and polished the ally half clamps.
I couldn't find any mufflers that appealed for my build, so decided to make my own.
I bought some 57mm tube for the bodies, some 41 and 45mm tube for the tail pipe and receiver end and had the ends coned out to 57 mm, and bought some 38mm tube for the baffles.
The cones were cut of each end of the 41 and 45mm tubes and tacked to the 57mm muffler bodies then mounted in the lathe and using a dial gauge marked so I knew where to weld to bring them straight. Once done the welds were ground and the joins smoothed over with a power file.
Baffles were cut to length, mounted on the lathe and scored to mark where the holes should be drilled so they would be in line, then 168 5mm holes drilled in each baffle and the ends capped.
None of these tubes will slide inside the next size up, .25mm too big, so using a drum sander I bored .25 mm off both the tail pipe and receiver ends Id. The baffle was then slid into place and fixed with an M6 stainless Allen head.
To support the mufflers I fabricated a couple of aluminium clamps/ hangers which clamp around the body of the muffler, polished it and fixed to the pillion peg mounts via M10 stainless allen heads. The pillion peg holes were 12mm so I bushed them down to 10mm with a couple of brass bushes I turned up. Mufflers are painted with high heat exhaust paint also.
These mufflers worked a treat, quieting the beast to a legal level.
I mocked up a pipe for the right side, welding together some exhaust pipe at the appropriate angles with the right amount of twist, fitted it to make sure it looked right, then took it to an exhaust centre and asked them to mandrel bend four bends from 42mm pipe to match the angles, so I could weld them together later.
I got the bends home and welded them together with the right amount of twist, but I didn’t like the angle of the tail pipe, so made a V cut in the pipe a few inches after the bend, bent the tail section up a little and welded the two pieces together. Repeating the process for the other side. ground them smooth, then painted them with exhaust black paint.
For the clamps I mounted some 10mm thick ally in the four jaw, turned up the 42 mm hole, then marked the position of the 10mm exhaust stud holes drilled them through, shaped the clamps and polished them.
For the lower mount, I bent up some 3mm steel plate in a half circle with short returns either side, shaped another 3 mm piece of steel to affix to the frame and welded it to the half circle clamp, then painted it exhaust black paint. Next I bent some 3mm ally plate in a half circle with returns each end, stuck it together with the steel half circle and drilled through four holes for stainless allen heads, and polished the ally half clamps.
I couldn't find any mufflers that appealed for my build, so decided to make my own.
I bought some 57mm tube for the bodies, some 41 and 45mm tube for the tail pipe and receiver end and had the ends coned out to 57 mm, and bought some 38mm tube for the baffles.
The cones were cut of each end of the 41 and 45mm tubes and tacked to the 57mm muffler bodies then mounted in the lathe and using a dial gauge marked so I knew where to weld to bring them straight. Once done the welds were ground and the joins smoothed over with a power file.
Baffles were cut to length, mounted on the lathe and scored to mark where the holes should be drilled so they would be in line, then 168 5mm holes drilled in each baffle and the ends capped.
None of these tubes will slide inside the next size up, .25mm too big, so using a drum sander I bored .25 mm off both the tail pipe and receiver ends Id. The baffle was then slid into place and fixed with an M6 stainless Allen head.
To support the mufflers I fabricated a couple of aluminium clamps/ hangers which clamp around the body of the muffler, polished it and fixed to the pillion peg mounts via M10 stainless allen heads. The pillion peg holes were 12mm so I bushed them down to 10mm with a couple of brass bushes I turned up. Mufflers are painted with high heat exhaust paint also.
These mufflers worked a treat, quieting the beast to a legal level.
Attachments
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WIN_20220412_15_44_21_Pro.jpg
