It been a slow process, working on the exhaust here and there, but I got the exhaust modified and back together.
Key to this project for me was the dremil tool. It gets you in the pipe for the fine grinding and cutting work.

1. I first ground down the welds that hold the stainless steel cover on the silencer and removed it.

2. Used a band saw and cut the back cover plate off the pipe.

3. Using a 1" hole saw cut the remainder off the stock .5" exhaust outlet off the first inside plate and opened up the hole on the cover plate.

4. Then I ground down the spot welds that held the first plate in and removed it.

5. Drilled lots of holes around the spark arrrestor/baffle and removed it. (the one guys are drilling with a 1/2" hole)

6. With access to the deeper part of the pipe I then drilled the second baffle to 3/4".

7. Cleaned up all rough work with the dremil tool.

8. Reinserted the first plate in the pipe and spotwelded in the original location.

9. Welded a slightly longer than stock 1" (OD) 3/4" (ID) pipe to the first plate.

10. Welded the cover plate back on and welded the new 1" OD pipe to the cover plate.

11. paint the exhaust pipe except for were the original spot welds were that held on the stainless steel cover.

12. Weld on the stainless steel cover and paint a strip down the stainless cover conection.


I took step by step pics of the pipe as I progressed through the project but the pics are 1.8MB each. Too big to attach to this posting. Crap, I would love to show the pics. I forgot to set the pic size to small.

I haven't put the pipe back on the bike yet so I'm not sure what the sound is like. I've always had 2-strokes so I'm sure I'll like the added noise. Better not be too loud though. I'm also waiting for the carb mod parts before I ride it with the exahust change. Should be any day now. I hope there is a little power gain from the exhaust. I might fire the bike up without the carb part just to see what I'm in store for.

 

while you had it apart could you see the catalitic converter at all? Did you tig or mig it back together

 

www.tinypic.com free image host, provides a link for the photos, and resizes them to be no more than 250 KB each. Also if you have WinXP go to www.windows.com and search for image resizer power toy. Adds a new function to right clicking on a picture in which you can resize it.

 

regarding your pic size I suggest www.irfanview.com download the viewer, its tiny but a very good program that will not only resize pix but has lots of other functions as well. Its brilliant, I can open a pic, resize it, save it and upload it all before photoshop even opens.

Cheers

Garry

 

Blacktail,

I could see the catylic convertor through the 3/4" hole I drilled in the second deeper baffle. The cat is located right were the head pipe transitions to the large chamber before the silencer pipe section of the exhaust. Interesting enough the cat only fills probably 1/3 of the large chamber on the exhaust. If you look at the outside of the large chamber area, you will see spot welds. These spot welds are the location of the back of the cat.

I did think of cutting the large chamber with the band saw and exposing the cat. For some reason I decided not to. You probably could cut out the cat and free up this part of the stock exhaust. I think I wanted to start off a little slower with my mod and perhaps I will cut the large chamber and see whats going on in there later on. I will be buying an exhaust system next year, so maybe then I will do it for fun and spread the word if it works.

I would think accessing the cat by cutting the large chamber and putting back together would probably be easier than all the cutting and welding I did on the silencer section of the exhaust system.

Josh & Garry,

Thanks for the picture resize websites. I will check it out later and hopefully post my pics. I'd like to share the pics of what the inside of the exhaust looks like to the forum guys. Could help someone else out, you know.

 

Photobucket automatically re sizes to 600 x 800 plus you can have hundreds of pics in there.

 

Random Picture. I love where I work. 11 years and counting, and I look forward to going to work everyday.

 

I did this mod also and WOW!!! This is awsome, could be a bit louder but for the price I gues I shouldn't bitch. I used a slightly bigger pipe though.
One question, what did you re-jet to. I am gong to try a # 132
Might be a little rich but I'll have to wait and see. I have a few other mods to so it might work out.

 

Deej,that place looks like a giant take out stand from the airjust raggin you bud,hell you can hunt right at lunch break in them there woods.