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Message started by aintright on 04/25/12 at 20:14:00

Title: muffler build
Post by aintright on 04/25/12 at 20:14:00

so to start out, i'm not really one to buy something that i can build, that is unless it's just too time consuming. oh and i'm kind of a cheap bastard too

now that the preface is out of the way i'll start with what i am doing.

here's how i built my "drag style" exhaust.

after looking through dozens of different types of baffles i settled on a quiet core baffle from cobra
http://www.motorcycle-superstore.com/3/13/118/17363/ITEM/Cobra-Quiet-Core-Baffle.aspx

here's the link for the baffle.

next i measured the OD of the stock header which happens to be about 2"

a trip to the local auto parts store was in place, where i purchased 2.25 ID x18" tail pipe section, along with a 2.125" ID to 2" OD exhaust adapter.

from work i punched out a circle of perforated steel with 5/16 holes. the diameter of the steel was about 2.125"

here's a pic of the lay out

http://i1130.photobucket.com/albums/m524/cantkillit/bike/layoutformuffler.jpg

the little circle is the perf. steel

i then welded the perf. steel circle onto the larger end of the adapter like so

http://i1130.photobucket.com/albums/m524/cantkillit/bike/perfpipetip.jpg

this was then slid over the stock header and welded

http://i1130.photobucket.com/albums/m524/cantkillit/bike/adapterwithperfpipeweldedonheader.jpg

i drilled two 3/16 holes in the tail pipe section about 90* from each other to hold the baffle in. i then slid the baffle in about 2" from the end of the pipe and drilled two 5/32 holes into the baffle and used self taping screws to hold it in place

http://i1130.photobucket.com/albums/m524/cantkillit/bike/cobraquietcorebaffle2indown.jpg

http://i1130.photobucket.com/albums/m524/cantkillit/bike/cobraquietcorebaffleback.jpg

i just used an exhaust clamp to hold the pipe onto the header so i can tune it. i haven't had a chance to fire it up yet but i will hopefully tomorrow

here's the mock up

http://i1130.photobucket.com/albums/m524/cantkillit/bike/layoutbeforefitup.jpg

and on the bike

http://i1130.photobucket.com/albums/m524/cantkillit/bike/initialmockup.jpg

for mounting i'm reusing the stock mount, i don't have pics yet but i'll post up with how i cut it. i cut the mount with the studs in it off the stock muffler, then cut the rear most stud off, next i cut the mount on the frame in half, leaving just the forward most hole. then i cut the mount off and spun it to meet the where the muffler wants to sit

don't worry it's already been jetted according to the threads in the tech section and a jet kit courtesy of Lancer

a new battery box will be coming soon too

Title: Re: muffler build
Post by aintright on 04/25/12 at 20:15:19

i have some exhaust wrap also, the plan was to wrap the whole header and muffler, but it seems everyone just stops at the end of the header, can anyone tell me why that is?

Title: Re: muffler build
Post by justin_o_guy2 on 04/25/12 at 20:52:32

If youre willing to spend enough time on it, all youll have in it is your time & the materials. A Dyna costs about $20.00, looks good, sounds good & is a "known" part. Jetting wont be that big of a deal,

How many hours will it take? How much will you have in materials?
How long does it take to earn $20.00?

False economy,, interesting concept,, took me years to learn it.
IOW, Id buy a good lookin Dyna & put it on,

Title: Re: muffler build
Post by aintright on 04/26/12 at 03:31:04

i'm just not a fan of how the dyna looks, plus the sound bytes i've listened to didn't impress me much either.

i like the look and sound of the jardine, but i'm not spending $170 for a slip on muffler.

i've got about $45 into it now and maybe 2 hours, which includes having to cut the tip off twice because i forgot to put the thing on that bolts the header to the motor, then i welded it at the wrong angle.

Title: Re: muffler build
Post by justin_o_guy2 on 04/26/12 at 04:01:04

3A32352F29323C332F5B0 wrote:

which includes having to cut the tip off twice because i forgot to put the thing on that bolts the header to the motor,

Dontchya hate that? I flared more than one piece of copper tubing to discover the nut wasnt on yet..but, that doesnt hurt as bad as getting all carried away getting just the right ratio of lettuce & onion & pickle & tomato on a cheeseburger & forgetting the meat,,
Twice,, ( not the same day, thank God!)

then i welded it at the wrong angle

Bummer..

Title: Re: muffler build
Post by aintright on 04/27/12 at 03:37:20

hahaha, can't say i ever forgot the meat in a burger, but i did try to put it back in the fridge to heat it up instead of the microwave. on more than one occasion

oh and no progress was made on the muffler, there was a needed impromptu trip to buffalo ny to see the reverend horton heat

Title: Re: muffler build
Post by aintright on 04/30/12 at 18:52:23

so everything is done on the muffler it's all mounted up. a new exhaust clamp is on the way, one that will actually seal the muffler so i can start to tune it.

per the recommendations in the tech section for jetting. i started with a 55 pilot and 152.5 main, 1/4 spacer and 3/4 turn on the idle mixture screw.

with that it was actually spitting out fuel from the muffler, i think. i turned the idle mix screw down to the stock location and nothing more came out.

i haven't had a chance to take it for a spin yet to see how it runs, but my initial feeling is i'm going to have to add some more resistance to the muffler.

i tried to make a video from my phone, but being to close to the bike and in the garage it was too loud for the phone to capture the sound and it just cuts out

Title: Re: muffler build
Post by justin_o_guy2 on 05/01/12 at 03:29:38

well,, that aintright..

Title: Re: muffler build
Post by Serowbot on 05/01/12 at 03:40:23

687771766B6C5D6D5D65777B30020 wrote:

.but, that doesnt hurt as bad as getting all carried away getting just the right ratio of lettuce & onion & pickle & tomato on a cheeseburger & forgetting the meat,,
Twice,, ( not the same day, thank God!)

Bummer..

...and that just ain't right, neither... :-?...

PS... I'd reduce the pilot... or go to 1/2 on the spacer... ;)...

Title: Re: muffler build
Post by arteacher on 05/01/12 at 04:23:49

584741465B5C6D5D6D55474B00320 wrote:

[quote author=3A32352F29323C332F5B0 link=1335410040/0#3 date=1335436264]i'm just not a fan of how the dyna looks, plus the sound bytes i've listened to didn't impress me much either.

i like the look and sound of the jardine, but i'm not spending $170 for a slip on muffler.

i've got about $45 into it now and maybe 2 hours, which includes having to cut the tip off twice because i forgot to put the thing on that bolts the header to the motor, then i welded it at the wrong angle.

Title: Re: muffler build
Post by justin_o_guy2 on 05/01/12 at 04:37:07

I really cant say much, can I? :) Well,, except for Ouch,,
Hey, at least ya didnt leave the weenie out of the hot dogs,,
Besides, you didnt really want that job anyway, did ya?

Title: Re: muffler build
Post by Drifter on 05/01/12 at 07:07:06

Are you going to add a sound bite? I like it, always nice to see creative thinking!

Title: Re: muffler build
Post by justin_o_guy2 on 05/01/12 at 08:39:27

4F79626D7F6E790B0 wrote:

Are you going to add a sound bite? I like it, always nice to see creative thinking!

Aintright said

i tried to make a video from my phone, but being to close to the bike and in the garage it was too loud for the phone to capture the sound and it just cuts out.

He tried, but he bit off more than he could chew

Title: Re: muffler build
Post by aintright on 05/01/12 at 14:35:55

yeah a sound byte will be coming soon.

thanks for the heads up on reducing the pilot. i'm going to try to ad to the spacer first and see how that goes.

there is a slight loss in power, but not much. it seems to be in the low end.
i do like the sound though, nice decently low note and it doesn't drone on the road either.

when revved up, sometimes a bit of black smoke puffs out.

Title: Re: muffler build
Post by aintright on 05/02/12 at 20:55:16

ok. so now that it is tuned properly. (my idle mix screw was out more than i thought) i'm getting blueish white smoke coming out of the exhaust when idling. after the engine is warm.

i tried out the top end and did lose a few mph, but when i let off the throttle the motor died. the header isn't blueing yet. but the weld at the end of the header and the clamp on the muffler sure are.

i'm thinking i may need to up the main jet to a 155. it's at 152.5 right now. idle mix screw is 3/4 out with 1/4 white spacer.

what does everyone think?

Title: Re: muffler build
Post by Serowbot on 05/02/12 at 21:49:00

Black smoke is fuel,... Blueish/white is classic oil symptom...
Something's wrong in Denmark, and it ain't jetting... :-?...

Are you running Seafoam, or other additive?... that'll make blue/white smoke... they usually contain a mineral oil, and will smoke when overused...

Title: Re: muffler build
Post by aintright on 05/04/12 at 13:35:41

i'm pulling the plug to be certain it's rich, but yeah the end of the muffler is all black..

oh and i found out the oil problem. when i removed the stock air box i just put the breather cap from the air box onto the breather tube for the "crank case" well it decided to spit it and and pit oil everywhere, which it then dripped down onto the muffler when i would stop.

fixed it with a little mini air filter from autozone. now i need to change my oil...

ahhh the joys of learning...

Title: Re: muffler build
Post by justin_o_guy2 on 05/04/12 at 16:27:14

Ohhh, thats not too harsh of a lesson,, its a lot better than the
" Ive REally gotta keep an eye out for that sandtrap rake" lesson.