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Message started by savagebob on 07/09/13 at 03:20:11

Title: Exhaust baffles
Post by savagebob on 07/09/13 at 03:20:11

Ok so here in NZ we don't have heaps of cheap dyna mufflers, and it's not really the look I want anyway.

I want the straight drag pipe look with a slash cut end.

I've got a 16" BSA slash cut muffler to go on the end, but the baffles aren't there. Usually there would be some sort of fibreglass baffle inside secured with a bolt but it's missing.

I don't actually know how to repack the baffle, or how I should go about adding a baffle to achieve the right amount of back pressure the savage needs.

I've read the BCB drag pipe just uses a few discs with holes drilled in. I'd love to know more about this in detail as it sounds pretty easy to add that in. Or if someone can explain how best to repack this little muffler that would be good.

cheers :D

Title: Re: Exhaust baffles
Post by Gyrobob on 07/09/13 at 06:16:42

203225323436313C31530 wrote:

With a 650cc single cylinder motor (large separate exhaust pulses) anything you try with fiberglass packing will be ineffective after a hundred miles or so. Use some solution that has baffles with no packing.

Here's one suggestion. See reply #277 in the Double RYCA Build thread.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1304722902/270

This pic shows the exhaust flow once the packing (a joke) is removed with two baffles and a sink strainer added. The stuff I added is shown in blue.

http://i258.photobucket.com/albums/hh253/Gyrobob_theOriginal/Motorcycle/RYCA%20CS-1%20LS650%20S40%20Savage/EMGOmoddrawing01.jpg (http://s258.photobucket.com/user/Gyrobob_theOriginal/media/Motorcycle/RYCA%20CS-1%20LS650%20S40%20Savage/EMGOmoddrawing01.jpg.html)

This shows the internal baffle (dished washer with added holes) welded in, the external baffle welded on, and the sink strainer welded on the end.

http://i258.photobucket.com/albums/hh253/Gyrobob_theOriginal/Motorcycle/RYCA%20CS-1%20LS650%20S40%20Savage/EMGOMod05.jpg (http://s258.photobucket.com/user/Gyrobob_theOriginal/media/Motorcycle/RYCA%20CS-1%20LS650%20S40%20Savage/EMGOMod05.jpg.html)

Title: Re: Exhaust baffles
Post by Dave on 07/09/13 at 06:24:58

I built a muffler that uses a megaphone and some perforated pipe. The system requires the exhaust to flow in and out of the perforated pipe 4 times, and the megaphone area acts as a chamber to even out the pulses. Bigger chambers would probably be better - but it does a good job and is louder than the DYNA muffler conversion but not as loud as a SuperTrapp.

If you are running a straight pipe it will be tough to cut the noise down much - the best you could do is install a perforated baffle that restricts the flow some and uses the header pipe to even out the pules a bit.

Title: Re: Exhaust baffles
Post by Dave on 07/09/13 at 06:44:05

With a straight pipe, the best you can do is install a perforated baffle that slides inside the pipe. It is going to be loud and make babies cry....and you won't be popular with the neighbors.

Not sure what is available in your area, but most aftermarket companies offer some sort of baffle like the ones shown below. You slide them inside your pipe and drill a hole and insert a bolt to hold them in place:

Title: Re: Exhaust baffles
Post by dan49829 on 07/09/13 at 07:08:03

I don't like the looks of aftermarket pipes - prefer the stock look - someone put a lot of time and effort designing them to fit the lines of the bike - so is there something that can be done to improve the stock pipes - which sound like crap to me?

Title: Re: Exhaust baffles
Post by Dave on 07/09/13 at 07:26:22

55505F0508090308310 wrote:

Look in the Technical Section, do a search, or look in this thread:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1316137961

Title: Re: Exhaust baffles
Post by Gyrobob on 07/09/13 at 08:32:30

Here's a thought, since you like the straight, fat, drag-pipe look:

http://i258.photobucket.com/albums/hh253/Gyrobob_theOriginal/Muffler_dragpipestyle20bucks01a4icnh_zps52cdafb2.jpg (http://s258.photobucket.com/user/Gyrobob_theOriginal/media/Muffler_dragpipestyle20bucks01a4icnh_zps52cdafb2.jpg.html)

Make the thing as long as you want. If you want it sticking out past the end of the motorcycle, you can do that easy. Three or four feet long, maybe. Two feet long would be pretty noisy.

It'll be cheap. All you'll need is a length of 2 1/8" pipe, a length of 1 1/2" pipe, a 3/16" drill, some scrap, a hacksaw, and access to a welder. Shoot,.. you could buy ALL the parts AND a wire-feed welder on sale at Harbor Freight for what a four-foot-long fat-looking drag-pipe would cost!

You'll also need a couple clamps and some bracketry of some sort to fasten the aft end to the bike.

After you make one or two of these, you could probably crank one out in a couple hours (not counting the time to drill and bend the zillion holes). Make a few, sell 'em, and get all your money back.

If you want it chromed, that'll set you back a few bucks. You could wrap it in a header-sweater or paint the thing with high-heat paint. Some of those paints work really well,... most don't.

Title: Re: Exhaust baffles
Post by savagebob on 07/09/13 at 14:18:40

thanks for all the detailed responses. Apparently the BCB drag pipe (which sounds pretty good to me) just had 4 discs welded inside with some holes.

that would be so easy to do. Can anyone confirm that?

This is the slash cut end I've got which the baffle is missing. I'll just use one of them, or maybe cut and weld them together onto a bit of extension off the header for the drag pipe look.

http://s15.postimg.org/qyphk2dwb/272762350.jpg

Title: Re: Exhaust baffles
Post by Gyrobob on 07/09/13 at 18:39:14

2C3E293E383A3D303D5F0 wrote:

Neither one of those alleged mufflers will make any difference sound wise unless you choke them off so much the back pressure will make the bike feel like a 350.

It's just plain physics. You have to have some volume somewhere to attenuate the sound pulses. Those little chromed bits have no volume.

Title: Re: Exhaust baffles
Post by savagebob on 07/09/13 at 18:51:12

how does the BCB pipe work then?

http://s17.postimg.org/t2g7vrstb/a_Suzuki_Sav_s40_side2.jpg

Title: Re: Exhaust baffles
Post by SALB on 07/09/13 at 20:43:09

Those chrome shorties will work like a megaphone with the large outlet. The BCB pipe has round plates with @5/16" holes welded in about 4" from the head pipe, in such a way that the holes in the plates are offset. The extra length and smallish diameter help with velocity/evacuation of gasses.

Title: Re: Exhaust baffles
Post by savagebob on 07/09/13 at 21:10:29

ok that's what I wanted to know.. how many plates are there? Do you know how many holes in each plate? Are they sort of like the sink strainer holes in the end of the std pipe?

I was thinking of making something like this:

http://s21.postimg.org/3ukvl5w2v/exhaust.jpg

Title: Re: Exhaust baffles
Post by Jolly Executioner on 07/10/13 at 01:11:10

I have the bcb muffler and the plates have four holes. Here's a pic, don't know if you'll be able to see it as muffler is on bike so had to take pic from other end.

Can anyone tell me what kind of impact removing one of the plates would have on noise and backpressure?

Title: Re: Exhaust baffles
Post by savagebob on 07/10/13 at 03:41:37

wow.. only 4 little holes.

How many plates are there and how close are they together?

Also, what dia is the drag pipe?

Title: Re: Exhaust baffles
Post by Jolly Executioner on 07/10/13 at 18:45:47

I've emailed bcb and asked those questions as I needed some info from them anyway, ill post here when they reply.

Title: Re: Exhaust baffles
Post by savagebob on 07/10/13 at 19:21:25

came across this trick for reversion cones which seems pretty sweet:
http://xlforum.net/vbportal/forums/showthread.php?t=247790

Title: Re: Exhaust baffles
Post by paulmarshall on 07/11/13 at 14:30:01

A guy in Auckland made my whole exhaust system at a reasonable price.

Title: Re: Exhaust baffles
Post by savagebob on 07/11/13 at 17:02:45

4D7378656865680A0 wrote:

[size=12]Here's a thought, since you like the straight, fat, drag-pipe look:

http://i258.photobucket.com/albums/hh253/Gyrobob_theOriginal/Muffler_dragpipestyle20bucks01a4icnh_zps52cdafb2.jpg (http://s258.photobucket.com/user/Gyrobob_theOriginal/media/Muffler_dragpipestyle20bucks01a4icnh_zps52cdafb2.jpg.html)

I like this, I can buy pre-drilled pipe either just holes, or louvered. But I've heard the louvered stuff is too restrictive. Plain holes is better for power and I'm more interested in performance than keeping my neighbours happy, I don't like them anyway.

Question about that diagram; you say to bend the edge of the hole facing the flow down to diver gas into the space above. Shouldn't this be the other way around? I would think the far edge of the hole from the incoming flow should be bent down slightly to catch the gasses and direct them out of the inner pipe. :-?

Title: Re: Exhaust baffles
Post by wearsabrowncoat on 07/11/13 at 17:59:36

Found my rattle and the answer to your question. Had a BCB drag pipe that came with bad disc welds. This is what a couple baffles look like. I only counted 3 discs but one might have fallen out before I realized the problem. Notice how the disc is not full diameter and the holes are offset one to the next. With only one baffle exhaust was slightly louder but I did have significantly more backfires. Don't know if a different jet would fix that and my mix level was previously turned out to the max for perfect tuning. By the way, BCB is an awesome company. I called and they immediately sent me a new pipe - with an upgraded disc attachment design with free express shipping. One last shameless plug - I'm selling the old pipe on eBay for anyone enterprising enough to do a repair.

Title: Re: Exhaust baffles
Post by LANCER on 07/12/13 at 04:28:39

25373320213330203D253C313D3326520 wrote:

I've not purchased any parts from them yet but there are some parts that I have set aside for possible future orders. It's good to know that their customer service is so good.
Thanks for the info.