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General Category >> Technical Documents/Reference >> Exhaust port mods, custom exhaust pipe
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Message started by lancer on 09/04/05 at 10:08:25

Title: Exhaust port mods, custom exhaust pipe
Post by lancer on 09/04/05 at 10:08:25

Message sent 7/14/12, 12-3-12

I am doing a few upgrades and just wanted to log them in to the community file.


Header under construction

http://images1.snapfish.com/232323232%7Ffp999%3Enu%3D323%3A%3E639%3E697%3EWSNRCG%3D33444%3B%3C%3B%3C6339nu0mrj



A little exhaust port work
Original port.........I measured the port before I started but cannot find in rignt now...I think it was about 32-33mm...at this point it is opened to 34.5mmhttp://images2.snapfish.com/232323232%7Ffp53245%3Enu%3D323%3A%3E639%3E697%3EWSNRCG%3D3236%3B89%3A57368nu0mrj

A little more porting to do yet, will be kind of a "D" shaped port eventually.
http://images1.snapfish.com/232323232%7Ffp39%3A%3Enu%3D323%3A%3E639%3E697%3EWSNRCG%3D3235944255478nu0mrj

Title: Re: Lancer Upgrade
Post by klx650sm2002 on 09/05/05 at 03:36:03

Hey Lancer

Exhaust port mods way to go.

Clive W  :D

Title: Re: Lancer Upgrade
Post by lancer on 09/08/05 at 13:04:34

I am making progress, it is a bit slow but step by step...

Some of  the pics of yesterdays work:

Welded header
http://images.snapfish.com/3449438323232%7Ffp3%3B%3Dot%3E232%3B%3D72%3A%3D788%3DXROQDF%3E2323%3A9884%3C2%3B7ot1lsi
Supertrapp muffler with welded adapter
http://images.snapfish.com/3449438323232%7Ffp47%3Dot%3E232%3B%3D72%3A%3D788%3DXROQDF%3E2323%3A98864%3A53ot1lsi
Complete exhaust system welded together
http://images.snapfish.com/3449438323232%7Ffp63%3Dot%3E232%3B%3D72%3A%3D788%3DXROQDF%3E2323%3A98893%3A%3C%3Aot1lsi
Muffler bracket being modified
http://images.snapfish.com/3449438323232%7Ffp64%3Dot%3E232%3B%3D72%3A%3D788%3DXROQDF%3E2323%3A98846%3B%3A2ot1lsi
Exhaust system set up in place in order to make new bracket

http://images.snapfish.com/3449438323232%7Ffp54%3Dot%3E232%3B%3D72%3A%3D788%3DXROQDF%3E2323%3A98886742ot1lsi
Exhaust port at the beginning
http://images.snapfish.com/3449438323232%7Ffp64%3Dot%3E232%3B%3D72%3A%3D788%3DXROQDF%3E2323%3A98893%3B49ot1lsi
Port during modification
http://images.snapfish.com/3449438323232%7Ffp64%3Dot%3E232%3B%3D72%3A%3D788%3DXROQDF%3E2323%3A98864%3A%3B4ot1lsi
Port cleaned a bit to see what else needs to be removed
http://images.snapfish.com/3449438323232%7Ffp63%3Dot%3E232%3B%3D72%3A%3D788%3DXROQDF%3E2323%3A9886%3B8%3A4ot1lsi
Exhaust port when finished, note a slight "D" shape, with the flat side of the D on the bottom of the port.
http://images.snapfish.com/3449438323232%7Ffp
58%3Dot%3E232%3B%3D72%3A%3D788%3DXROQDF%3E2323%3A988766%3B2ot1lsi

http://images.snapfish.com/3449499523232%7Ffp58%3Dot%3E232%3B%3D72%3A%3D788%3DXROQDF%3E2323%3A988766%3B2ot1lsi

Title: Re: Lancer Upgrade
Post by lancer on 09/12/05 at 09:05:05

Installation complete.

This was taken on Saturday.  On Sunday I went on the March of Dimes Ride, which was a lot of fun.  I am a  new memeber of the Southern Cruisers mc club and rode with them for this ride.  I met a lot of good folks and am looking forward to a lot more of these rides.  This club is linked to several others in this area of the state and they have stuff going on all the time.  I receive emails several times per week about the activities that are coming up, and with the different clubs all linked together everyone gets the info from everyone else.  
I like it.



The complete bike..........


http://images.snapfish.com/3449769523232%7Ffp47%3Dot%3E232%3B%3D72%3A%3D788%3DXROQDF%3E2323%3A%3A655768%3Aot1lsi

After the ride was over, on my way home...actually about 1/4 mile from the house the muffler hits the pavement......grinding sounds...............not good..........
The weld at the front end of the muffler did not hold.

BUMMER!!!!!!!!!!!

The surprising thing was that after I removed the muffler in order to ride to the house (got to get the car and go back to pick up the muffler....that sucker was hot!  Burned the green grass dead).   Anyway, with just the header and no muffler, the bike ran great.  It had been running rich all day.  I had put an Edelbrock Quicksilver  on it for the days ride but was not able to lean it out enough...needed a different needle.  So it had been running rich in the low and high range, but good in the midrange.  After the muffler was off, and just the header, the engine loved it...ran much better and the sound was just AWESOME!!!

So now I need to work out a new attachement for the Supertrapp...I will leave  the discs off the next time and run with just the open muffler .  The Amal goes back on until I can get some new needles for the Edelbrock.


Title: Re: Lancer Upgrade
Post by Greg_650 on 09/24/05 at 10:33:11

BTW - since you aren't using the muffler bracket with your SuperTrapp, you can completely remove it from the frame.  Might clean up that area even more if you do...just a thought.

Here is what I did to mine for the Raask pipe.

http://i21.photobucket.com/albums/b277/gmdinusa/MufflerBracket01web.jpg

Title: Re: Lancer Upgrade
Post by wpv on 02/02/09 at 19:19:48

hey lancer what other mods have you done the engine

Title: Re: Lancer Upgrade
Post by verslagen1 on 02/02/09 at 19:30:01

You got them seats filled with helium?
Or is that a 12" shock?
Most people lower the front end when they want sport bike stearing.

;D

Title: Re: Lancer Upgrade
Post by LANCER on 04/03/09 at 06:35:11


6A796E6F707D7B79722D1C0 wrote:
You got them seats filled with helium?
Or is that a 12" shock?
Most people lower the front end when they want sport bike stearing.

;D


I have 12.5" Progressive 418 rear shocks on it.  Another great deal from ebay.   8-)

Title: Re: Lancer Upgrade
Post by diamond jim on 04/03/09 at 08:54:19

Edlebrock Quicksilver?  Is that similar to the Carters?  Does it have the adjustable jetting?

http://i255.photobucket.com/albums/hh128/russ_diamond_jim/34497695232327Ffp473Dot3E2323B3D723.jpg

Also, your intake setup in this pic has perked my interest.  How do  you have it set up?  

Title: Re: Lancer Upgrade
Post by LANCER on 04/04/09 at 15:27:13


060B030F0D0C06080B0F620 wrote:
Edlebrock Quicksilver?  Is that similar to the Carters?  Does it have the adjustable jetting?

http://i255.photobucket.com/albums/hh128/russ_diamond_jim/34497695232327Ffp473Dot3E2323B3D723.jpg

Also, your intake setup in this pic has perked my interest.  How do  you have it set up?  




When that photo was taken I had an Edelbrock carb with a 6" velocity stack, and it worked great.   8-)

Title: Re: Lancer Upgrade
Post by diamond jim on 04/04/09 at 18:21:28

I see.  Cool!

Title: Re: Lancer Upgrade
Post by Mr. Hyde on 04/13/09 at 06:05:10

Hey Lancer - as one Southern Cruisers member to another welcome to the hood. I am 2nd Officer for Chapter 106, Kingston, Ontario, Canada. My handle there is Savage Larry.

Title: Re: Lancer Upgrade
Post by srinath on 04/13/09 at 07:21:36

Muffler - broke @ the weld. Please tell me you didn't mount the exhaust on the swingarm ... I couldn't tell from the pics ... the swingarm ... its ... well a swingarm, it swings ... you have to fit it back on to that stock carrier you lopped off. Like make a cradle or somehting ...
Cool.
Srinath.

Title: Re: Lancer Upgrade
Post by srinath on 04/13/09 at 07:24:15


023720221A737075450 wrote:
BTW - since you aren't using the muffler bracket with your SuperTrapp, you can completely remove it from the frame.  Might clean up that area even more if you do...just a thought.

Here is what I did to mine for the Raask pipe.

http://i21.photobucket.com/albums/b277/gmdinusa/MufflerBracket01web.jpg


I cant see your pic, but I thought that muffler carrier also carries the rear motor mount and the battery box.
Cool.
Srinath.

Title: Re: Lancer Upgrade
Post by verslagen1 on 04/13/09 at 07:32:31


4F4E55525D48543C0 wrote:
I cant see your pic, but I thought that muffler carrier also carries the rear motor mount and the battery box.
Cool.
Srinath.

It's mounted by the same bolts as the rear engine mt. but doesn't carry it.

Title: Re: Lancer Upgrade
Post by srinath on 04/13/09 at 08:59:37

Battery box is on that thing though right ?
Cool.
Srinath.

Title: Re: Lancer Upgrade
Post by LANCER on 04/14/09 at 04:58:11


76491573425F5E3B0 wrote:
Hey Lancer - as one Southern Cruisers member to another welcome to the hood. I am 2nd Officer for Chapter 106, Kingston, Ontario, Canada. My handle there is Savage Larry.


Unfortunately, our local chapter dried up last year.  
However, it looks like some guys from my church are organinzing a riding group, which will be nice to have some close by in our little towns.

Title: Re: Lancer Upgrade
Post by LANCER on 05/08/09 at 21:51:12


75746F6867726E060 wrote:
Muffler - broke @ the weld. Please tell me you didn't mount the exhaust on the swingarm ... I couldn't tell from the pics ... the swingarm ... its ... well a swingarm, it swings ... you have to fit it back on to that stock carrier you lopped off. Like make a cradle or somehting ...
Cool.
Srinath.


Actually, I did have it mounted to the swing arm briefly ... very briefly   ;D

Title: Re: Lancer Upgrade
Post by AngloSaxon on 05/21/09 at 09:00:02

I cant believe you mounted the muffle on the swinging arm. It just goes to show that even the best of us are fallible. Rock on Bro.

Title: Re: Lancer Upgrade
Post by mikestrikes on 05/21/09 at 09:44:04

What size tube did you use to build that header ?

Title: Re: Lancer Upgrade
Post by srinath on 05/21/09 at 10:11:55


705F565D5E6250495E5F310 wrote:
I cant believe you mounted the muffle on the swinging arm. It just goes to show that even the best of us are fallible. Rock on Bro.


I would use a short piece of flex pipe if I was ... but a straight thin wall pipe with a short baffle can just sit witout a mount ... start getting fancy and you need mount brackets etc etc ...
Cool.
Srnath.

Title: Re: Lancer Upgrade
Post by LANCER on 05/21/09 at 15:16:19


4662606E785F7962606E780B0 wrote:
What size tube did you use to build that header ?


I bought basic tube that was 1.75" OD and 1.6" ID.  The assorted pieces I got were swagged on one end so they would slide into each other at the points I wanted.  Kind of a "cut & paste" type of thing.  I managed to weld it up so it stayed together and does not leak.  I tried to do another but was unable to repeat my earlier work.  Not sure if it was just me screwing up, or the inexpensive welder not performing well, or some combo effect, but it was a no-go.  
At least the first one does work well.  I hope to try again in a few weeks...we shall see.
The 1.6" ID works very well with a modified engine and high flow exhaust.  If you have a stock engine I would suggest using 1.5" ID pipe and a Dyna muffler at least, or Supertrapp, etc, for the good flow.
When I measured the ID of the stock header I got 1.3" ID on the inner pipe.

Title: Re: Lancer Upgrade
Post by mikestrikes on 05/21/09 at 17:10:39

Thanks.

I was going to use 1.5" for the first bend out of the motor and 1.75" the rest of the way to the muffler..

Title: Re: Lancer Upgrade
Post by LANCER on 05/22/09 at 05:09:03

The header on a Savage is only about 30-33" in most cases, unless you go unusually long.  If your engine is stock you will get better all around performance out of a 1.5"ID  pipe, especially if you have a high flow muffler on the end.  Going longer on the header may add some low-midrange torque even if you do go with the bigger tube.

I just made arrangements to get on old 87 model with a stock engine and will try to make another header but will be using the 1.5"ID pipe for it.  As soon as it is running I will do some jetting tests with stock carb and header; I think it has a dyna muffler on it now but am not sure.  After that is done then I hope to do the new pipe with same stock carb and same muffler and just rejet/tune to suite the engine with the new header and see what the differences are.  Hopefully, I can document the process on a local dyno...subject to funding of course which is always an issue.

KLX does this stuff for a living over in England and if he comes around this thread maybe he can throw in some professional wisdom.

Title: Re: Lancer Upgrade
Post by verslagen1 on 08/07/09 at 08:59:35

You've menstioned it before but not here...

You've had Silican Carbide cylinder treatment aka Nikasil done to Ol' Rex.

I've been searching for Phelonius Piston and doing this cylinder treatment.

Lukes Racing offers the service and the piston

Luke says "IF the bore is cast iron then the charge for replating and boring is $230. The piston kit is $143. 4597M09500 is standard bore."

Luke offers free shipping (over $50) and there's only a couple of shops that do the Nikasil thing.  For those of you near PA, seems reasonable.

Title: Re: Lancer Upgrade
Post by Duane on 08/07/09 at 12:19:53

Those stilt shocks make it look like a dirt bike.  ;D

Title: Re: Lancer Upgrade
Post by LANCER on 08/08/09 at 05:11:52


I would really like to put the new 97mm piston I just got into REX but I will need to send a spare cylinder & the piston to Bore-tech for the rebore and silicone carbide, but money is short right now so will have to wait a bit.
At least the engine was not damaged by the engine stop event just before the Dragon ride.

Title: Re: Lancer Upgrade
Post by LANCER on 08/09/09 at 05:55:30


4E7F6B646F0A0 wrote:
Those stilt shocks make it look like a dirt bike.  ;D


It did make it look high but the extra travel of the shocks and the quality of the shock effect is just great.  
During the rebuild of REX I tried to mount the new fender to minimize the tire-to-fender space so it did not look quite as high.  The replacement front forks I put on also jacked up the front a little so the whole bike is taller.  I may alter the mounting of the bars so I can slide the tubes up through the triple trees, resulting in a lowering of the front.  Will see how it goes when I can get back to working on it.
I have been having a difficult time the past couple of weeks with chronic physical issues which slows everything down.  Such is life.

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