We were impressed with how HEAVY the stock exhaust systems were when we took them off and cut them up as part of our double RYCA build.

We'll be using the stock header pipe and RYCA muffler initially, but we are starting to ponder something lighter.

The pics below were taken from the gallery here.  There are undoubtedly a bunch more "interpretations" of how to effectively and/or stylishly get the hot air out the back.

We'd like something that is a lot lighter, not too hard to fabricate, and doesn't look too dorky.

Ideas?

Harley dyna/sportster stock castoff or screaming eagle muffler. Look in the Tech section and search. The harley ID is slightly larger than the header OD. Most people use a cut up can of some sort to fill the gap before clamping it down. I got a peice of driveline tubing from work cut it to about 10 inches long, expanded one just a wee bit to it would slip over the header, the other end was a perfect fit to slip into the harley muffler. I had the header end of the tubing bent at 10* outward and welded it all together. Looks awesome, sounds awesome, cost me $20 on ebay for the muffler, $5 at MIDAS for the bend. If you do not get the 10* bend you will soot up your rear brake and you rear brake cable will rub on the muffler. If you get the extension without the bend the muffler will hit the swingarm.

let it breath!!!
large radius sweeping bends low restriction tail secdtion...

Yeah, let's wrap the exhaust around the cylinder, because it doesn't get hot enough. And heating the gas in the float bowl is always a good idea.  

Motobuddha said in reply #10, "Yeah, let's wrap the exhaust around the cylinder, because it doesn't get hot enough. And heating the gas in the float bowl is always a good idea."

I agree.  What could possibly be the advantage for an exhaust routing like that?  My suspicion is there is no advantage -- that "concept" is to exhaust systems as the concept of hangy-down ankle-pants is to the trouser industry,... simply there for a reaction.

Extremely interesting project.  Excellent work on your part.

Who is doing the exhaust work?  One thing you might consider (for the rest of us) is to find some way for the fabricator to remember how he did that pipe.  It could be lucrative for him and helpful to us if he could reproduce that pipe for sale.