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-Baf...

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



the little circle is the perf. steel

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



this was then slid over the stock header and welded



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





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



and on the bike



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

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,

aintright wrote on 04/26/12 at 03:31:04:





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..

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

justin_o_guy2 wrote on 04/26/12 at 04:01:04:


...and that just ain't right, neither... ...


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

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?

Drifter wrote on 05/01/12 at 07:07:06:



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

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?