SoC
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SuzukiSavage.com Rocks!
Posts: 498
New Jersey
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I am trying to fit a new muffler to my header. As everyone is aware the OD of header is slightly less than 1.75". I know about using 1.75 ID" and placing a small sleeve to make up difference. Problem is the new mufflers ID is 1.75". So I went to local muffler shop and had them make a bend in some off the shelf "Pep Dudes" 1.75" OD pipe. Problem was the expansion die they needed was the only one they didn't have. I took it and the header to the local Meineke, the guy asked if it was for a Harley, I said no, he said is it for a "Kawisucki", I said no a Suzuki and his comment was "same difference". Any way he put it on machine and just hit the peddle until it burst at seem. He than told me it was cheap pipe and if I had them make it from their superior pipe it could be done. They want a big piece of change to make one. He did lay a bead of weld on the split. but it is a mess inside and needs ground out and is still split at area of overlap i.e. weld doesn't extend to the end.
I am going to try the whole process again with the slightly heavier wall Napa tube, but if it doesn't work? I'm sure there are those who have done this sort of thing before, any advise.
One problem is that it is a short adaptor and the bend needs done in a longer piece of tube, then cut to size and the expansion done after it's cut.
So cut to chase, if I have thicker wall 1.75 OD tube from Napa, have tried to expand it myself by hand with a manual expander but cant get it large enough. My idea is to cut a series of fine lines in the end, the length that it over covers the header and try to expand it than.
Or would it work to take 1.75 ID, do basically the cuts in other end but instead try to compress it down to fit into the muffler. Obviously I don't want the thing leaking at the joints.
Anyway, maybe I am going about it all wrong, any advice would be appreciated.
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