Homemade exhaust

[teapot39]

Hello everybody!

I wanted to show you something I've been working on in the past weeks. I was inspired by jtarkany thread (here) and finally decided to give a shot at making my own.
I really like the Two Bros style so I used them as a guideline, I just couldn't replicate the oval shape as it would have been a lot harder to built.

The pipes, inlets/outlets and the tips are all aluminum. I also have some 1.75" perforated stainless steel tubing (not pictured). Now everything just need to sanded/polished and it should be ready to be assembled.
It's a little hard to tell on the picture because of the perspective but the whole can will be 14 inches long and 4 inches wide.

I haven't decided yet whether to paint/anodize them or keep the polished look..

 

[ChanceCoats123]

Wow, that looks awesome. Are you going to use a fiberglass pack, or just run it with no deadening material? Do you have any more pictures of the middle section?

 

[FinalImpact]

Have lathe will machine! Looks like a good start! :thumbup:
Keep us updated! Tks!

 

[teapot39]

Thanks! Here are some more pictures of the middle part. The one with the groove on the right will go between the pipe and the tip. I will cut a custom gasket to fit the groove and try to prevent leaks.

I plan on using a layer of steel whool and then another layer of ceramic whool as I have read online that it should last a little longer than fiberglass.

 

[kinderwood]

Wow, way cool. Looking forward to more updates. Maybe some audio when you get it bolted on?:cheer: Are you going for street legal noise levels, or is this for track use?

 

[teapot39]

I'll definitely post a video comparison when they will be installed!

I'm going for a "street legal" level, but I really don't know what to expect.. I'm hoping they won't be too loud, but if they are I will build or buy some db killers or maybe experience with the packing materials.

 

[teapot39]

*** Please excuse my really dirty bike! ***

The exhaust is installed! Love the sound and the new look. They are not polished or painted yet but they will be soon and I will find some new stainless bolts for the tips.
I never heard a true aftermarket fz6 exhaust in person so I can't really compare the sound level, but I would call it reasonable.
Also, since I didn't have a welder or a tube bender, I had to do my Y pipe mock-up on the bike, then disassemble everything to bring the pipes at school and weld it. Because of that, the mufflers are at an angle (clearly visible from the top view).

Here is a short video captured with a gopro: https://youtu.be/5yqPz1rmAos

For the packing material, I ended up using a first layer of stainless steel mesh, the second layer is stainless steel wool tightened with steel wire and the third layer is Roxul insulation wool. I chose Roxul over other packing materials mainly because it is fire and moisture resistant, cheaper than fiberglass or ceramic wool and was locally available.

The total cost of this project was around 280$CAD.

 

[SANGER_A2]

Love to see some build pics!

 

[RoadGator]

Look good to me! Are you thinking about selling them?

 

[raja777m]

Thanks! Here are some more pictures of the middle part. The one with the groove on the right will go between the pipe and the tip. I will cut a custom gasket to fit the groove and try to prevent leaks.

I plan on using a layer of steel whool and then another layer of ceramic whool as I have read online that it should last a little longer than fiberglass.

Firstly, it looks cool, just a polish/carbon fiber wrap or plasti-dip to make it much more appealing. For me it sounded much more deeper tone than two bros, infact I actually loved the sound (after listening to it a couple of times :thumbup: ).
I won't make changes in outer appearance, but I would like to make my stock like yours.

I'm a total noob, but steel wool can burn and release red hot metal fragments, is that true?
In that case, do you still need to repack after XXX miles?

steel wool as muffler repacking - General Dirt Bike Discussion - ThumperTalk

 

[Serzedo]

Props to you, seems better than some expensive so called brand exhausts!

"V"

 

[raja777m]

BTW, when you are you taking for a dyno? I suspect you would gain some hp, am I wrong?

 

[teapot39]

First of all, thanks a lot for your comments! I attached some pictures of the assembling of the cans.

[MENTION=26989]RoadGator[/MENTION]: I did consider building more and selling them, but it couldn't be before 2-3 years because I'd have to buy or rent all the tools needed to do it again (lathe, milling, band saw, etc.) since I won't have access anymore to the ones I used at school. I do plan to buy these tools, but at that time most people will probably already have an aftermarket exhaust!

[MENTION=26729]raja777m[/MENTION]: Yes you are right, regular steel wool would have probably made a pretty awesome flamethrower/firework! That's why I chose to go with stainless steel wool. I tried to burn one of the scrubbing pad using a small propane torch for a good 30 sec and it only expended/deformed from the heat. I don't know yet if they will need to be repacked, but I still have a lot of roxul wool and scrub pads, so I'll probably open them up this fall to check if it's worn-out.

I will try to take it to a dyno if I can find one not too far. I did not feel any major difference in power, but I do however get a larger smile when I start it up and rev it!

 

[elus1ve]

Some people have too little money and way too much time on their hands!

Amazing work though. Wondering how it sounds and if the po po are bothering u. The po po have sensitive ears in this province.