KB2WYL
CQ CQ, DE KB2WYL
So, didn't want to just put this in that other thread. That was "where can I find a Y pipe, heres some ideas, etc". This is more like "One mans way to build high performance cans for 50$ and 2 full night's time".
So the project goes like this. Originally I gutted my exhaust can (stock). Great, sounds better, better flow. But didn't do too much for performance. It's still a giant chamber for exhaust gases to slow down, cool off, and plug up the works. Been wanting to get cans for a long time, but they're expensive. That and I always told myself, "If you really wanted them Loren, you would just build them". I thought about getting the Y-pipe, but discovered that to get the type I wanted, the same expensive rule applied. Thanks [MENTION=6338]TownsendsFJR1300[/MENTION] and [MENTION=15974]FinalImpact[/MENTION] for the suggestions.
I went down to my local exhaust shop (they do all welded work, all real steel, thick tubing, etc etc.) Talked to the man there about what I wanted. Our exhaust is 1.75" so don't want anything expanding too much larger than that. Especially since we have dual exhaust cans. Well, turns out the smallest "glass packs" he had were 1.75" ID. He tells me about how it's good to keep it like this (keep the 1.75" for the dual exhaust) because larger chamber (like stock muffler) means you have to be moving a LOT more air to keep up your exhaust velocity. More air=higher RPM=higher torque/hp curve. In our case, with the numbers already so close to our redline, having to move more air to keep up exhaust gas velocity pretty much = loss of power. Y'all know this, that's why we get rid of that stock exhaust in favor of aftermarket systems. All of which are similar in the fact that they are big cans, packed with sound muffling material, and a smaller perforated tube running through them to keep up this velocity unlike our stock systems do.
He goes on to tell me how he uses these on his quads and his bikes and he likes them. They're 24$ each, I can weld right on to them, and he has 2. Perfect.
So the easiest way for me to do this is to just post up the pics and describe them as I go. Hopefully somebody somewhere can take something good from all of this. Feel free to ask questions, advice, or tell me how crazy I am and how you are glad you just went with the scorpions Blah.
Well, There's my famed stock muffler gut. I'm going to need the brackets off of it. Also, you can see the 2 cans ans some spare tubing I picked up. Can we make something work with this and a TIG welder??
I should have taken pics of the backside where I cut it open and did the weld. It was my first wire feed weld, with the HF flux core. It's atrocious.
Ok, now we're getting somewhere. For the first bend, it was the only one that was going to be a little severe. Not much room with that under seat/fender box. I wanted it to be smooth still, so I cut slits into the pipe so that I could bend it gradually in pieces. We can always weld that up later, I thought.
There you go, better shot
Hey hey, not bad. We can't see this part anyhow, but now we don't have any sharp edges in which gases can do their little vortex things and slow down the flow.
And again, another angle.
Oh the atrocity is back again. This time sans brackets. I love plasma cutters.
Oh geez, there it is. Looks like I was welding with a battery and coat hangers 
Ok back to that bend. Good penetration on the welds. Good, we're doing something right this time.
Alright so I've made a cut in the bent piece, and I'm sizing up where I need to cut the other can, so that I can weld together my "Y Pipe".
Oops, only 10 per post...to be continued....
So the project goes like this. Originally I gutted my exhaust can (stock). Great, sounds better, better flow. But didn't do too much for performance. It's still a giant chamber for exhaust gases to slow down, cool off, and plug up the works. Been wanting to get cans for a long time, but they're expensive. That and I always told myself, "If you really wanted them Loren, you would just build them". I thought about getting the Y-pipe, but discovered that to get the type I wanted, the same expensive rule applied. Thanks [MENTION=6338]TownsendsFJR1300[/MENTION] and [MENTION=15974]FinalImpact[/MENTION] for the suggestions.
I went down to my local exhaust shop (they do all welded work, all real steel, thick tubing, etc etc.) Talked to the man there about what I wanted. Our exhaust is 1.75" so don't want anything expanding too much larger than that. Especially since we have dual exhaust cans. Well, turns out the smallest "glass packs" he had were 1.75" ID. He tells me about how it's good to keep it like this (keep the 1.75" for the dual exhaust) because larger chamber (like stock muffler) means you have to be moving a LOT more air to keep up your exhaust velocity. More air=higher RPM=higher torque/hp curve. In our case, with the numbers already so close to our redline, having to move more air to keep up exhaust gas velocity pretty much = loss of power. Y'all know this, that's why we get rid of that stock exhaust in favor of aftermarket systems. All of which are similar in the fact that they are big cans, packed with sound muffling material, and a smaller perforated tube running through them to keep up this velocity unlike our stock systems do.
He goes on to tell me how he uses these on his quads and his bikes and he likes them. They're 24$ each, I can weld right on to them, and he has 2. Perfect.
So the easiest way for me to do this is to just post up the pics and describe them as I go. Hopefully somebody somewhere can take something good from all of this. Feel free to ask questions, advice, or tell me how crazy I am and how you are glad you just went with the scorpions Blah.
Well, There's my famed stock muffler gut. I'm going to need the brackets off of it. Also, you can see the 2 cans ans some spare tubing I picked up. Can we make something work with this and a TIG welder??I should have taken pics of the backside where I cut it open and did the weld. It was my first wire feed weld, with the HF flux core. It's atrocious.Ok, now we're getting somewhere. For the first bend, it was the only one that was going to be a little severe. Not much room with that under seat/fender box. I wanted it to be smooth still, so I cut slits into the pipe so that I could bend it gradually in pieces. We can always weld that up later, I thought.There you go, better shotHey hey, not bad. We can't see this part anyhow, but now we don't have any sharp edges in which gases can do their little vortex things and slow down the flow.And again, another angle.Oh the atrocity is back again. This time sans brackets. I love plasma cutters.Oh geez, there it is. Looks like I was welding with a battery and coat hangers Ok back to that bend. Good penetration on the welds. Good, we're doing something right this time.Alright so I've made a cut in the bent piece, and I'm sizing up where I need to cut the other can, so that I can weld together my "Y Pipe".Oops, only 10 per post...to be continued....
