Exhaust Chop

So someone ran into my bike in a parking lot and left a nasty dent on my brand new can- needless to say I was ******. Anyway, shortly after deciding to just deal with it instead of buying a new one I realized if the dent didn't cover too much of it I could probably just chop it. I checked, and sure enough I could salvage about 12" of it.

The can with damage marked at 12" with tape
http://photos-a.ak.fbcdn.net/hphotos..._1192433_n.jpg

http://photos-g.ak.fbcdn.net/hphotos...9_703538_n.jpg

I decided to remove the Yoshi logo because if I left it the way it was the brace would have gone right over the middle of it and I thought it would've looked sloppy.
http://photos-d.ak.fbcdn.net/hphotos..._2190882_n.jpg

The sleeve cut around the circumference with an angle grinder and slid off the core
http://photos-f.ak.fbcdn.net/hphotos..._2534211_n.jpg

The easiest way to get the last 6" off was to just cut a slot along the length of it because of the damage
http://photos-h.ak.fbcdn.net/hphotos..._5065706_n.jpg

Removed Dent
http://photos-e.ak.fbcdn.net/hphotos..._5089457_n.jpg

Removed packing from the good part
http://photos-c.ak.fbcdn.net/hphotos..._3914634_n.jpg

Removed End Cap
http://photos-f.ak.fbcdn.net/hphotos...9_674392_n.jpg

Sleeve with some visible distortion- I had to put some work into getting this back to a true shape so I could fit the base cap back on. I then drilled out the new holes for the rivets.
http://photos-d.ak.fbcdn.net/hphotos..._2859703_n.jpg

I cut the packing to the size of the remaining pipe, wrapped it around the core, and slid the reshaped sleeve over it- This is the easiest way to put it back together without letting the packing material bunch.
http://photos-c.ak.fbcdn.net/hphotos..._1793347_n.jpg

I added some RTV silicone and replaced the end cap and started to re-rivet.
http://photos-g.ak.fbcdn.net/hphotos..._4003167_n.jpg

Riveting it
http://photos-e.ak.fbcdn.net/hphotos..._5727176_n.jpg

Now what to do with the emblem?
http://photos-h.ak.fbcdn.net/hphotos..._4111616_n.jpg

My Solution:
http://photos-b.ak.fbcdn.net/hphotos..._5005307_n.jpg

Completed Pipe
http://photos-d.ak.fbcdn.net/hphotos..._6078792_n.jpg

On the bike
http://photos-f.ak.fbcdn.net/hphotos..._2285304_n.jpg

The brace isn't on in these pics but there is about an inch gap between it and the Yoshi Logo.
http://photos-e.ak.fbcdn.net/hphotos..._7436168_n.jpg


Overall, I'm very happy with the job and I actually think it would've been a worthwhile project even if the can wasn't damaged.

Here's the sound clip: http://www.youtube.com/watch?v=FwvFUMrenUA

Sounds impressive, looks good, great job.

Nice, it looks clean.

looks good!
would be nice to know how you took out the rivets... did you just drill & punch them or you have another way of doing it?
was there any change sound-wise after the chop?

Yeah I just drilled them and pushed them in.

It got a lot louder, especially at first, but now it's quieted down a bit. It's still a bit louder now than it was before, but I'm thinking I'm just gonna put a baffle in it.

Awesome job dude. Very well done. And props on the yoshi solution I really like that.

So my Yoshi baffle just came in the mail and I put it on to see how it sounds. It turns out that the baffle quiets the pipe down a LOT more than I anticipated and I didn't want it to be a permanent addition (the baffle is supposed to bolt in but my end cap doesn't have threads so I was gonna JB weld it in)

So instead here is what I did:

Baffle
http://sphotos.ak.fbcdn.net/hphotos-..._7546430_n.jpg

Drilled a small 3/32 hole where the bolt holes are on the baffle.
http://sphotos.ak.fbcdn.net/hphotos-..._7397115_n.jpg

Here's the hole
http://sphotos.ak.fbcdn.net/hphotos-..._4139638_n.jpg

And I put two wood screws in them with washers
http://sphotos.ak.fbcdn.net/hphotos-..._4047324_n.jpg


I actually had started to thread a 4-40 bolt in and it was cutting its own thread pretty well but somehow I overlooked the fact that they were brass bolts and it sheared so I just ended up going with these instead.

Here's a sound clip as well:

[ame="http://www.youtube.com/watch?v=7LO-OvXyJL0"]YouTube- Yoshi RS-3 with Baffle[/ame]

You really can't tell in the video but it is MUCH quieter.

Good Job!

If u had a dented muffler, I think u could have used an iron pipe to roll the dent out from the inside. This can be done if u have everything taken apart.

But I love the shorty exhaust, I gut mines too.

I vote for no baffle!

more, cut m0arrr

You didn't need to use silicone to put the end cap on. I cut down my Yosh pipe to 10" and my brother's to 12" on our F4is. The 2" difference between our pipes made a huge difference in sound with mine being louder and the sound is unique.

I even cut down my carbon fiber Akropovics on my Busa to 9".

Quote:

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Originally Posted by 3M_TA3

I vote for no baffle!

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I'm starting to as well especially since it reduced my mileage a bit, but I think my neighbours/ general public that I dont want to piss off would be on the other side of the fence about this.