My exhaust creation.

Thought I'd whack up a few picks of my endeavours.
I put an 33F motor in my 37H frame a while back and it has been good, but never quite as good as I wanted so...

I was given a complete 900 31A with a bad motor so I basically grabbed the wheels and swingarm and gave the rest away to other XJ'rs.

I also couldn't stand the way my 4into1 hit every single thing that was slightly raised including when I was doing some sweeping right hand turns and so... after doing some research and thinking all the crap exhausts were just as crap as each other I went on a bit of "I'll make it myself!" type of thing.

Also thought I'd put some of the sexy progressive springs into the forks and am now a definite supporter of the practice.. smooth braking for the win.. or FTW for the cool kids.

Pictures below.

I used 32mm Nominal Bore light wall Galvanised for the headers with 38mm mandrel bends for the 90degree into the head...
This is standard Australian CHS (circular hollow section) and the actual measurements are,
38mm ID
42.4mmOD
32mmNB bending form... funny stuff but the 38mm mandrel bends slip right in... very sexy!

I used 10mm cuts of the 32mm NB to make the stops on the headers and welded it all up with a MIG.

The plates/brackets I made out of some random pieces of plate that I welded together and ground the hell out of after drilling the holes.

The plate I used for the collector was some 1.8mm galv sheet that I had in the garage.

The pipe to the muffler is 63mm pipe from an exhaust place that I beat the end, into submission, until it matched my square fitting on the collector. I also put a slight bend in it first.

Did all the bends using a dawn bender (great piece of gear).

Enjoyed myself, as per usual... took it for a ride today and seemed good and I know I won't hit another speed hump with it as it is as high or higher than the original exhaust collector now.

Besides it will be damn hard to dent those headers on anything!

 

Very nice...Im sure you could sell your creation ...very creative.

 

Quite interesting. Bet it doesn't sound like your typical 4 into 1 exhaust.

Tony

 

No, it has a definite bark now, or a bark with a touch of a ring when its cold.
Next version will have some baffles to direct the flow a bit more I'm thinking.

 

Nice work but be careful when welding galvanized steel due to toxic fumes. Weld in a well ventilated area.

 

Bought a gas level mask a while back after a few spates of poisoning myself after welding... I swear I 'TRY' to remember to use it.
Once you jam the helmet on and start welding you really lose track of the amount of smoke in the area, not to mention in my garage when there isn't enough air flow to move the fumes out of the roller door and side door.
Next time I'll use that damn expensive mask... definitely!

 

That looks sharp, nice job!!

 

That looks absolutely amazing. I've been wanting to make my own sort of collector box. Its to bad I'm absolutely terrible with a welder

 

Grab som scrap and start laying down beads. Practice, practice, practice.

 

Hmmm...
Super lean!
Plugs are WHITE!

Time to pull off the exhaust and create some flow in the collector to try and simulate an extractor type situation... I think, maybe.

What do you reckon? Time for some artistic baffle creation?

Grinding is big part of the way I weld. BTW

 

Couldn't wait...
Time for surgery.
Open collector surgery!

Cut her open...

Open her up...

plan what to do... ish... and get some bits to make the baffles.

Cut and tack the baffles in...





Paint it with cold galvanising paint...

Close her up... with a big more colgalv... not as nice as the hightemp spray paint but beggars and all...

oh... and I used this, this time

 

Seems good...
after a colourtune I had to wind out the mix screws by 2/3 to 3/4 of a turn, to get a bit of orange so we shall see.
Sounds less barky thats for sure.

 

Hey mate, great work on your whole bike, not just the exhaust which I think is a great solution.
What suburb of Perth are you in? I would love to catch up and shoot the breeze and pick your brain sometime - I need some spark to get me going again on my project '84 750 and I would like to bounce some idas off you
Keep up the good work

 

Ideally you don't want any orange, just bunsen-blue; right about halfway betwen a touch of orange and a touch of white.

 

Shaynus, pm sent.

 

Happy to see you used the respirator so you can ride another day.

 

And replied to

 

Amaze-bums™! Rarely do we get to see a home brewed system that is as well thought out and executed as this. I would put that on my bike, for sure! And you were able to keep the center stand as well! Just excellent work.

 

Hi CDS,
Excellent work, what are the chances of a you tube sound check video?

 

John,
the sound is much nicer now with the baffles.
Tell you what I'll have a go at doing a video tomorrow and whack it up here.
I switched back to the a TCI from the erd dynapak and it runs a whole lot better too...
Strange! I will be investigating the regulator I'm thinking.
Get ready for tinny mobile phone audio! tomorrow