Building a Better Boat Anchor

[ralphus]

Many have stated in the past the stock muffler is only good for a boat anchor. So I thought I would have a go at building a better boat anchor.

Inspired by LemansNZ who did a bafflectomy on his stock muffler with pleasing results. I started my little project to make an el cheapo sports muffler out of stock muffler.

My objectives were to make it flow better and create a little more noise than the stock.

First stage was to gut the original muffler

[IMG][/IMG]

Second stage was to fit a core tube from the inlet pipe to rear centre pipe making it the same diameter as the intake.

[IMG][/IMG]

Third stage was to pack the inside with fibreglass packing and weld the lid shut and the three pipes into place at the rear. The two outer pipes are dummies.

[IMG][/IMG]

Last stage was to get TOR tune downloaded and fit muffler to Sprint.

The only visual clue that this pipe has been modified is the larger diameter centre pipe.

Result, a muffler that is slightly louder than stock and runs beautifully. I am now one happy chap, the bike now pulls beautifully from 2500RPM.Yee Haa!!:

[dave333]

Nice job! Talk about bang for the buck! I have to get a welder and learn to weld! Quick question for ya, where is the catalytic converter that I thought I remembered reading about?

[caddydaddy]

Originally Posted by dave333

Quick question for ya, where is the catalytic converter that I thought I remembered reading about?

I thought that was only on the US spec'd Sprints?

[pelon717]

Nice job! I've done some welding (poorly) in the past but intend to take some classes to improve.

You could have saved some time and simply bolted on a Pepboys fart-can Honda Civic muffler. j/k

[ralphus]

Originally Posted by dave333

Nice job! Talk about bang for the buck! I have to get a welder and learn to weld! Quick question for ya, where is the catalytic converter that I thought I remembered reading about?

We don't have catalytic converters in the land of Skippy the kangaroo.

To remove the lid I used a 12mm drill to drill out the plug welds and a 1mm cut off disc on an angle grinder. That stainless is a bastard to drill!

The core tube from memory was 45mm diameter. You can usually get this from an exhaust manufacturer or installer, it may need to be specially rolled.

The outer case is made of stainless so you will need to use stainless MIG wire preferably small diameter or TIG it.

Below is pic of what it looks like from behind. Not the best pic but it came up pretty well.

As for a Pepboys fart can, you would still have to mess about making up mounts for it and it would look pig ugly. So I doubt whether it would work out to be any cheaper.

I was in no hurry to do this job as this was a spare can I acquired from a friend. Probably a good winter project for you boys in North America that get snowed in.

[IMG][/IMG]

[oldndumb]

Stock cans are available frequently on ebay. Some members may even have one available.

[Triple Ripple]

Now that's a boat anchor I can get excited about: Heck with selling them to someone who's looking for new airplane floats.
And yeah, winter'll be here in the next 3-6 weeks (sigh). So this just might be my big winter project. All I have to do now is find someone with the right welding tools and patience to put up with me.

Thanks for the inspiration :

[jeffro]

But no perforated metal just one solid pipe out the middle. Can you post a sound clip?

[mepeck]

Nice work! Too bad I can't weld.

[kremin]

Love the mod. If your bike has the catalitic converter what other things would be necessary.
I'm in New Zealand, but from somewhere I got the idea my bike (07 Sprint) was built for the Spanish market.

How can I check?

Cheers
Kremin