ok so finally here it is. all for ~25 dollars
you have somthing like this
you want this
tools needed:
drill ( a little bit bigger than your pop-rivits or a little smaller than the screws you use.)
hammer
screw driver (long one)
pop-rivits and a gun (you can "rent" a gun if needed i did)
cutting wheel( i sugest something bigger than a dremel i used a rotozip\air grinder)
mask, and eye protection
muffler packing of your choice.
1.ok so remove your exhaust either slip on or bolt on.
once this is removed from the bike take it inside or to where you plan on working.
2. remove screws on both sides of the can if you wish(usually you need both off because the can is so tight on the exhaust caps). or you can only remove the side with the exhaust dump. this is either secured by screws or rivits. drill out the rivits, dont worry about how deep you go just get them out. be careful to not slip off a rivit and scrape your exhaust.
3. once rivits\screws are out you will see the exhaust packing around a pipe. you will probally have to use a hammar and screwdriver to hit this out. use some force.
4. remove packing. if its fiberglass which it probally is wear gloves\eye protection\mask.
5. now you should have 3 parts: can 1 end cap, and another with the exhaust on it.
6. get your cutting tool and test it on the very end of the material. (use the end your removing to do this test) if all goes well decide where you wanna cut.
7. once desired spot is found mark with painters tape to create a straight line around the can. (taking into concideration the extra length provided by the end cap that goes towards the header. in most cases this is the side you will want to shorten)
8. cut the can
9 get the muffler part that had the packing and put this through the can. it will extend out the can, this is ok. mark where you want to cut this part. keep in mind that most headers have extra pipe that will come up to meet this part inside the muffler. **i kept the coupler on my exhaust as you see below i dont see why you NEED to so its up to you***
10. to reconnect the end cap you will need to drill holes. i wraped the old cut part with painters tape and pokes a pen through the old screw\rivit holes then applied that tape to the newly cut section. you will notice that where the can wrap meets there should be 2 holes very close to eachother. make sure you like those holes up as it is on the other end of the can.
11. drill new holes
12. put end cap on that contains the pipe. or wrap that pipe prior to insertion (depends on packing type) i used loose stuff.
13. pack your exhaust TIGHT! your muffler is much smaller than once before. get it in there!
14. put exhaust together and test fit. if happy with this result put it back together.
if you reuse your "coupler thing" id attatch it with something i used muffler paste it works for me.
i got ~3/4of this in the muffler
final turn out.
**this was done on a D&D exhaust if you screw yours up its not my fault!!!!!!!!!**
have fun BE SAFE! enjoy the new attention your bike gets.
[ This message was edited by: big2332 on 2007-04-07 00:15 ]
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