Did Full Exhaust Gut This Evening- my experience and how-to

Well, about 5 months back I bought a 2nd set of stock cans from a forum member. Been sitting on them a while and just never got around to gutting them until tonight after I clocked out at the shop and I said 'that's it! I'm taking some ME time!'. Pulled the suckers out on the welding table and did the following:

1. after removing all shields: with thin cut-off wheel cut completely around the can about 1/4 inch in from the factory weld on the end of the cans...

2. then take a screwdriver or other pry device and gently pry enough space between your cuts to fit a sawzall blade in and cut the two baffle pipes that connect to the end caps...

3. the end caps/baffle pipe pieces come off...voila you now have an open can and see the baffles jiggling around inside...

4. on the outer lower side of each can, at about the halfway point, is a plug weld...it is my theory that this is one of the things holding the baffles inside the cans...drilling this outer one will help get the baffles loose...the 'inner' one would require reaching between the cans (not necessary, drilling the outer will be enough)...drill this plug weld out (you can reweld it closed later!)

5. I then arranged the cans in a large vise by gripping each side on the mounting tab: I then attached a vise grip to the baffle inside each can, then attached a chain attachment for my slide-hammer to that vise grip with ANOTHER vise grip...connected it to my slide-hammer...couple real good slides with the slide hammer: Baffles OUT!

6. I can TIG weld...so I then TIG welded the end cap/ trimmed baffle pipe assemblies back on with 304 stainless wire! Result: UBER COOLNESS!

Anyway, I'm going to install the modified set of cans sometime this week and then post about the results, whether I like the sound, etc. CAN'T WAIT!

Hopefully they won't sound like shit. I've watched a lot of Youtube vids which seem promising, but I won't know until I actually hear them in person. If I don't like it, I will sell the set of lovely cans to a forum member and save up for a Remus or Leo Vince system.

 

I did the exact same mod on my '05. I haven't stopped smiling since!!! I love the sound. The only way I can describe it (and friends have as well) is like a Nascar engine. You WILL NOT BE DISAPPOINTED! Enjoy...

 

Well...tonight was the maiden voyage...phrases that come to mind are: 5.0 Mustang, NASCAR, Shelby Cobra, Corvette C6R...to name a few. WOW! It is just like a straight-piped V8. I imagine a proper aftermarket exhaust would smoothen/deepen the note and make it more 'buttery'? I like it. And it does not seem obnoxiously loud. I started the bike with NO exhaust before I put the newly de-baffled cans on, and I actually really loved it as an open pipe...but that WAS obnoxiously loud...with the new cans it's just right. I really love the look of the stock pipes...but maybe I will end up getting an aftermarket set...just to have them and swap from time to time. So far I am pleased...it DOES NOT sound like shit. Hahahaha. It was LOL in my helmet the whole ride.

 

A neighbor has an '05 with gutted pipes (not sure to what degree) and I don't think it sounds as nice as mine with the 2-Brothers.

 

Yeah, it definitely is a little raspy...but still not bad, it's pretty much the same as one forum member described it...a straight-piped V8 vs. a V8 with a nice Flowmaster or Borla exhaust...the addition of a good straight-thru muffler helps dampen the exhaust's pinginess and resonance. I will ride with the cut cans for a while anyway and then pick up some Scorpion or Remus or Leo pipes eventually.

 

With your welding experience, you could run a good side-job business! Those of us with stock pipes and a week or 2 to spare can send in our stock pipes, you do your thing and send them back...$$$ !
I'm willing to spend $250-??? for my stock look with a killer sound! Maybe some baffles to smooth it out. Doesnt an engine need some resistance before it burns valves?
Anyways, I'm just wishfull thinking, but remember, the other exhaust companies got started somehow in some garage....

 

Recently purchased and 03 and will attempt to do the same. I hope that the sound is good enough until I can fab up another exhaust. I will let you know as soon as I can get some space in the shop to cut and weld.

 

What about gutting the pre-muffler / cat under the bike in the headers? I removed the cat on another bike I have and it made a very noticable difference in the torque/hp. Anyone know if that's ever been done and posted here?

 

I'm pretty sure VFR Benny did a cat gut. I remember reading it about 6 months ago

 

Came into work this morning and since we work 4/10's, Friday is my day to catch up on things. Since bikes seem to sell better if they sound great, I decided to gut the cans on our 03. The sound is 100% better than stock. I guess that an exhaust system would be better but this aint bad. The growl will bring a smile to any face.

After getting the baffles out, I machined the end caps to remove the remaining small piece of baffle before Tig welding things together. I could be wrong but, I think the bike runs better.

If anyone is interested in having theirs done, send me a PM. I have the shop and all the tools.

 

Now cut out the cat in the pre-muffler under the bike and see what that does / how that sounds...... ;-)

 

I was interested to hear if this mod effected the fuel milage in any way. I just purchased a 2002 that has gutted exhaust and I love the sound.

 

howzaboutsumpix?

 

I did not notice a difference in the fuel mileage either way, up or down.

 

I purchased a 2002 stock exhaust to gut for my '03. A friend is going to do the job for me, he wants to know the gauge of the muffler steel, anyone know? I assume since people were able to complete the mod that they had no problems welding them back together, but since I am not a welder myself, I do not know the specifics. Is there anything special needed for the weld job?