Ducati Monster Forum

Well, can't seem to sell the cans off my 696 so I'm ready to hack away and see what sound I can get out of them...

Wondering if anyone has done it with the 696 cans specifically?? I have complete access to welding and machining, so pretty much ready to hack away. Wouldn't mind a run-down on the particulars of the job if someone has delved into it before tho...


 [beer]

I have done about 20 sets of cans on the 696. I also did a how to thread here http://ducatimonsterforum.org/index.php?topic=18040.0 (http://ducatimonsterforum.org/index.php?topic=18040.0)

Is there a special trick to drill out the welding spots? All my drills failed so far. Seems to be made out of titanium or some crazy ultra resistant NASA material.

I used a pneumatic die grinder with a high speed steel cutting bit. There is another way to half core them where you don't have to drill those things out. It is just 2 cuts with a band saw and the first section of baffles falls out. PM me cause I don't have time to type the whole instructions out.  How you core them will change the sound quite a bit.

Have you also done this with the M1100 cans?  In terms of loudness, how would you compare them to say the termis without the baffles?  I may have to try this......

You know, I was thinking about this some more.......Why couldn't you simply cut both ends of the exhaust can and rivet / screw them to the ends of the aluminum tube using an exhaust sealant to seal it all up.  You'd still want to keep the cat intact (I suppose) and then the only other issue is fabbing something to pickup the hanger bolts.  Maybe cut around the original weld-nuts and tack them to the inside of the aluminum sleeve?  I'd probably also want to add some exhaust packing to insulate the can somewhat.  This would save weight and possibly eliminate the need for welding (I can't weld!) Thoughts?

Have done one set like that where I cut just behind the hanger bosses and did the whole perf tube and packing job. They sound pretty decent too! It is a little more involved process to do that, but you could just do the complete gut. It may sound a little strange?

Thanks for the link... I did a search in this area of the forum but didn't think to look in the tutorial section [beer]

I think I will simply try chopping out the baffle section and drill and screw them back together with some nice stainless hardware. Motocross cans have been built that way for years so it isn't really a new concept. You mention it may sound a little strange in your last post....other than a section of the inner sleeve missing I would think it would be the same in sound as welding it back together.....no?

One thing that concerns me is the possibly discoloration of the outer sleeve from the heat... ???  

 What is everyone's opinion on breaking in a bike with the lesser back pressure of a baffle-less system? My bike has yet to be even ran other than the PDI...

Seeing as you can buy a brand new bike with Termis installed and be covered under warranty, I wouldn't think you need to worry about running a baffleless exhaust.  I believe the Termis are a straight through, cat-less system (even less backpressure).  Of course it does come with the DP ECU which modifies the air / fueling mix. 

Actually, do you risk running the bike lean with fuel injection, or will the ECU compensate?

The 696 has the Siemens ECU with 2 O2 sensors, so I'm not sure if it would automatically adjust to the change in backpressure, but that sure would be nice.  I know for sure the older model ECU's on the pre-2009 monsters would not adjust automatically.

The Siemens computer will compensate for A/F there has been no issues with cored cans especially with the cats still in them.

Here is the half core instructions

I don't have any pictures of the half core process, but it is easy to describe....

1) Cut the back of the can off

2) In the center of the can there are the 4 spot welds. If you look down the baffle the bottom pipe goes all they way through to the first chamber, the top pipe only goes to the second chamber but there is a metal strap that holds the baffle.  The location to make these cuts is about 1/4" away from the spot welds towards the back of the can.  Cut enough to go through the pipe on the bottom and then cut just enough to go through the metal strap. The back half of the baffle will then essentially fall out.

3) Since you didn't cut the can in half a second time, it is much easier to patch weld the two saw cuts and then you simply weld the rear of the can back on.
 

 interesting.... I may give this a try to start. How does the half baffle sound?

The half baffle is a deeper tone than the full core job. The full cores are much more "stingy" or sharp like a 2 cycle exhaust.

Gentlemen, I have a problem. Look what I did. And still the baffle wont move  ??? Any ideas?

(http://img441.imageshack.us/img441/421/dsc01070g.jpg) (http://img441.imageshack.us/i/dsc01070g.jpg/)

(http://img525.imageshack.us/img525/9641/dsc01069x.jpg) (http://img525.imageshack.us/i/dsc01069x.jpg/)

(http://img69.imageshack.us/img69/9319/dsc01067nz.jpg) (http://img69.imageshack.us/i/dsc01067nz.jpg/)

(http://img402.imageshack.us/img402/7581/dsc01066bp.jpg) (http://img402.imageshack.us/i/dsc01066bp.jpg/)

It seems to me like the only strap that I cut is the one that you can see through the top pipe...

The second picture is right. Where you see that strap you only need to cut a little more to sever the strap. Now turn the can 180 degrees on the saw (the bottom of the can) you now have to saw through about 90mm of the can because you have to go all the way through the pipe that is inside. It looks like you made 4 cuts every 90 degrees which will not remove the baffle.  It only takes 2 cuts, a little one on the top and a large one on the bottom of the can. Also if the pipes have been on the bike for a long time, it may take some persuasion to get the baffle out.  I have used the jaw of a long gear puller to do this if it is being a real bugger.  I can see however that these stock cans are pretty much brand new..

(http://img130.imageshack.us/img130/2513/dsc01069xcopy.jpg)

(http://img97.imageshack.us/img97/8636/dsc01066bpcopy.jpg)

perfect [beer] I'll be back in 30 min... [thumbsup]

Here is a quick diagram I made....Sorry for the poor photoshop drafting skills.

(http://img101.imageshack.us/img101/1015/696exhaustcandia.jpg)

strike! [beer] baffle removed thanks to ryanracer  [thumbsup]

(http://img38.imageshack.us/img38/5769/dsc01071q.jpg) (http://img38.imageshack.us/i/dsc01071q.jpg/)

Now theres another problem with the other can. I'm not able to remove the aluminium cover because it gets blocked by the muffler tube:

(http://img10.imageshack.us/img10/5374/dsc01074s.jpg) (http://img10.imageshack.us/i/dsc01074s.jpg/)

(http://img8.imageshack.us/img8/8798/dsc01073lq.jpg) (http://img8.imageshack.us/i/dsc01073lq.jpg/)

(http://img408.imageshack.us/img408/4810/dsc01072b.jpg) (http://img408.imageshack.us/i/dsc01072b.jpg/)

Any ideas?

weird

This normal, you have to grind the left side pipe down to allow for clearance for the cover to slip off

You mean grinding just the corner of the tube (will it still be airtight when remounting it?)?

Or would it be better to cut a small ring from the tube and to re-weld it afterwords?

Yes, just grind the corner of the tube. You could cut the tube off and re-weld it I suppose just make sure you have accurate alignment marks. We have not had any problems with leaking since it is a double slip fit.  Make sure you leave enough as it will only be about 13mm that still goes into the midpipe on the one side.

great thanks. I thinks I'll saw the corner so that I could re-weld it in case I cut to much!

Thanks for all the hints! Great Forum!

By the way: Does anybody know if theres a difference between the US and EU Versions of: 1. The ECU and 2. The cans themselves?

I have both versions of each...for sure I will need to mount the EU Aluminium Can-Covers because theres the EU-Norm stamped on it... [leo]

Cheers from Germany [beer]

From what I have seen, we have the same exhaust cans in the U.S. as Europe.  I know that they change the stampings on some of them.  Since I have done several sets for folks in the U.S. I have seen some of the covers come in that had the E3 emissions stamp on them weird huh?

Thats really weird. And the different versions of the ECUs? Is the only difference the "US" or "EU" on the dashboard display when turning the ignition on?

you can change the setting on the ECU
I have mine set (when running) on EU but it's a US spec bike

Whats the difference between the settings and how do you change them?

Very informative thread guys [thumbsup]

Going to hack into mine soon...I'll post up the before and after sound clips when I get to it...

As far as I know there is no difference in the ECU on the 09' USA and EURO boxes. The only difference is what units are displayed on the dash i.e. KM /MPH, C / F ....etc. You have to go into setup mode when you start the bike to set the country. To get to the setup mode, hold the page button up while turning on the key.  You will see 000000 PRO on the dash. Now, hit down on the page button and you will see unit set hit down again to scroll through the country codes then hold down on the key to store the country, you will see MEM when it is saved....

Hey Joebar696, any update on your cored cans?  How do you like the sound?

didnt have the time to bring the cans to the guy who "re-welds" them for me. Think it wont happen this week but will post "before-after" videos when done ;D

will get the welded cans back this weekend.... [moto]

yeah! I Like!  ;D

Before (already with a lil hole cored in the baffle):

Monster 696 standard exhaust with cored pipe (http://www.youtube.com/watch?v=fWlhdi24jJI#lq-lq2-hq-vhq)

after:

monster 696 standard exhaust with half removed baffle (http://www.youtube.com/watch?v=LKjjPib1npo#lq-lq2-hq-vhq)

you're in Berlin?

I like it!  Just so I understand correctly, the second video is with the half baffle removed method, and the final video is with the entire baffle removed?  So you actually cored your pipes both ways and installed them on the bike?  Great work!  I wonder if I would get similar results with my M1100.  It would be really cool if you could do a side by side comparison with a Termi setup  [thumbsup]

@Raux: Yes I'm from Berlin

All Videos except the first are with the half baffle removed. The first video is with stock condition except a small hole drilled through the main pipe of the baffle (nearly no difference at all comparing before after)

it might sound a bit more radical on the last videos because they were taken in a closed garage

I'm down in Kaiserslautern.

god bless you

Great info and comparison!   Sounds MEAN! [evil]

Thanks for posting up the vids [beer]

I will attend a Wheelie Training in July near Düsseldorf http://www.moto-action.de/ (http://www.moto-action.de/)

Maybe something for you too?

I think I'll have to try this on my M1100, at least until I can afford some boomtubes.  They sound great!  Thanks for the detailed instructions and sound clips!

Hello!

    I'm new to the forum. I would like to half core my 696 exhaust. I cant seem to view any pictures on the forum. Could somebody please email them to me?

I will post before and after vids

Thank u

mpjetblue@aol.com

Sorry for the necro-post, but I'm also new here looking for more info on coring the stock cans. Ideally, I'd love to buy a cored set or find someone to do it.....