How to: Stock exhaust mod on Monster 800

[willyfog]

Well, my first post however important one about modding your stock exhausts. I did mine on Monster 800 from 2004.

The outcome is great and you can listen to it here:
Ducati Monster 800 Dark - stock exhaust mod
Here is the video when exhaust completely removed:
Ducati Monster 800 Dark - No exhaust
Note: sorry for my English â€" I'm not native speaker especially in tech jargon. Bike was modded in Poland.

Ok, now to details in steps:
1. Slide back aluminum cover from your exhaust to achieve this: (can be quite difficult, and you may need rubber hammer to do it) â€" use rubber to protect metal during clamping
http://www.fotosik.pl/pokaz_obrazek/9e440f16d427174f.html

2. Notice that end alu cover is welded only in 4 points. In order to remove it you will need to cut off them using grinder
http://www.fotosik.pl/pokaz_obrazek/136289bf5ed5455b.html

3. You may now cut off the small end pipe and start working on cutting into the pipe welded to inner end of the exhaust back
http://www.fotosik.pl/pokaz_obrazek/c5057ab34b185159.html

http://www.fotosik.pl/pokaz_obrazek/40fc7c08abbdd6bd.html

4. Once you achieve cuts around it it's time to cut off inner ending of the exhaust
http://www.fotosik.pl/pokaz_obrazek/422fe7bdf2dc2bae.html

http://www.fotosik.pl/pokaz_obrazek/e6dca773ad9c647c.html

http://www.fotosik.pl/pokaz_obrazek/3c1d1f54b617e382.html

5. Now the tricky part. The end of that pipe at it base is welded in 3 points. Take a welder with long welding electrode and weld it off. (no pic but see next you will understand).

6. Then take long metal bar that will fit into that small pipe, put it into it to the end and start moving it hard in all direction in order to loosen it to the point that it will fall off.
http://www.fotosik.pl/pokaz_obrazek/6dc0d7cda0160986.html

http://www.fotosik.pl/pokaz_obrazek/86d50015f47a9f40.html

7. So the main part is complete, now time to work out the ending of our exhaust. Take the nice shining ending that we chopped off in 4 points and notice that there is a cap welded into it. We need to somehow remove those 4 weld points. I have used drill rock to scrub it and then good screwdriver and a hammer to tear off each point. Then that cap which is diminishing our exhaust end diameter needs to be hammered down so long with screwdriver until it will be completely removed.
http://www.fotosik.pl/pokaz_obrazek/c2f42c3880838a79.html

http://www.fotosik.pl/pokaz_obrazek/a74e2ef2ee06cfd4.html

http://www.fotosik.pl/pokaz_obrazek/195bfceb650961b4.html

8. Now it's time to work off nice round exit in inner ending that we cut off before. Make cuts in star shape then cut the bit's and pieced off and round up using drill stone scrub.
http://www.fotosik.pl/pokaz_obrazek/57a1a0ed7fd2783b.html

http://www.fotosik.pl/pokaz_obrazek/dab6d49b328db050.html

http://www.fotosik.pl/pokaz_obrazek/631df62450ddb289.html

9.   Now you should have this in your hands:
http://www.fotosik.pl/pokaz_obrazek/fdf8bd6184c4ffb1.html

10. Time to weld it back. First inner ending and grind of all excessive weld parts
http://www.fotosik.pl/pokaz_obrazek/9dd5092d8474bd9f.html

http://www.fotosik.pl/pokaz_obrazek/9ec9543c4e6efc97.html

11. The weld back shiny ending in 4 points and move back alu cover. That's it.
http://www.fotosik.pl/pokaz_obrazek/5b4f413cc7ff57b6.html

http://www.fotosik.pl/pokaz_obrazek/9e440f16d427174f.html

During the process you can get ride of the catalysator but that's another story .....

[ajw85]

This is a GREAT write up!

Please find another site to host the pictures on, the advertisements are painful.
www.flickr.com
www.photobucket.com

[Shifty]

Nice!  Sounds great. Anyone else tried this? Maybe on a 620?