Chop Stock exhaust

[fsx]

I read a lot of the tutorials, but y does everyone slide the sleeve off and remove the welds of the cap before chopping? It seems like the welds are the hardest part y cant we chop then remove them, that way u have better access to the inside of the welds?

How I was going to do it:
Remove exhaust, measure where you want to chop
Secure and chop the whole thing with a miter saw
Then separate the end cap from the chopped piece
Slide sleeve back, put cap on, slide sleeve in place
Drill holes in top, bottom and side.
Rivet


Anyone see anything wrong with this?

[Scooter Montgomery]

What is your bike? I've done this on my 620 with low mounts both 1/2 core and I just did a full core job to the same exhausts. If they are low mounts I can give you tips.

[fsx]

I have low mounts on my 620 also.  thanks

[Scooter Montgomery]

When I did mine the first time I shortened the outer sleeve 4", now I have shortened them another 1 1/2". Here is how I did it.

1. Remove muffler from bike.
2. Remove bracket from muffler.
3. Slide the outer shell down towards the header end, as far as you can.
4. Now you can see the cap. Grind or cut the cap off. Maybe use masking tape to cover the cap so you don't hit it by accident.
5. Pop the cap center out, I think I just beat the crap out of mine because its a press fit.
6. Back to the muffler. Figure out how much you want to short the pipes when done and mark it on the outer shell.
7. Using masking tape, wrap the tape around the shell at the line, covering the good side of the exhaust.
8. Cut the outer shell.
9. With the shell shortened and slid down toward the header, cut the muffler. You'll cut through the outer shell and two pipes.
10. Slide everything back into place. I would suggest trying to get some high temp RTV between outer shell and the muffler at the header end.
11.reattach the hanger bracket. It helps hold things to together while you are working it.
12. RTV around the end cap and slide it back into the sleeve.
13. Rivet the end cap back on.
14. I didn't do this the first time, but also rivet the header end. Mine always had a rattling sound that I didn't like, but other people never noticed it.
15. Reinstall, and go annoy the neighbors.

If you decide yo want to go full core let me know. I'm thinking of offering to do this for people that are interested, because I'm looking for a reason to buy a welder. On a scale of 1 to 10, 1 being stock and 10 being Sil Moto carbon fiber slip ons, the 1/2 core is 5 (a good sounding 5) I would rate my fully cored ones at 7.5. That rating might go up once my bike is running right. You'll be happy with the 1/2 core if you take your time make they look nice and clean. My picture is my bike with the 4" cut off.

Bob

[Caboose]

Don't do it!

I absolutely hated the sound.  My stock Kawi ATV sounded better.

[OT]

http://www.ducatimonsterforum.org/index.php?topic=2312.0