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  #1  
Old 8th May 2014
Phelan's Avatar
Phelan Phelan is offline
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Default Built a new post-header exhaust for my S2T

I built a new setup for my S2T. It's not really a "muffler" as it's nothing of the sort, and I split the collector to make my system a 2-1-2 exhaust. It's all stainless as well, like the header.

Originally I bought a stamped 2-1 collector (to use as the splitter) and 2 - 11" reverse cone megaphones. I didn't know at that time that I would shortly thereafter be blessed with a chopsaw (among an influx of other tools as well, from my Dad), and was looking for a way to put it together with not much work. When I got all the pieces in, and received the chopsaw, I realized the splitter would hold the megaphones too far apart to be ideal. So I cut it up to fit the megaphones side by side. Here was the result.







That worked (after I added a mounting bracket), but it was ugly, and there was material overhang inside, which caused bad reversion. I took it off and ordered some 2" stainless tubing, which I should have done from the get-go, and built a new splitter.



Cut off the larger diameter slip-joints from the old splitter and welded them together to make a slip-joint in the front about twice as long as pictured above. Once it was all welded together, here was the result.



Much better look overall. I still have to clean it up, slot the slip-joint, and figure out how I'm going to make the baffles (which I have a bit of stainless wool wrap for), but overall I'm pretty satisfied with my handiwork .

The bike it's going on



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Last edited by Phelan; 8th May 2014 at 16:48..
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Old 28th May 2014
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Good work so far. Got ay further yet?
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Old 28th May 2014
NRHS Sales NRHS Sales is offline
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If you come up here in fall we are going to work on getting you to TIG weld.
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Old 29th May 2014
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Did you use stainless steel wire or steel gasless flux core wire??? your weld look crystalized
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Old 29th May 2014
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Thnaks guys! Yeah my welding on this sucked; before this I was well out of practiced and had the wire speed too fast. It was working good and I put baffles in it (no pictures unfortunately), but I got a killer deal on a D&D full system, so if I can get that to fit (it's for '99-'02, different frame), I'll use it, but I may adapt this muffler to it. That would require cutting and flowing in a 2.5" collector as it's made currently for a 2". So it's on hiatus for now until I get the new system Friday.

Dan I'm all for it! I WANT to get better for sure! The wife and I will be moving end of August, I'll be up there probably early August to seal the deal on a place .
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Old 2nd June 2014
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Not the greatest picture, but here you can see the cleaning up I've done thusfar on the dual megaphones muffler. You can also see that I'm quite exhausted :P

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Old 2nd June 2014
NRHS Sales NRHS Sales is offline
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looking forward to seeing this in person
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Old 2nd June 2014
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Quote:
Originally Posted by NRHS Sales View Post
looking forward to seeing this in person
Thanks! I'm hoping to have the muffler adapted to a 2.5" inlet with a matching header of some sort by the time I come up there, and maybe try it out on the dyno and see how it performs . The D&D indeed will not fit in any form or fashion, so once I get it cleaned up and presentable I plan on selling it, as well as the race muffler, though it's a bit banged up and I'm not sure it's stock, because I looked inside it and there is NOTHING.
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Old 8th June 2014
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Phelan Phelan is offline
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Another update, my previous baffles were more of a temporary job, and since one of them came loose, I decided to take the opportunity to make some new ones. I cut the reverse comes off my megaphones and flattened and re-rolled the mesh I used for the previous setup, and cut some 2" and 2.5" tubing to make the front and rear of the baffles. Then I stuck the rolled in mesh and adjusted it all so it will fit tight when I weld the reverse cones back on. Tomorrow I'll weld the pieces of the baffles together and pack them either with stainless mesh or rockwool (still haven't decided) and weld everything back together .



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