Homemade custom muffler build (with pictures) - Second Attempt

[quiktaco]

Thanks Tang! I really liked the sound of the loud one as well, but it would have been too much trouble.  The one I went with sounds pretty similar to that one, just a little muted, so it's still legal, and I won't be hated.

[Tang]

most def. man lol

good work hopefully when i'm doing a muffler i might come to u for help lol

which probably will be never haha cuz i'm so dang lazy haha

[frankieG]

ditto is it on the bike yet? youtube it so we can hear it too.  good luck with the project. i admire your innovation

More pics, I demand more pics of a finished project!!!   

keep us posted!

[quiktaco]

Yeah, look at page 3.  There's pictures of it on the bike, and 4 links to youtube for sound/video files

[quiktaco]

I just took the bike out for a test ride and I really feel a lack of power now.  I did a plug chop at 5k RPM's and they were white; like I expected and hoped.  So that means the the new exhaust is less restrictive than the stock exhaust.  So I'll be going up from the 140 mains that I have now to 150's.  I'll probably get some 147.5's while I'm there just incase it's too rich with the 150's.

Let me know what you guys think of the final product, also.  I'd like your opinions.

[spc]

Honestly, you surpassed my expectations.  It looks and sounds a lot better than I ever would have thought.  I actually kind of like the look paired with the GS
Superb Job!

[quiktaco]

Thanks!  It really surpased my expectations also.  Truthfully, I expected it to sound like crap, but figured it would be worth a shot.  And since it was my first mig welding project, I didn't know how great it would turn out.  I've Oxy/Acetyline welded in the past, but just got a mig.  I've always thought that the bug cans coming off the back look so dumb and just added on cause it had to be, so I wanted to do something about it.

While riding today, I did notice an odd high pitched sound, but I think it was coming from the intake, not the exhaust.  My wife said she didn't here a high pitched sound at all, so I'll have to hunt that down.

[GeeP]

Looks good!

Now for version 2:  Chrome!   

[quiktaco]

NO CHROME! YOU CAN'T MAKE ME! I HATE CHROME! 

I ALL CHROME OFF THIS PLANET!

[quiktaco]

Just picked up some 147.5 jets.  I'm hoping that gets me in the ballpark.  They were 5 bucks a piece, so I'm holding off until I know if I need something different.  This Suzuki dealership is so weird, cause they never have a set price on their crap.  Last time I bought jets from them (the 140's)  They were 2.99 a piece, and this time it's 5?!?  I don't get it.  Oh well.

[quiktaco]

I installed the 147.5 mains last night and took if for a spin.  There's a major flat spot around 5-6k RPM at WOT.  It just sits in that range for a good 3-4 seconds, then gets past it.  It will pull after it, but it seems I had more power with the stock exhaust and the 140 mains (which I thought were a little lean).

Are the jets too big?  I don't know if I'm lean or rich yet...haven't chopped it yet.  What would cause these symptoms?  Maybe just turning the mixture screw in or out a half turn will help.  The strange thing is that it only happens at WOT.  If I move just slightly off the throttle, then it seems to pull through the RPM range, but still seams to lack the power I had before up top.

Any suggestions?  Anyone know what causes this?

[The Antibody]

I'm not an expert on jetting, but I wanted to say that this turned out damn nice. Good job. You seem to be very handy with metal work. I hope you resolve the power issues.

Very nice work!

  -Anti 

[quiktaco]

Thanks Antibody, I think I may have, although I haven't taken it for a test ride yet, but when I had the 140's in, I knew I was on the lean side, so I had the mixture screws turned out 4 turns.  Now with the 147.5's they were still at 4 turns, when they probably should be around 2-2.5 turns out.  I'm guessing that's the main cause for the rich flat spot that I had.  We'll see when I get on her later tonight.

[morbidelli17]

One word - nice!

[quiktaco]

Thanks.  Took it for a test ride, and during the ride, I guess the nut and bolt that holds the baffle on vibrated loose, and my baffle ended up on the side of the road.  Five seconds later after I pulled over with my open pipes, a cop drives up, slows down, but luckily passes.  Had to run back to grab the baffle, then hook it on the bike so I could ride the rest of the way home.  Definitely way to loud with the open pipes.  Just a few minute ride was way to much to take.  I'm suprised this baffle really make that much of a difference.  I didn't get much of a chance to test out the flat spot and see if it was gone, by the time the baffle came out, though.  So I'm going to drill a hole in the side of the bolt and safety wire it on this time, so it can't come off.

[frankieG]

please do another youtube and REV the dang thing....none of this idle crap and to heck with the neighbors lol

[quiktaco]

lol, just got your comments from youtube.  I'll redline it during a ride and post that video.  I'm getting it tuned first so I'm not redlining while it's too lean.  I have one more test today with the new jets, then I'll try to get a couple more videos of the thing.

[frankieG]

that would be great, thanks

[theGrinch]

Wow, what a nice exhaust! Sadly it won't be road legal in the UK - let alone in Germany

/edit: Did you get that carb problem solved?

[quiktaco]

Why wouldn't it be legal?  It's not too loud at all.  It's actually relatively quiet.  Just slightly louder than stock.