Just wanted to start the thread for my custom muffler build. I'm making my own muffler. From scratch. No slip ons. No pre-made stuff. The reason...I hate the look of a muffler. I'd like to just chop it off, but things like back pressure and noise level have kept me from that. So my solution will be a short and small homemade muffler. it's about 11 inches long and it will be 2.5 inches in diameter. I want it to almost look like I just chopped it off. It's going to go straight back with no bends, and almost look like a straight pipe. Very clean and simple, to make the bike as minimalistic as possible.
As I go, I'll post pictures of the actual build, the conceptual drawings, and video so that you can hear the sound of the muffler when it's complete.
I'm estimating the cost will be significantly less than $50 to complete, with much of the cost going to fiberglass packing (hopefully I can find it cheap). So far I've spent about $15 on the actual pieces of the muffler. It will all be welded together with a Hobart Handler 140, except for the baffle, which will be removable to make adjustments and to repack if it ever needs it.
I welcome all your comments and suggestions, good or bad. In the end, I'd like it to be as quiet as possible and maintain about the same back pressure as the stock muffler. I know it's not going to be possible in a significantly shorter and smaller space, but those are my hopes for this project. I'll be rejetting afterward to get the air/fuel mixture back to how I have it now.
Hopefully you'll enjoy this, and be inspired to do some project on your own bikes.