Oh yea ... damn I'll sell my GS for $390 ... :lol:  :lol:  :lol:  - the 46K one wiht most of the pretty parts taken off and swapped out with the red stuff and the parts made for me (one off's) also swapped out ... disclaimer city ...
BTW the pipe itself cost $80 for a 20ft length ...  :x ... that shaZam! is expensive ... The guy commented that the section of pipe I used was in there for 2 years ... he thought no one will buy it... and he said the current $$ is prolly higher but that was what that pipe had as a price tag, so he sold it at that price... Steel pipe he said was under $10 for that 20ft,and bends up better ... I said I'll try the SS, wasted 18 inches trying to bend it, then took it back to them and they sliced and bent it all ... nice job. You'll see ... one of it is comming to you jacob... ...
BTW adam wade,and bigorange ... please PM me you address ...again and also let me know what bolts you have ...that are holding on the can to the flange ... tapered allen heads or straight allen heads...
Cool.
Srinath.

True mandrel bends are hard to find, but look oh-so-sweet when you finally see them.  Grr, somebody buy my damn guitar amp...I'm itching for an exhaust and clipons!!!!

If you are planning on making it to adapt to readily available cans, there are a lot of options. Suzuki uses 3 & 4 bolt cans for their stock systems. Aftermarket systems will vary in pipe diameter. Like M4 uses 2-1/8" clamp-ons for the SV650/s and 2" for the GSXR (IIRC).

For what it is worth...Yosh does have a slip together connection under the motor which allows it to be taken apart. Better for crash replacement and/or repair as well as shipping.

Dgyver, good point about the shipping.   Hmm, I wonder how much effort a slip fit would require.  It would make all aspects of the design process easier for sure.

Some new news on progress:  I spoke with a custom exhaust shop(with a real mandrel bender) in the area and he confirmed my suspicions, that the first set would cost around $1000-$1500.   This would include making the first set buy actually welding them together while on the bike, then making a pattern from that set and bending the stainless to fit the pattern.  He said after that that it would be relatively simple but for ten sets, for instance, it probably wouldn't be worth it.   He said if I was planning on doing "alot" then it would be worth it.  Then he talked about the skyrocketing prices of stainless and that there would be some lost material(misbends, etc.).

So unless there is a huge demand for them you might not get the huge discount that I was hoping to provide.

I think I might still bang around the idea with some other shops and see what other alternatives there are out there.

What a lot of people with se-r's used to do is buy the ends from jc whitney or the like.  You figure out the angles and whatnot; buy the bends, take the to a shop and have it welded together.

I cut a deal with one of the CAD designers at my work:  I'm gonna do his brake pads and rotors and he's gonna draw some blueprints up.  The hard part is that I am going to have to mock them up somehow on the bike.  Still trying to figure out how to do that.

I spoke to another shop today that said that they can bang them out, no problem, as long as I have all the dimensions and X-Y-Z coordinates.  I am still looking for someone in the area with a CNC mandrel bender though.  Those are some awesome machines.  They look like a lathe with a bender at one end, and as it bends it out, it can rotate the tube to whatever angle it needs to be for the next bend.  I know that such a machine exists, I just need to find someone in the area that has one.

I'd love to add an order if the price is right  i am guessing you are past the design stage but i would like to see a set that took as little modification to the bike as possible , (like origonal exhaust mounting pointes ect.) and the rest it sounds has also already been figered out. so .  ii'd take one made out of ss, ti, Alumineum!!!!(how ever the hell thats! spelled) tin canes even!!!  
i'v been trying to get a a cheap stock system off ebay so i could try and make my oun by doing a little cutin N' tackin.    well i'm wating and waching this post with great HOPE!

The only modification so far is having the muffler hanger point tacked to the rear left passenger peg bracket.  The reason I suggested that is so it would match the other side...whatever...I'm picky...

Maybe I'll figure out a clean looking way to bolt to it.

GL Dom, let us know your progress. Just know im down for a set.

Dom : ive just seen this thread , i have a few ..err vauge pics of the system if it helps , you might have some clearance issues with the centerstand and exiting out of the back of the bike ..if i could get a full under bike shot you would see the routing is not symetrical.. anyways heres the pics ..










Hope that helps



Lev

who made yours lev?

A company over here called Predator Motorsport , they do a 2 into 1 stainless system as standard , so i just hassled them into a dual system  


http://www.predatormotorsport.co.uk/



Lev

so how much is shipping to the US? lol

funny enough they do ship to the US..but you may want to be sitting down  :lol:

:lol:

Two into one into two...  Took me a bit by surprise.  Great pics, Lev, much appreciation!

I had planned to try to have them drop below the centerstand hangers, if at all possible.  The reason being that, one, the hangers could be utilized for any mounting purposes, which after seeing Lev's bike, have deemed to be unnecessary.  Orrrr...is that a hanger?....the little black thing in the first photo after the collector?  Lev?  And secondly, it would minimize the amount of alteration to the bike(i.e grinding off the centerstand hangers).

Lev's 2-into-1-into-2 merger collector is expensive to fabricate...I might opt, if necessary, for an X shaped colector(IMHO, simpler to build).  Ideally I would like to skip the whole collector/equalizer feature unless someone convinces me that they are absolutely necessary, srinath?

Cheers!

Equaliser or no equaliser ...makes no diff in perfornamce on a stock motor...for that matter neither does the fact that its a 2 into 2 or 2 into 2 into 2 ...or a 2 into 1 ... in short you'll see no gains with a 2 muffler system unless you are severely modding your motor ... even so the weight penalty is likely to be worse... effectively ...do it for looks, not for performance ... BTW aftermarket systems dont have the equaliser so they must be on to somehting ...Total BS...
Aftermarket systems dont have a crossover due to these 3 reasons ...
1. No gain in reality, so no need, but they can tout the fact that its different from stock and hence its better for your stock motor ...
2. The cross over is an extra manufacturing step with more materials and labor ... so it costs them...
3. The same header system can be used for the EX500 and the GS 500 if you dont have the cross over ... the pipes have a bit of give in it so it can be spread or squished to give you the fit on either bike ... that's also why the flanges are egged for bolt holes ...
Simple ... do the easiest ... none of it is going to make a diff in power.
Cool.
Srinath.

ok status check ,.....ya i know .....but i'm excited i got a line on a maching set of pipes there not stainless but i just need a set of dule headers so i was wondering how things are going.

This weekend has been dedicated to, yesterday, fabricating hanging brackets for my Buell dual headlights, and today, to making my Suburban Machinery knock-off drag bars(which I just learned I might have used the wrong kind of metal to make)...

For the headlight brackets I copied Antibody's twisted beauties.
http://www.gstwins.com/forum/viewtopic.php?t=7435&highlight=dual+headlights
Now, if I only had a snazzy paintjob like his....

As for the headers, I am going to go to the metal yard in the next couple of days to see what I can dig up to help me fabricate the prototypes.  Then my coworker is going to draw them up in AutoCAD.

Probably a week or so until I get the prototypes done.  This is the most time consuming part of the build: getting all the dimensions down pat.  After that they will be done and I can give them to any metal fab shop anywhere in the world and they will be able to make them.

I have been toying with the idea of using a shop with a CNC mandrel bander but I don't know if there is one in my area.  Those things could punch out dozens and dozens of headers in a single day...but they are a damn spendy investment so they might still be damn expensive.  Probably the best thing about a CNC bender would be 100% uniformity.  

lol :lol:  i'll take the prototype headers when yer done . i sertanly dont need ss headers but if thats what is decided on then i guess i'l have to go with it   lol   good luck