Got the farings with out too much trouble.

Got my headers off...f#$$%^ those bolts are tight!

Unbolted my old muffler.

Cut my old muffler off...


Test fitted the flange (made by the dude Srinath, painted by me with high-temp paint)  ...


Put the headers back on... F#$$%^ those bolts are hard to get back on!!!

I had put a small cut into my mid-pipe (not shown and I think I need to lengthen it) and clamped on the flange...


Now where I need help...the muffler sits too far back so I can't put the hanger on it and needs to be rotated a bit...would cutting some length off the flange fix this?


From the rear...


Side near turn signal...


More pics here

Any suggestions?

OK you should - Or my intention was to have the cut made right where the pipe has the larger part welded on ... you'd lose the whole larger section ... then slide the flange over that smaller pipe ... AKA cut again - ~3 inches forward of where you cut it right now ... then it should all line up.
BTW extrordinary pics and documentation (You learnt from Kerry ) - even if a little out of the box ... no harm done - cut it again and try it. Better this way than cutting too much off ...
Cool.
Srinath.

And yea cutting off the flange would work as well ... the angle of the snout is a shade off .... but again no real value lost there.
Heck - I am now going to have the new GS'es fit the old flanges this way ... I have no more new ones - so this has given me an idea.
Cool.
Srinath.

So I have 2 choices...

cut my mid pipe ~3 inches back...basically getting rid of that last bit of larger pipe. (going with your intentions)
--OR--
cut the flange back ~3 inches. (going with my "out of t he box" idea  )

I  think I will  to mastah srinath and cut that last bit of larger pipe...put a notch in the flange for the clamp...and put it all back together.

This means I need to take the freaking headers off again!!!      Atleast I still have the farings off. 

BTW...I did fire her up for a bit... Sounds f'in sweet!!

More pics when I am done and maybe a sound clip...I tried one but it sounded like cr@p, I had a fan blowing in the background.

till tomorrow...or by my clock later today!

I have good news and bad news...

First the good news...I got the Wileyco on!!!   

I cut my mid-pipe back about 3 inches from where I first cut it. Basically right past where the larger pipe is welded on. This leaves a that smaller section of pipe on the original headers. The flange fits right over it.

It did take a bit of tweaking to get it all lined up. Hanging the wileyco was probably the hardest part. I used the hanger that came in the kit and it took a bit of reshaping to get it to fit to the rear-peg set. My rear brake clears the flange, at first it didn't look like it would. I did use some muffler tape as the flange and mid pipe didn't mesh 100%. So there was a bit of an exhaust leak and the clamp I had just didn't correct that enough. Overall the muffler still could be rotated a bit so that the tailpipe points a bit more towards the ground, but it's on and I cannot complain.

Ok so now the bad news...I took pics, but my @#$%^&ing card reader locked up and deleted all the pics and video. 

I'll have some pics up soon, but they will all be of the final product.

Tail pipe pointing to the ground ... dammit ... everytime I hear this ... I get convulsions ...  ....
First they were close to stock, people wanted high exit  then they were "burn your turnsignals high "  ... then people wanted them lower  ... OK so I made some that were lower ...  then people said high was OK ...  so i made them high again ... grrrrrr .... 
You dont need that right turn signal, the muffler will burn it off for ya ... 
Your passengers ass also should be burnt a shade in the process ... that is the design ...   
OK good you got it on ... now these pics should work for anyone that is attempting to slap an old (will say old on the box when you get it) flange on a new GS ... cos I have olny old left ... news are all out I think ... I got a couple modded ... but anyway ...
Cool.
Srinath.

LMAO...man Srinath...I should have clarified...

The flange is freaking AWESOME!!!

Don't mean to send you into convulsious...on my bike it's more of "burn my inspection tag" direction, so if that's how it's supposed to be then cool, I was just thinking it needed to twist down as so the exhaust shoots straight back. Besides who needs a stinking inspection tag anyway??? 

Now that i think about it most of my passengers are smokin hot babes anyway, so this might be a cool breeze to them.     

So first go grab yourself a  then...well...you making a bars again anytime soon? 

Once again thanks for the flange!! 

OK Ok ... thanks ... didn't mean to like swamp with emoticons ... They come up when typing as text ... but on the display they are like huge ...
Anyway put up pics ... I did mean them to exit maybe 2-4 inches below the T/S ... and some cans have the snouts at different angles ... Adam - I forget his handle ... had a can he had, perfect fit, then someone stole the can ... and he ordered another wileyco ... and the new wiley co is pointing way off ... like WTF ... they riveted it in the wrong place ...
So there is some variations in the wileyco's I'll say ... anywa put pics up ... I'll say if that is within design specs ... obviously it cant be waaaay off ... I had them jigged and rigged and tested and tested again ... dammit I did only take like 2 months from the time I had the pieces ...  ...
OK Bars - now see welder is in his prime trailer roof fixing window ... so i might have to sit on it ... not too long hopefully ... I have the thing down to where it can be done with very little time from him ... I'll let y'all know - I'll start asking for orders ... then you know its comming.
Cool.
Srinath.

Pics!!!

It's on!! But what's that on the right??


LOL...cheap muffler tape...maybe I need to double wrap it. I am probably going to eventually get it welded up.


Close up of the flange and mid-pipe.


Tailpipe angle...please ignore the chicken strips! 


Sound clip coming soon...

Cheap-arsed sound clip

I did this in my garage with my camera...so the mic is not the best in the world. One quick high rpm rev and the rest are to 4-5K rpm.

Just a thought after looking at the photos and reading: I would cut four slits in the flange pipe, each one at 90 degrees (so if you looked at it straight on the slits would be at noon, 3, 6 and 9) and about 1.5-2 inches long and then clamp that on with a muffler clamp instead of a hose clamp. That would cure the exhaust leak.

Nice-looking can and flange.

It should be tight enough ... that after a few rides with it spewing soot onto the frame it should get right about enough sooty powder on there ... it should seal up ...  ...
Or OK ... get all fancy now ...
Cool.
Srinath.

Quote from: dbNnc on August 08, 2006, 06:44:13 AM
Just a thought after looking at the photos and reading: I would cut four slits in the flange pipe, each one at 90 degrees (so if you looked at it straight on the slits would be at noon, 3, 6 and 9) and about 1.5-2 inches long and then clamp that on with a muffler clamp instead of a hose clamp. That would cure the exhaust leak.

Nice-looking can and flange.

I already have one slit on the underside...I'll cut 3 more this weekend. I have a muffler clamp too...just thought the hose clamp *might* work. 

Maybe with that and the soot, like Srinath, it'll seal up just right!