FNG alert. Messing with my exhaust system....

[crAKer-47]

Let's see how bad I screw this up. This WAS a perfectly good exhaust system.

[Nails]

[crAKer-47]

PSA: The tips on our stock exhaust are as fugazi as my wife's engagement ring.

When I bought my Sporty thirteen years ago, it had a V&H exhaust on it.

I'm not an engineer, but I think that might flow a little more exhaust gases.

Now to attach it to the stock pipe. SIDE NOTE: That Harbor Freight folding bar LED light is awesome.

[Nails]

I'm probably not getting everything you're trying to say with these photos.

[crAKer-47]

My wife tells me the same thing. The inboard tip on our stock exhaust is fake.

I cut up my Sportster's old exhaust to repurpose the 2-1/8 inch tips, and retrofit them to the Voyager's system.

That small one-ish inch perforated steel tube ran the entire length of the main muffler body, requiring some cutting and fabrication of new "partitions".

Now I've got to weld it all back together.

[crAKer-47]

Why no officer, that is the exhaust that came from the factory.

I can't wait to hear these pipes.

Now to deal with this " clean air system".

PSA: The inverter welding machines at Harbor Freight are really good actually. For the past 25 years I've made my living with the Big Red and Blue machines, but these HF machines weld every bit as good as I can.

[Nails]

Thanks. But I'm still not sure about some of this. You left in the 1" constriction, shortened it, and cut more holes in it? But then cut it short of the outlet, which is larger than 1"? (I'm not clear what "partitions" means.)

This stock exhaust sure seems mighty restricted.

[crAKer-47]

No worries. The one inch section of tubing has been removed completely, from the collector (Images 4,5 and biggest chunk in image 13) to the outlet (Images 11, 12, smallest chunk in 13). The "partitions" inside the muffler body had one inch holes in the center of them to allow the original section of tubing to run through them, which I opened up to 1-3/4 inches and reinforced (images 13, 14). Now the muffler is 1-3/4 inches from the collector(biggest chunk in image 13) to the back of the outlet (smallest chunk in image 13), where it transitions to 2-1/8 inches out of the new tip (images 7,8). Simple, isn't it?

[Nails]

Simple, isn't it?

With some hand-holding.
Curious to hear how it sounds and whether you have to fuss with jetting. I'm guessing you're cutting the back-pressure in half or more.
Continued thanks.

I'm planning to build a new off-set piece and weld a Harley muffler to it -- basically dump/replace everything in photo #13, including that second cross-over, from that big under-belly unit on out. The Harley inlet and the XII outlet are the same diameter. I'll buy a couple 30-degree elbows and cut some appropriate section on of the middle of the elbow, then flip one half 180-degrees from the other and weld it back together into the offset S-bend I need (something like 2" by eyeball estimate). I'd have to fab the muffler supports, probably dumping the passenger floorboards in the process -- I ride solo.

I think I'll end up with about the same flow as you did. Maybe a little lighter. Maybe I'll melt the heels of my boots.

I hesitate to fuss with that under-belly unit or anything upstream.

[crAKer-47]

I'm sure I'll have to fuss with jetting, and airbox mods as well. Your set up will definitely be lighter than mine, as the stock Voyager exhaust is well built and very stout. My mods only netted a ONE pound total loss for BOTH mufflers. It must have cost Kawasaki a small fortune to manufacture this thing. I'm a fan of the double crossover and tuned volume approach they did on this system, which is why I went this route.

Hit your local exhaust shops and ask them if they sell their boo-boos. Some do. Cheap. Otherwise, you know where to get the bends you want. Good eye Nails! I just measured my muffler and the offset is 2-1/8 inches C to C. Good idea using Harley take-offs, they are also well built and dirt cheap. The muffle support brackets have a small offset in them, but nothing you can't bend up with a hacksaw and a vise.

[Rhbrandy]

if it aint broke don't fix it.

[Nails]

Make it yours.