Custom exhausts

[MR.E]

Now then

Sorry for the radio silence, work's been rather demanding!!
Hope you're all well.

As i've been busy with work etc, i've not really progressed with the bike build, so last week i made an effort to get it wired and running.
I decided to build an exhaust, which required some light reading to ensure i didn't hinder the engine.

and this is what i've built..... and i'm happy with it and it sounds good!!

[montmil]

Rather sporty looking.

Did you remove the threads from the exhaust spigots to fit the header clamps? I recall seeing these aluminum attach components offered as an option with stripped threads on the spigots.

What type of muffler or exhaust extension are you thinking of?

[Rob Valdez 79 R65]

What type of muffler or exhaust extension are you thinking of?  

See the last picture.

I'll bet it won't be quiet, but it looks GREAT!

Congratulations!

[marcmax]

If I remember correctly Mr E is planning on racing this R65 so I am sure that exhaust sound is the least of his concern. Awesome setup. Any concerns about elevated oil temps running an unshielded exhaust directly under the sump?

[MR.E]

Cheers lads, really pleased with it
I even did a little dance when it was mounted.

The Threads seemed to be in good nic, but when i fastened on the rose nut it locked solid and had to be cut off.
The other problem would be, as i've used formulas to work out the exhaust setup, the pipe is 3mm larger in diameter than stock so it butts up to the cylinder head and doesn't go in it.

This one i will hopefully be hillclimbing, on tickover it's putting out 96DB's, but as i've not built the air filter system yet i'm reluctant to rev it!
The Rear can sits nicely between the rearsets and the rear shock and is from a 2002 R6.

Only bad point is i'm not allowed to race it in the classic series as it's too modified, they care more that it looks right than whats powering it.
I've a spare engine here that i've built a second set of headers for that'll be running a r100 camshaft, which i assume should give me more lift on the vavles........... i say assume because i forgot to measure the bloody things!

The pipe does sit close to the sump, the thought of oil temps made me think of attaching a shield to the engine mount bolts as it'll nicely squeeze in.

I've been asked to make a 3rd set for a mate, happy to document it if you want to make your own, or i'll make you a set at the same time if you're interested.

All the best

[MR.E]

here is a link of the bike on tickover

http://s1203.photobucket.com/user/ellmud/media/BA68C7AB-AD72-4ABD-B5AF-456EAA758ABE-6159-0000012A3C2381CF_zps5237f31b.mp4.html

[steve hawkins]

I sincerely hope you get this completed.

As our American cousins would say:

"It would be Awesome!"

Cheers

Rev Light

[Dave 2]

Beautiful work on the exhaust system. I'd be interest to hear how you made  "butted "headers secure. Your bike looks and sounds great. Dave 2

[Rob Valdez 79 R65]

Those R6 shocks sure are handy things!
I bought one from a '08-'12 for my CBR250R.  Much cheaper than the specialty aftermarket shocks, with all 4 adjustments!

[MR.E]

Dave
I tacked a flange to the header pipe and have used the stock compression washer, though i opened it a little on the lathe.
For the spare engine I've turned a couple of mm from the exhaust port of the head to allow it to slide in a little bit too.



As an update here are some vids of the bike running.
The first should be the video of the rev counter, you can hear about half way through when i open it up again it splutters but eventually picks up, problem was i had to go to a hotter plug from stock as i've modded the exhausts, apparently i've increased the pulse rate of the back pressure



And here it is kind of finished, think i'll spend a few days riding it before it goes to paint

[MR.E]

First Ride up the road