b12ty

I did try sticking the original tailpipe inside the 2" pipe, same sound, but quieter. So it would seem that may be a way to go. Sound seems to be affected by those 2 things, hole size into cat chamber, and outlet size. ( assuming you get rid of the s pipe. )  
Up in the canyons early this morning, I thought it sounded great. Just a enough of a low rumble when cruising along in 5-6 gear to let you know it's there, and nice rising pitched growl/wail when you get on it in lower gears. I still think it's a bit loud stoplight to stoplight, but think i'm getting used to it.
 
A friend up there thought it sounded great. ( he's not riding his FJ atm, because of recall, ack! )
 
 
 
Ty

Do you wear earplugs Ty? I always do so it may not be too loud for me.

 
I do not. Check your messages.
 
Ty
 

I did try sticking the original tailpipe inside the 2" pipe, same sound, but quieter. So it would seem that may be a way to go. Sound seems to be affected by those 2 things, hole size into cat chamber, and outlet size. ( assuming you get rid of the s pipe. )
 
Up in the canyons early this morning, I thought it sounded great. Just a enough of a low rumble when cruising along in 5-6 gear to let you know it's there, and nice rising pitched growl/wail when you get on it in lower gears. I still think it's a bit loud stoplight to stoplight, but think i'm getting used to it.
 
A friend up there thought it sounded great. ( he's not riding his FJ atm, because of recall, ack! )
 
 
 
Ty

Put my Ermax on and rode to work today. Here are my observations: Light black is very dark, like limo tint 5%, but still able to view through it.
The screen is very stable at speed and looks great.
If you are over 5'8", you may need something taller.
I am 6' and will be taking the screen off tonight after only one ride.
Way to loud and head buffeting for my height.
Hoping to sell to someone local (20% off of what I paid) so shipping does not kill me.
Any interest?

 
That sux, I know you were really looking forward to receiving this screen.
 
Back to the CalSci?
 
Ty
 

I don't find mine loud. I assume the extra noise is proportionate to the size of the hole through the baffle. Mine is perhaps half the size yours is.

That's good info then. If someone else were to do this, they could know to make second hole according to how loud they want it. Mine is just a little bit louder than I want. Could be just a personal preference. Gives me an excuse to tinker more.  
I'll judge the reaction next time I go up Angeles Crest Highway for breakfast. At least a couple of FJ-09s are usually there, plus a couple that may buy one. They are gonna be surprised at the sound of my "stock" exhaust..hahaha!
 
That's what I really love about this mod, besides being free. It retains the cat for possible future emissions testing laws, and I really think the stock exhaust is very cool looking. More so than any other bike i've owned. The extra power doesn't hurt anything too, thx for dynoing yours!
 
Ty
 
 

Just to continue the muffler experimental mod, I may at some point construct a simple DB killer insert. While sounding killer and does NOT drone at all on the freeway, I think it may be a bit too loud on the street.
 
It sounds to me somewhat like an Akropovich without the DB killer. ( maybe not quite that loud! ) The low notes are great, but like the Akro, a bit loud. With the DB insert in, it's pretty quiet, too quiet for my tastes.
 
Soooo, it would be a simple project to play around with making a DB killer. I could play around with the configuration till I get it just right. I'l keep you guys updated, Fun stuff!
 
Ty
 
Ty

Sounds really great. Yours has just a little more popping on decel than mine, perhaps because of the larger opening in the baffle. It is a very rewarding mod for those that have the equipment at hand. 
Cheers,
Chris

Ya, I was surprised when I heard the video. I didn't hear the decel popping much from inside my helmet. But ya, I do have a bigger 2nd opening than you.  No worries, I could always block off the AIS, but I see no need. I was riding it harder than normal in that vid also, downshifting and such. You're hearing it at it's loudest.
 
Ty
 

Finally got out to do a test ride up in the canyons. I can now hear my bike as I go thru the gears !
 
Triple sound is very addicting...  
 
Really glad I did this project, and it cost almost nothing. Just time. Here's the vid:
 
[video src=https://www.youtube.com/watch?v=uCBeU9R3FsY]
 
Ty
 

Looks and sounds great! Enjoy...

THX! 
Ty
 

;)Great work Ty! So, you didn't cut your O2 sensor wire off then?
You & Papac have pioneered the work for a budget do it yourself pipe work!
1 question I asked Papac, could you have added a little bit more of the cut off pipe including the bend when you added it to your new hole to point it out towards the outlet? Like the photo you asked Papac about?
Would you get the required back pressure?
Other than that query, great work you two!
Cheers,
Steve

 
I left that idea for the next guy to try.
 
Ty
 

Hey Lewis, by the time you guys met up for your ride i'd already been to Newcombs for breakfast and back home again! Took the Suzuki...
 
Busy weekend, but I finished up the exhaust ( and tail light, but that's another thread. )
 
 

 
 

 
How does it sound?
 
Idle: A lot louder, low pitched, slightly boomy sounding in helmet.
 
Around town: Sounds great, not too loud unless you get on it, then it growls. Can finally hear the engine when going over 40mph!
 
Freeway: Does not drone, just loud enough to let you know it's there.
 
Roll on: Once again, growls, not high pitched, throaty.
 
Higher RPM revving: Sounds sweet, a nice triple sounding muted roar?!!
 
Power: It definitely increased the power a bit. Let's just say the front wheel gets very light more easily.
 
I will say more once I have a chance to take it to the twisties, but I know i'm gonna love it!
 
 
Here's a quick vid I made. Unless you have good speakers or a sub woofer, you wont hear the low notes. It sounds higher pitched than it is.
 
 
[video src=https://www.youtube.com/watch?v=IqLSGt5mJVw]
 
I will try to post some fly bys in a video this coming week.
 
Ty
 

Got a lot done today.
 
Cut a remnant of old S pipe and fit it to second hole I drilled into the cat chamber.
 

 
Cleaned up the inside faces and bent/widened the mounting tabs for new tail pipe.
 

 
I cut a new tailpipe out of 2" O.D. stainless tubing, using stock one as a template.
 

 
Fit new tailpipe to muffler.
 
 

 
Check fit by screwing on bezel with the 2 screws underneath. When screws go in smoothly, and pipe protrudes centered in opening you're there. ( you will have to crush pipe slightly oval at end to fit thru bezel. )
 

 
Tack welding.....
 

 
All welded up. Upper bezel mount was cut to 1/2" tall and lined up with the bezel.
 

 
All three screws should go in, and bezel opening centered...took some time to get this all fitted and welded, but worth it.
 

 
Cover tack welded in place.
 

 
All welding finished! I had difficulty with the muffler case material. It would burn thru REALLY easily. I ended up welding it in short bursts, letting it cool for a second in between. Doesn't look too pretty, but it's tight!
 

 
Ready to go back on the bike. Tomorrow I hope to get it installed and hopefully get a test ride and a vid soon. I'm so excited to fire it up and see what it sounds like!
 
( if it sounds like crap, i'm going to ride up to papac2000's house and      ..... just kidding! )
 
Ty
 

@motomachines - Got my clear Ermax Touring Screen in the mail today! AWESOME!!! It's beautiful! Fits perfectly, great design...I couldn't be happier. This is the screen that will stay on my bike. Yes, those are the LED lights installed on the hand guards. Love 'em.

I take it it's a lot quieter than stock on the highway? Stock screen works ok for me, just noisy.
 
Source  for LEDs on handguards, or did I miss it?
 
Thx, 
 
Ty
 

Very nice, Ty. You have done a much more complete and thorough documentation of the process. I vote yours becomes the new reference! Looking forward to seeing the finished product.

Thx! 
Several members asked for more pics, drawings, and documentation when you did yours. I'm trying to oblige.
 
But hey, i'm just copying your pioneering efforts on this. You the man!
 
Ty
 

Ok, next installment:
 
Cut off upper bezel bracket. Save for reuse later.
 

 
Cut free the two lower mounts by cutting thru at the top and sides, prying outward then cutting at bottom. I will clean up the inside faces later before rewelding on new 2" tailpipe.
 

 
Cut off tailpipe and remove, taking inner remnant of "S" pipe with it.
 

 

 
Drill pilot hole for holesaw.
 

 
Drill thru, being careful not to go too deep and hit the cat. ( I shortened pilot bit to make sure )
 

 
Tada! One new hole to release more gooder sounds and a bit of pressure. See the cat? !
 

 
Remnant of "S" pipe fits perfectly in the new hole. ( Hey papac2000, what do you think if I welded it in like this??? !! )
 
The plan is to cut it to length like the pipe next to it, making 2 exits from the cat.
 

 
I picked up a length of 2" O.D. stainless tubing today after work. Next time i'll fashion a new tailpipe, then weld it all up!
 
Ty
 

I could do that. What is your reasoning for not just leaving a hole? Just curious how you think adding a pipe would affect things.
 
Ty

Looking good, although your tape measure appears to be broken. It looks like there are 16 millimeters for each centimetre...

Or you're on the wrong side of the pond...   
Ty
 

This is a very rough sketch of what's inside the cat/muffler, before and after i'm done. papac2000 style.
( internal pipes laid out beside each other for clarity )
 

 
No turning back now. Made the cuts...
 

 
Aha!
 

 
This upper tube extends into the cat chamber aprox 2-3". Cat off to the right inside 1" back from wall.
 

 

 
Some measurements...
 

 
 

 

 

 

 
S pipe cut out... getting dark, that's all for today.
 

 
At this point, this is at stage 1, stage 2 will to be to cut off the exhaust tip and add a 2" diameter one. And drill another hole to the right of upper pipe. 1-1.5"?
 
Ty
 
 

 
gold tape on rims and under tracer logo...still can't decide if it looks good

I think it looks great!  
Ty
 

Best of luck! A smaller cutoff disc tool may allow more precise cuts, if you can get one. Will be watching your progress with interest.

I have other tools also. That was just a quick pic to show my "intentions" !  
For Steve:
 
Ty
 

Exhaust is too quiet. I like the look though. I either end up saving $1,000+ or.... i'm out $550ish if I screw it up. Pics and sound vids as I have time to work on it. 
 

 
Ty
 
 

Mar 14, 2015 8:13:31 GMT -7 ULEWZ said:
Just say nay to the grey.
_____________________________________
 
 

 
Ty
 

Thx for info.
 
Ty
 

Woohoo!
 
Can hardly wait... this looks worth doing for sure. And leaves the cat in for emissions should that ever be a problem.
 
Ty
 

I use Purolator ML16817. About 3/8" longer than Yamaha's, and has an o-ring like Yamaha instead of a flat gasket like some.
 
Works for me.
 
Ty

!!!  
 
Ty