Getting started building a custom exhaust

[WiredForStereo]

Here's the story. I've modified my stock '08 XB12 muffler a number of times. I think I'm coming to the limit. Currently, it's essentially a U pipe from behind the valve to the back then back to the front chamber. The back and middle chambers are welded off. Exit in the front, only sound dampening is from the front chamber and the fiberglass or whatever it is the front tip of the muffler.

But it's not loud enough! And the timbre of the sound isn't quite what I'm looking for.

So I want to start construction (winter project) on a replacement pipe. What I want to do is attach at the header in the usual spot, then travel back down the left side of the bike, loop around the back in front of the rear wheel, up the right side, then exit at the front right. At this point, I want start with a long straight pipe, but depending on sound and response, may add baffles or a mild muffler later.

Something like this eventually:

I love the handling of the Buell, but one of the reasons I bought it was for the sound. I want that strong 45-degree V-twin sound and the way I have the muffler now just isn't doing it for me. My brother's Buell has a Jardine, and I like the sound, but I want the longer pipe and a more durable concept, and without the loss of low end power.

I am a competent welder, and own a welder, and no problems doing iterative construction. The first thing I need is the part that attaches the pipe to the header. I've heard of using a Jardine elbow. What other options are there?

Any advice anybody has would be awesome. All suggestions considered.

 

[Omiotek]

Make your own elbow

If your a competent welder and fabricator it would be easiest. The Jardine will dump in the middle. You probably need to be offset

 

[Omiotek]

Edit.

Double post

 

[WiredForStereo]

So find a pipe that slips over the collector and go from there? Anybody know what size that is off hand? I'd rather have a stack of supplies before putting my bike out of commission for a few weeks.

 

[Omiotek]

If you wanna make a slip fit you will need a piping expander or I'm sure a muffler shop could expand your pipe for you for little money.

 

[Sirius815]

Gpr makes a reverso that doesn't sound bad from the video clips I've heard.

 

[Sirius815]

Nitto12ss has a reverso type muffler in his Lightning. You may want get in touch with him.

 

[WiredForStereo]

I do like the reverso, but I'd like to build my own. Also, not inclined to spend that kind of cash for something I wouldn't want to cut up.

 

[Omiotek]

Depending on what and how your building it and from what materials you will equally spend what an exhaust can cost. I don't know your fabrication skills though

 

[WiredForStereo]

Depending on what and how your building it and from what materials you will equally spend what an exhaust can cost.

Not even close. I'm expecting to spend less than $100 on this project.

 

[d_adams]

$100 in materials won't get anywhere close to this (or the one you posted originally).

 

[WiredForStereo]

I don't see why not. $75 in pipes, $25 for a baffle, balance from my father's junkyard.

 

[d_adams]

As the saying goes, you get what you pay for.

 

[WiredForStereo]

Which is exactly why I'd rather do it myself. Nobody cares about my stuff like me.

 

[BambamXB12r]

I would tend to disagree, the quality fabrication and craftsmanship that goes into some of these exhaust systems are truly impressive. Dean Adams And Kevin Drummer are just the first two that come to mind. These guys care about every system that goes out no matter who's it is. In addition to the quality of craftsmanship, your also paying for many years of experience and R&D, including dyno time. There is so much more to creating a competitive exhaust system than welding some things to gather and trying to make it look pretty. In my opinion if you want the best sound and performance out of your bike it's worth the investment. In the end I guess Dean sums it up pretty well. You get what you pay for.

 

[WiredForStereo]

I was really just looking for advice on how to make or find a slip fitting.

If I wanted a store-bought exhaust, I would have bought one. If I wanted to be like everybody else, I wouldn't be riding a Buell.

 

[d_adams]

Get a piece of 2" 304 ss tubing, take it to a muffler shop, have them expand it. Simple enough I suppose. What you're after is 2 1/8" tubing so that it slips over 2" tube, assuming you use .065" wall thickness tube.

You're like about 140,000 other Buell owners. Well, there might not be that many actual owners, I have 3 myself right now and I know of several guys that have 10 or more each.

 

[WiredForStereo]

I get that. However I might see a hundred Harleys a day, several dozen sport bikes, maybe one Buell a month. I even saw an 1125 one time.

Went to Sturgis this year, saw thousands of Harleys, one Buell. As far as I can tell, most Buells are like my brother's, sitting in storage with 3000 miles on it. I've put 8000 miles on mine since Thanksgiving. I seem to be pretty unique. All a matter of perspective I guess.

 

[AZmidget91]

I've been avoiding posting on this, but anyways....

You say you are at the limit of modifying your stock exhaust. What exactly do you mean? Been on the dyno and got the most power out of it? Or just the loudest you could make it? What kind of welder do you have? Are planning on using stainless steel like the exhaust you posted? Who is doing your tuning? Have you thought of how you are going to mount it? Or how to mount the chin faring?

 

[WiredForStereo]

By the limit, I mean I don't think I can do anything else to make it sound the way I'd like it to and also function the way I want.

I have a Hobart mig welder. I also have access to a tig welder if I want, but I'm not as practiced or as skilled with that one.

Planning on using steel. Maybe in the future I'll use stainless after I've perfected what I want to do.

I use TunerPro. I'm going to need to retune anyway because I'm moving from 5500 feet to 1500 feet.

Yes, I'm thinking of fabricating a plate that mounts to the engine to replace the crescent shaped aluminum piece. Whether or not I use the chin fairing will depend upon how it turns out. I'm not hung up on it.