[bike10]

excuse the quality, but these were taken with my phone.
here's the write up.

My whole purpose was not for power gain. I just couldn’t stand the fact that this bike sounded like a 600cc Singer sewing machine and I too liked the factory look a lot! I don’t like the fact that the after market pipes stick so far out and if I wanted a more powerful bike, I would have just got the R6. So with the whole point being that an FZ6 is just an FZ6, I chose the path to a louder exhaust only.

I did design a strait pipe set up first since the CAT is a small muffler and the exhaust system has so many bends, the noise volume would not have been too much. That idea was shelved when I figured how much work it would have taken to fabricate mounting brackets for the system and the exhaust cover (again factory look).

The operation took place on the bottom of the muffler to avoid all the mounting tabs on the top. I used a rotary (Dremel) tool and stone blades (29) to make a thin cut (makes easier welding). I cut a rectangle approximately 2/3 of the bottom, cutting through one of the baffles and around two of the spot welds. I cut squares around each of the spot welds to pull off the outer skin and left the inner perforated skin for the blow torch.

I was lucky enough the have a friend who’s back yard looks like the cable show Junk Yard Wars. He has anything and everything to make ANYTHING. So the blow torch and TIG welding were done at his place. This brought the cost down considerably.

The muffler is designed just like a car muffler with three chambers and two baffles. It reminded me of the inside of a BOSE subwoofer. The exhaust enters chamber #1 and is transferred to chamber #3 and then back to the middle chamber #2 and then on out your twin exhaust tubes.

We started by using the cutting torch to remove the perforated inner skin where I had made my cuts and then cut out the first baffle and tubes and then the second baffle and tubes so that it was one big empty muffler can. Once that was done he cannibalized the parts I had cut around to fill in the wholes on the outer skin and weld the cut pieces back in. we used that same outer skin to seal up the muffler. This was about a 90 minute weld job. That fact alone makes it expensive, but still cheaper than a set of pipes. we reused the original muffler skin, so it looks a bit factory with a surgury scare.

The completed job looks good and the bike has a unique sound. It is not as nearly as loud as normal after market pipes. The sound is a cross between a muzzy, a two-stroke bike and an F1 car. I know it sounds crazy, but it does. And the sound is cool!!

I have pictures in my TREO phone, but can’t get them to download into my computer, so if you want pictures, I’ll have to send them via cell phone for now.

As a note, my friend is a certified welder and on the side makes patented metal and fabrication work for off road trucks, buggies and bikes. This means he will do the mod for anybody intersted, but for approximately $150.00 if you bring him the muffler. If you live in the So. Cal. area, let me know. You can even look at and hear my bike in person to see if you like it.

Bike10

P.S. here's the sound clip. unzip it first, it's an MP3 file.