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Discussion Starter #1 (Edited)
Well, I FINALLY booked out to the garage and started ripping and tearing the bike down for the exhaust project.

The idea being to replicate the no-longer available WOLF exhaust for the VFR800:







First thing on the menu of course was to remove all the tail plastic plus the stock undertray and battery box:



This left me with a jumble of wires and such to deal with:


Later, later. Let's start making stuff!
 

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Discussion Starter #2
Next thing I did was to reinstall the tailsection plastic and hang the mufflers to get an idea of how everything would sit:





Triple exhaust anyone?


Width is good, about the same side-to-side as the later, smaller Dia. WOLF cans:


They don't stick out much more than the Micron does, I'll wait to see how they sound before I decide to shorten them (or not):
 

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Discussion Starter #3
Yeah, I know, they need to be shifted to the right a bit. A man can only do so much with ZipTies:



I decided to make the undertray in two pieces, one upper and one lower. The upper one sits aft of the round crossmember and mounts atop the subframe rails like so:



The notches on the sides are for the passenger seat, so the appropriate bits sit flush with the subframe rails when the seat is installed. The notches toward the bottom of the pic are for the riders seat, so the two hooks can still hook underneath the round crossmember.

Here, the upper portion of the undertray has been drilled and riveted into place, fixing it to the subframe:



I felt if I mounted it atop the framerails in this manner, it would leave me maximum clearance for the cans, moreso than the WOLF undertray pics I've seen to date. I plan to attach some aluminum angle to the underside of the upper part of the tray to enable me to hang the cans from with some band clamps. This is where using 1/8" Al sheet will begin to make sense as it will be a stressed member so to speak, holding the weight of the dual cans.



Now to do something about the forward portion. It needs to run underneath the subframe rails to provide clearance for the rider's seat pan. The plastic seat pan dips below the upper rails and would not clear if the forward tray were mounted up top. Here is the vacancy that needs to be filled. There's an old kid's snowsuit protecting my CF hugger so it doesn't get marred while I'm messing about:



This is the simple piece I wound up with, 1 bend and cut narrower at the leading edge to clear the lower subframe rails. it's clamped in place as part of the fitup and in preparation for drilling and riveting:

 

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Discussion Starter #4
It will be riveted to the subframe and to the remains of the stock battery box which has been trimmed and rotated forward to allow more clearance for the Y-pipe that will connect the two mufflers.





I'll have to make a small vertical filler piece to close the gap and have that welded in place to join the two levels of the undertray. Don't want to invite water and road grime through that huge opening, but the Hugger and the dual cans, they should block at least some spray.


I'm planning on removing the whole works this winter and having it powdercoated. For now, it'll stay as raw aluminum. B)

Next, I made templates of the sidepanels to check the fit:




Clamped in place in preparation for riveting:
 

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Discussion Starter #5
This sucker ain't goin' nowhere:


View from the outside, note 3/4" Al square tubing behind the steel plate that the R/R mounts to:


Template and the actual cutout:


Clamped in place for riveting:


It's actually starting to look like something now:
 

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Discussion Starter #6
RH side view:


Various shots showing how the forward portion attaches to the battery box:







I may yet wind up modifying the undertray similar to this pic for more clearance:
 

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Discussion Starter #7
After that, I'll take the bike to Edmonton to have the custom up-pipe and Y pipe fitted. It'll look something similar to the WOLF plumbing shown below except it'll be a 2" splitting into two 1.5" at the Y.



 

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Discussion Starter #8
I went another few rounds with the bike today. In the end, the bike won.

More about that later.

First order of business was raising the front portion of the undertray to allow greater clearance for the Y-pipe going into the mufflers. I gained 3/4" of clearance Versus the previous iteration.

Next, I set about fabricating supports for the taillight. I had read reports of the tailsections vibrating and cracking, so I made this contraption using the stock rubber grommets from the plastic undertray:



I finalized the mounting brackets and got one can clamped in place:





The problem arose when I installed the second can. The rear portion is spaced well, but the fronts are too close together.



I'll have to remove them and space the leading clamps apart, possibly with some washers between the inner part of the T-bolt clamp and the drop mount.

Elevation and symmetry look good, just have to get the leading edges of the cans spaced apart 1/4-3/8" or so.



I also got in touch with the guy who's going to be doing the custom connector pipe for me, and I'm taking the Viffer in on the 26th.

Can't wait to hear the V-4 roar from 2 mufflers at once!

Or as my wife so eloquently put it: "You paid 350 bucks for new mufflers so your bike could fart out the back instead of the side?"
 

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Discussion Starter #10
Hey, I picked up the bike today, and the workmanship on the new piping is superb!

Here are the pics of the completed project, my buddy took the pics with his camera, and the quality isn't quite what my previous pics were, sorry 'bout that:





 

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Discussion Starter #12
Sound file, click on the image:



At low RPM's, it has a quieter, lower tone rumble than the single Micron I had on there before.

When I spank it, the exhaust pitch sounds sharper than the Micron, and a tad louder.

It's not really better/worse than the Micron, just different.

Bike seems to pull just as hard as ever, but with no dyno numbers, it's hard to say exactly.

It made 100.6 HP a couple of years ago with the Micron, but that would be tough to compare even if I did a current run. Different dyno's, elevations, etc, etc.

But I'm not so hung up on whether I gained or lost 1 HP, whatever. I mainly did the mod because I love tinkering, and the satisfaction of knowing that I did something unique to my bike.

And it looks Kewl too! :bowdown
 

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Discussion Starter #13
Here's 2 quickie snaps I took the other day just before work, in my driveway.

Sorry about the lack of artistic talent, or scenery for that matter, but I had only about 25 minutes to shower/change, grab some lunch and head off for nightshift....



 

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Discussion Starter #14
More work on the underseat project, getting the final touches done now that I know it's all working properly and no interference.

First off, I got the aluminum undertray welded together so it's all one piece now:


Then I got the entire rear subframe and aluminum undertray Ceramic coated in black:


And last but not least, I had the stock headers Jet-Hot coated:
 

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Discussion Starter #15
And here's the custom up-pipe that I had fabricated last year, it's still dirty as hell from riding, but it'll clean up great with very little effort:




 

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Discussion Starter #16
Someone had asked me where I got the mufflers from.

They were hanging on the wall at a Honda dealer about 1.5 hours away from me in Edmonton. I had seen them there on several occasions over the past few years and they were more than happy to blow them out for a rock bottom price as they'd been gathering dust for over 5 years.

I paid $350 Canadian for the complete (brand-new) Devil shotgun slipon with pipework that was originally intended for a CBR954.

I later sold the 954 pipework on EBAY and recouped some of the cash.

Here's a pic of the Devil cans in their original application:

 
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