Fitting just about any exhaust muffler to your mid-pipe - ZX Forums
 
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post #1 of 5 (permalink) Old 10-25-2013, 06:44 PM Thread Starter
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Fitting just about any exhaust muffler to your mid-pipe

Not a new thread, but may help for those with Forum Search anxiety.

I'll start off showing the result. I started with a 2002 ZX-9r. The mid-pipe outlet is 2 3/8" OD. I purchased a SuperTrapp muffler with a 2 1/2" ID, so the fit was a little loose.

The first stop was to Autozone for a 4" length 2 1/2" OD x 2 1/2" ID muffler sleeve and Permatex 101BR Ultra Copper silicone gasket. I cut the sleeve ID off, keeping the remaining ~1 13/16" length OD cone (see below). Next I made two length cuts to that, taking out about 1/4" (a single cut would have worked as well), turning the cone into a "C" shaped sleeve. A metal file was used to smooth out any rough edges on the muffler internals, sleeve, and mid-pipe outlet.

Everything is ready for a snug assembly. Just need to take it down for the rear set bracket TIG welds. Permatex will be used during final assembly to seal any air gaps between the three pieces. Let dry for several hours.



Step 1 of 10
Unbolt chrome beauty ring and make cut right at the mid-pipe exit weld.


Step 2 of 10
Not all hack saw cuts end up straight. I had to try about four different angles.


Step 3 of 10


Step 4 of 10


Step 5 of 10


Step 6 of 10
I removed the burrs with the sleeve away from the bike. This picture is just an example of the tools and angles used.


Step 7 of 10


Step 8 of 10


Step 9 of 10


Step 10 of 10


Drill muffler retainer pin hole, slide over the end clamp and tighten.


Alright! Trading bikes for a while was fun.I'm ready for mine back. No, seriously, get off my bike. Ahh, what a privilege it is to have such a sweet ride.
At the track she's said to be outclassed, but on the street, she reigns unmatched. She's the only big-bore canyon carving hypermiler I know of. -- Picture gallery, K&N air filter, SuperTrapp Aluminum Racing Series exhaust (Made in USA), ZG touring shield, & otherwise stock.
Science & OODA literate. ACA covered.
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post #2 of 5 (permalink) Old 10-26-2013, 08:36 AM
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Nice! Some thought and vision and looks great. Good work and nice write up (with pics of course).
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post #3 of 5 (permalink) Old 11-24-2013, 08:34 PM
Quinton Phuckin Tarantino
 
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Good write up, I was just curious though what is that perforated metal in the mid pipe? Is that a stock mid pipe? It almost looks as if there were some fiberglass packing in there.

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post #4 of 5 (permalink) Old 12-03-2013, 03:51 AM
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Yes...that is great...Thank you!!!

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post #5 of 5 (permalink) Old 01-01-2014, 01:26 PM Thread Starter
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I Ride: 00 ZX-9r Lime Green 02 ZX-9r Lime Green, California E1 & F1 models, respectively

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Quote:
Originally Posted by iron8 View Post
... I was just curious though what is that perforated metal in the mid pipe? Is that a stock mid pipe? It almost looks as if there were some fiberglass packing in there.
That's a stock pre-stage catalyst. It leads into the stock muffler's honeycomb catalytic converter. And I believe for those who buy the aftermarket bolt-on mufflers, the pre-stage catalyst remains in the mid-pipe.

Alright! Trading bikes for a while was fun.I'm ready for mine back. No, seriously, get off my bike. Ahh, what a privilege it is to have such a sweet ride.
At the track she's said to be outclassed, but on the street, she reigns unmatched. She's the only big-bore canyon carving hypermiler I know of. -- Picture gallery, K&N air filter, SuperTrapp Aluminum Racing Series exhaust (Made in USA), ZG touring shield, & otherwise stock.
Science & OODA literate. ACA covered.
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