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.