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Discussion Starter #1
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.

 

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Quinton Phuckin Tarantino
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18,914 Posts
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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Discussion Starter #5
... 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.
 
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