eBay Exhaust System mod

[kirbo7106]

I finally mounted my eBay exhaust system. Instead of drilling out the mounting flange, or using an angle grinder to cut the flange, I just used an Dremel tool with a Dremel Tungsten Carbide Cutter tip. It was SO Easy! My Dremel tool isn’t an actual Dremel, it’s an old Big Lots special! The tip was an authentic Dremel tip. The part number is 9901. It cost around $10 and I bought it at Home Depot or Lowe’s. I was able to modify the flange in under 10 minutes!:tup:

Have a great day!

[JerryHawk250]

Okay, I don't believe you. Where's the pictures?:p I'm going take a long ride and expect pictures and/or video when I get back.

[Angus67]

pics? how does it sound? u like?

[kirbo7106]

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Here’s the exhaust system. I dropped it down about half an inch to an inch with a piece of aluminum stock. I used the spacer that comes with the exhaust system to move the muffler out enough to clear the license plate/fender. I have about 1/8 to a 1/4 inch gap between the pipe and the air box. Hopefully that is enough to prevent air box meltdown! I will upload some more pictures.

[kirbo7106]

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As for the sound...it’s just like everyone else says. It’s got a deeper tone and it’s louder. Now to tune the carb. I have a 30 pilot jet and a 120 main. I’m using the air box with the famous mod and a K&N filter.

[kirbo7106]

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That’s the Dremel bit and the finished product.

[Musictrek]

11077

Here’s the exhaust system. I dropped it down about half an inch to an inch with a piece of aluminum stock. I used the spacer that comes with the exhaust system to move the muffler out enough to clear the license plate/fender. I have about 1/8 to a 1/4 inch gap between the pipe and the air box. Hopefully that is enough to prevent air box meltdown! I will upload some more pictures.
looks good. I'll probably do the same. I want to make a heat shield on mine to protect the air box plastic. Just some metal with some exhaust wrap on one side for the heat shield to protect the box.

[roundhouse]

Thanks for the tip. will be doing mine next month when I get some time

[JerryHawk250]

Nice job.:tup: I would definitely put some kind of heat shield or heat wrap to protect the air box.

[pete]

Nice job.:tup: I would definitely put some kind of heat shield or heat wrap to protect the air box.

Nar mate... yer just ride fast so the wind never gives
the heat time to get to the air box.....




..

[kirbo7106]

Nar mate... yer just ride fast so the wind never gives
the heat time to get to the air box.....
..

I like the way you’re thinking! :yay:

[Weldangrind]

I spin nyloc nuts onto the exhaust studs after the main nuts are properly tightened. I don't spin them all the way down; the only purpose is to capture one of the clamping nuts, should they come loose. I do the same thing on the brake rod of a drum brake.

[kirbo7106]

I spin nyloc nuts onto the exhaust studs after the main nuts are properly tightened. I don't spin them all the way down; the only purpose is to capture one of the clamping nuts, should they come loose. I do the same thing on the brake rod of a drum brake.

I thought about putting stainless steel acorn nuts to use as jam nuts.

[Megadan]

I thought about putting stainless steel acorn nuts to use as jam nuts.

I essentially did this with a little anti-sieze on the threads, and while it looks a bit goofy, it also works. It is a great way to shield the threads behind the nut from gunk and corrosion.

[timcosby]

seems like i read somewhere that someone used the wrap and it touched the airbox and melted it too so make sure you have clearance even with the wrap

[kirbo7106]

After riding for 30, the air box wasn’t melted or on fire! Hopefully, the gap was enough. Either that or my 30-45 mph speed was keeping it at bay!