How To Make A Custom Baffle

I never did like the big pipes hanging off a foot peg so several years ago i came up with a idea to lighten up the exhaust.

All you need is a beaten up stained exhaust pipe and baffle.In this instance i used a Kerker but i imagine you could use what you have.

Next you cut the muffler at the weld.

We will be using the small piece here.

Then remove the portion of the mounting bracket.

I used my chop saw as a vice.

Next i cut off the part of the baffle i didn't need.

The last one i built i left the baffle hanging out the end but this baffle is bigger in diamenter.

I trimmed down the big end of the baffle so it would fit snug in the big end of the pipe.

I then inserted the baffle. You can braze or i imagine a two part putty would hold it as it is quite tight in the pipe.

Then try for fitment.

Then get a nice cotton sock. insert pipe in sock.

Then stash pipe under seat.

When you get pulled over by the man you say,"Officer,have you got a hammer i could borrow to install my muffler?"


:laugh: :dry: :S :laugh:

I started the day off removing the cam covers and checking the cam caps and retorquing the head bolts.

I took care of one oil leak at the oil pressure sending unit. Then i thought i would install the 34 mikunis.

Every thing went down hill from there.

I removed the small boots installed the big one. Looked for 30 minutes for the bracket that holds the throttle cable.
Finally found that and installed carbs.

Two friends were waiting on me so we could ride.

Fired bike up and the carbs leaked and bike wouldn't idle. Probably pilot jets stopped up.

Bike dies. One friend says he seen smoke come out from under rear fender. Sure enough the PO ran the tail light wires between top of frame and rear fender. Unplug wiring harness install fuse. Bike fires. Bike dies. Pull Tank off and the plug to the coils has pulled apart.

Tell friends to go ride.

Rewire bike front and rear. Remove big carbs and boots.
Install 28mm and boots. Bike misses on number 1. Check wiring change plug change plug wire.

Ride bike to town to get a new plug. Bike runs great at 5000 Rpm.

Get to parts store and buy two plugs. Bike misses on no.1
Rewire coils again. Bike misses. Started to pull the pod filter off no. 1 and the carb boot is not tight.Go in store and buy metric allens. Remove carbs and tighten boots.

And i tell poeple not to getin a hurry.

Then i had a nice little ride.Roy

Looks good, hows the little shorty pipe sound?

It is a lot better than the open header. Nice crisp sound. Roy