For those that have had their mufflers apart, does it look like the entire muffler can be easily gutted leaving only the canister? I have an idea for a different mod, and all I need is the canister and the pipes themselves. If not, is there anyone out there w/some metal working tools that could fab a matching size canister for not too much $$$?

 

I think you'd be much better off making a new cannister. It looks like it would be a trick to cut all of those baffles out of the cannister. If I can remember correctly, there are at least 3 baffles that you have to drill through and I'm not sure what kind of cutter you'd use to cut them out. If you can find a cannister of the right dimensions, it doesn't seem like it will be that hard to weld a plate on the back end for the exhaust pipe to weld to, and the flanges to connect to the ATV.

 

i agree,It would be a pain to get some of those baffles outa there.I would cut both ends of the stock muffler off,and try to find a suitable piece of pipe to weld them to and there be your open can.

 

The only way I can think of cutting the 4 baffles inside would be burning them out with a stick welder w/ long sticks. I don't even know if it could be done...never done it. Have heard of people burning/melting/cutting metal with a welder, it would be the only way of reacing the 10-12" inside the cannister.

I just installed my pipe back on. I took it off, sanded it down to bare metal (got that rust crap off), cut the end cap off, drilled eight 1/2" holes through the 4 baffles and had it welded back on. It sounds awesome (just right, has the growl the HMF has but quieter, sounds mean in mid-range). With 128/132 dynojet mains it ran good, backfired slightly when letting off the throttle. I changed the mains to 132/136 and there's a noticable get up and go. Definately worth doing...

 

That's what I was afraid of. I cored the mufflers on my ducati last year and like the sound and performance increase I got. The duc's muffler baffels are all press fit, so once the ends are off you can force all the internals out. A major pain, but well worth it. I was hoping the kawi's were the same, but if they're welded I guess I'll have to look in another direction. I guess I could do they Nyroc route until I find a suitable casing to try my idea with.

thanks for the replies.


Next ?, anyone have a pic of how supertrap puts their mufflers together?

 

I did the Nyroc mod with 6 3/8" holes and I love the sound of it.

 

If you know someone with a plasma cutter, they should be able to cut the baffles out for you.

 

Go to a sheet metal place and get them to roll you a new can. Shouldn't cost too much. A welding shop should be able to cut out the two end caps for you with a plasma cutter. Make it out of stainless!!!! It'll never rust out and will look sweet!! Damn---------now you got me thinking about making one!!!

 

You can see where the baffles are welded from the out side if you grind that weld off you should be able to get them out and then just weld up the grind holes? just my 2 cents