Homemade muffler using stock parts

Posted by shinyribs on Oct 14, 2011; 4:19am
URL: http://vintage-and-classic-hondas.81.s1.nabble.com/Homemade-muffler-using-stock-parts-tp3420689.html

I put my new(to me,thanks Tools!)4 into 1's on the bike and liked the look of it so much without the muffler that i hated to use it with the muffler.It was a little too loud with just the header on there,so i came up with this idea.Now,if you are going to be riding two-up,this might not be the best setup for your passenger so ...

First remove the factory baffle and cut about yea much off

I then turned it around to reverse the direction of the scoops.This was my plan for helping to reduce the effectiveness of the factory baffle to make it a little louder than stock.It worked.Now,take what was the inner flange and cut it down to fit inside the header, but leave two ears so you can bend up two tabs for mounting purposes.

Then i turned up a few of the louvers on the opposite end to help locate the baffle in the center of the header tube.I left them a little long and bent them not quite 90 degrees so that it would wedge itself tightly inside the header.

And thats pretty much it.I sunk the baffle in the header about an inch to help it be a little less noticeable.Drilled a hole and popped a little stainless steel machine screw in.

Now this setup is fairly loud.With the header alone,and no muffler at all,the exhaust had a real raspy sound to it that i didnt care for.This cured that but didnt do alot of silencing.I would say that is quietened it down about 30% compared to no muffler at all.Its loud,but almost as smooth sounding as the factory setup.I am very pleased with the results,not to mention just plain lucky that it actually worked out ok.Plus i like the look of the bike with no tail pipe on it,just the short header.Kinda racy looking,and it eliminates the need to hang and support a muffler.Just thought i would share another hair-brained idea with you.