Gixxer exhaust & header on a 919. - Wrist Twisters
 
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post #1 of 22 Old 02-13-2012, 02:57 PM Thread Starter
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Gixxer exhaust & header on a 919.

So I thought some members might find this interesting.....

I have a bolt on '04 GSXR 750 Yoshi Tri-oval that I picked up for dirt cheap. Originally I was going to fab up a Square 4 bolt flange to use it with my steel 900rr header/midpipe.

I was looking around on EBay the other day and decided to pick up a full 04 GSXR stainless header with the flange. Got it for $30.00, so I couldn't really resist. The new idea is to graft the gsxr stainless back half to the OEM 919 stainless header.

I got the header today and was surprised at how similar the 900rr & gixxer header looked sitting on the bench. The cylinder port spacing is dead on, overall length is similar and ID/OD are exactly the same. The only major difference is the bolt holes on the exhaust port flanges on the gixxer will need to be opened up or dragged to fit the wider 919 stud spacing.

I bolted it on anyway with a few studs and it lined up half decent. The pipe stays very low, a little lower then the 900rr setup. It might rub before the feelers not really sure yet.


I may continue to tweak/modify this setup and run it. I think if you were to unbolt/remove the crossbracing and give it a few extra bends it might look pretty sweet......Or go back to the hybrid ideas. Either way it was an interesting dicovery.




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post #2 of 22 Old 02-13-2012, 03:00 PM
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Wow. That's a trip. You may have opened up a whole new avenue of exhaust mods.

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post #3 of 22 Old 02-13-2012, 03:05 PM
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- '96 Race-retired GSXR 750 (Sold)
- '01 RC51 SP1 (Sold)
- '03 919

"Security is mostly a superstition, it does not exist in nature: avoiding danger in the long run is no safer than outright being exposed. Life is either a daring adventure or nothing."-Helen Keller
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post #4 of 22 Old 02-13-2012, 05:40 PM
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Man that's too cool. Great to have another option if you can't find a 900RR header. Great find.

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post #5 of 22 Old 02-13-2012, 07:07 PM
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+1! Would love to see you get some dyno results on that vs. a 900rr header...

Makes me wonder if there would be any drastic differences.

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post #6 of 22 Old 02-14-2012, 01:30 AM
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Thats some weird shit!

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post #7 of 22 Old 02-14-2012, 06:37 AM
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That's just wacky. Keep us posted!

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post #8 of 22 Old 02-14-2012, 04:47 PM Thread Starter
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Step #2........brute force and ignorance.

I notched open the exhaust flanges on one side so they would bolt up to the exhaust studs. Worked great for mock up purposes. Not pretty but got everything lined up for now.

Then made two relief cuts in the the header to give it a spot to flex.

Clamped it down in the vice, stuck a 5ft long steal pipe in the exhaust end of the header and gave it a few hefty tugs. After a few tweaks, and a bit of heat she lined right up. The can lines up really well, tucked in and tight to the rear-set. Also the OEM mount is workable with a small bracket.



Next its off to a co-workers to weld up the relief cuts. As far as the flanges go I think I will make some new ones, split them and have them welded on. Anyone got a smashed/crushed 919 header they want to cut the flanges off and donate to the cause?

The worst part is the bike is weeks away from being back in a running condition. Lots of parts/work to come before she can be fired up and tested. But since I have a full 900rr setup in case this is a failure, I think i will finish it off and see how it works out.

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post #9 of 22 Old 02-14-2012, 05:03 PM
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Did you not get flanges from the scrap 9er?

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post #10 of 22 Old 02-14-2012, 05:05 PM
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I'm sure you can fab up some 2 piece overlapping design. 2 half rounds made from some of the aircraft aluminum.

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post #11 of 22 Old 02-14-2012, 05:14 PM Thread Starter
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That one went in the trash. I can make up some, shouldn't take much.

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post #12 of 22 Old 02-15-2012, 12:24 AM
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Very interesting - looking at it the headers may be a bit shorter than the 9ers - do a rough tape measure-up as I'd be interested to see.

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post #13 of 22 Old 02-15-2012, 01:04 AM
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Get your friend to tig weld a bit more metal on the flanges then file smooth and just drill out the hole in the correct place again.

http://i121.photobucket.com/albums/o222/woodyeee/IMAG0306.jpg
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post #14 of 22 Old 02-15-2012, 03:11 PM
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Quote:
Originally Posted by woodyeee View Post
Get your friend to tig weld a bit more metal on the flanges then file smooth and just drill out the hole in the correct place again.
We have a winner

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post #15 of 22 Old 02-15-2012, 03:15 PM Thread Starter
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Quote:
Originally Posted by jay313

We have a winner
Seems like the eastiest solution. Found out today the K4 gsxr titanium header is a bolt on swap for the K4 gsxr 750. So in theroy a full titanium system could be adapted as well.

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post #16 of 22 Old 02-15-2012, 05:03 PM
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Quote:
Originally Posted by HeliMech View Post
Seems like the eastiest solution. Found out today the K4 gsxr titanium header is a bolt on swap for the K4 gsxr 750. So in theroy a full titanium system could be adapted as well.

that would be very cool, except your likely to be the only guy on here who knows someone to weld Ti.

'04 Honda 919, Candy apple red met., 17/44t sprockets,f-16 windscreen,delkevic ss exhaust,Tharbars,givi engine bars, billet alum. led turns w/ running lights,red adj.levers from china, bar end mirrors,grip heaters,adj. foot peg brackets,adj. bar risers,dunlop Q2(that are better than your pp 2ct,lol)bike wired for gps and phone charger
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post #17 of 22 Old 02-15-2012, 05:14 PM Thread Starter
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I will have to look into it. That one might cost me more then a few beers!

On a side note i dropped off some booze at the paint shop at work today. Gotta love my job sometimes. Here's a little teaser....


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post #18 of 22 Old 02-15-2012, 07:20 PM
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looks great

'04 Honda 919, Candy apple red met., 17/44t sprockets,f-16 windscreen,delkevic ss exhaust,Tharbars,givi engine bars, billet alum. led turns w/ running lights,red adj.levers from china, bar end mirrors,grip heaters,adj. foot peg brackets,adj. bar risers,dunlop Q2(that are better than your pp 2ct,lol)bike wired for gps and phone charger
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post #19 of 22 Old 06-10-2012, 01:19 PM
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Thread revival!

Heli, what made you ditch this experiment? It was looking promising.

My classified(s):
Nothing at the moment

----------------
------------
---------
------
---
- '96 Race-retired GSXR 750 (Sold)
- '01 RC51 SP1 (Sold)
- '03 919

"Security is mostly a superstition, it does not exist in nature: avoiding danger in the long run is no safer than outright being exposed. Life is either a daring adventure or nothing."-Helen Keller
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post #20 of 22 Old 06-10-2012, 05:19 PM Thread Starter
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It's still one the shelf in the garage. I ended up just using the flange on my 900rr pipe, which was the original plan. I might play around with it again this winter. It was fitting well and only required some slight tweaks to make it work, I just got side tracked and never got back to it.

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post #21 of 22 Old 06-10-2012, 09:59 PM
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Right on, very interesting and like mentioned above can be a whole new setup for an exhaust.

My classified(s):
Nothing at the moment

----------------
------------
---------
------
---
- '96 Race-retired GSXR 750 (Sold)
- '01 RC51 SP1 (Sold)
- '03 919

"Security is mostly a superstition, it does not exist in nature: avoiding danger in the long run is no safer than outright being exposed. Life is either a daring adventure or nothing."-Helen Keller
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post #22 of 22 Old 06-11-2012, 02:50 AM
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Nice find. The best thing about those older GSXR headers is that they have a 4 bolt flange from 2000-2005 so a slip on would b very easy to obtain and there are many options.

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