900rr exhaust help? - Wrist Twisters
 
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post #1 of 30 Old 04-20-2009, 01:42 PM Thread Starter
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900rr exhaust help?

Gentlemen...I'd be interested in hearing some tips or tricks/advice, etc...

Scenario: I've got my 900rr header bolted up, (even did a nice job connecting it to the centerstand mount) , flange cut off leaving me an open pipe to connect to the exhaust, however my exhaust (Scorpion street extreme for CBR600F4i) is a slip on exhaust and the diameter of the slip on really makes it more of a "slip-in" i.e. the slip on flange of the exhaust ALMOST fits perfectly INside of the header.

My question is, how do I mate these pipes? I tried a little exhaust sealant, but that is simply NOT going to cut it.

I was thinking about cutting 2-4 perpendicular cuts into the header and using a hose clamp over the header along with some high temp sealant, but I'd hate to cut into the header if I can help it.

Using my poorly written scenario, any advice or anything on how to secure this clusterF together?

What about welding it? I'd have to take it somewhere though bc i AM NOT taking that header off the bike again.

Etc. Any advice is appreciated.

No pics at this time.

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post #2 of 30 Old 04-20-2009, 01:49 PM
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What is the outside dia of the header? The header I used was about 60mm in dia and the ID of the can inlet was 63mm. Mine definitely slipped on and not in.

Was it an aftermarket header vs a stock one from a 900RR?

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post #3 of 30 Old 04-20-2009, 02:02 PM Thread Starter
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The header was advertised as stock. I got the F4i can per your suggestion of same dimensions of that ZX-10 can, alas - no slipON dice. I ain't complaining for the price I paid though!

I'm sure theres a way to make this work, I had it fully mounted up with some sealant, but that's not a permanent solution. Need a good strong connection..

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post #4 of 30 Old 04-20-2009, 02:34 PM
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Inside is bad. Find another muffler


And I say this having been shop supervisor in a exhaust shop.



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post #5 of 30 Old 04-20-2009, 03:02 PM
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Quote:
Originally Posted by barton664 View Post
Inside is bad. Find another muffler


And I say this having been shop supervisor in a exhaust shop.
What job haven't you had??? Oh, I know the answer to that one, but I'm not supposed to share what I hear during a therapy session...

If he wants to stay cheap, an exhaust shop might be able to solve this problem quickly and cheaply.

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post #6 of 30 Old 04-20-2009, 03:20 PM
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Quote:
Originally Posted by ndcent View Post
The header was advertised as stock. I got the F4i can per your suggestion of same dimensions of that ZX-10 can, alas - no slipON dice. I ain't complaining for the price I paid though!

I'm sure theres a way to make this work, I had it fully mounted up with some sealant, but that's not a permanent solution. Need a good strong connection..
This link is from Dennis Kirk for the F4i one and says the inlet is 63mm, so I guess the specs listed are wrong or you header is different than mine. Anyway, I hope you get it sorted out and can make it work.

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post #7 of 30 Old 04-20-2009, 03:59 PM
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Quote:
Originally Posted by sike View Post
What job haven't you had??? Oh, I know the answer to that one, but I'm not supposed to share what I hear during a therapy session...

If he wants to stay cheap, an exhaust shop might be able to solve this problem quickly and cheaply.
I was shop supervisor and lead fabricator and welder for a marine exhaust shop here in ft laud. That's why I moved here. Then I got injured keeping something heavy from killing 2 of my employees. So after 8 months of phys rehab I was allowed to go backto work in sales. Now I am 100% and back to normal type work. But thanks. My work ethic usually makes me excell inost things I do. Btw I am a certified master tig welder as well as mig and stick. 6gr tests if ya wanna try one



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post #8 of 30 Old 04-20-2009, 04:02 PM
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2+2=?





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post #9 of 30 Old 04-20-2009, 04:53 PM
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Pictures would really help determine if it is a stock header.

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post #10 of 30 Old 04-20-2009, 04:59 PM
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And sike is correct your local muffler shop or welding shop should be able to fix this fairly cheaply



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post #11 of 30 Old 04-20-2009, 05:14 PM
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if it was me, i think i would get a exhaust reducer fitting to go from outside of stock header to inside of your muffler stainless would be ideal so it would match. have that peice modified to work. thats what i would do on the cheap.

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post #12 of 30 Old 04-20-2009, 05:15 PM
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oh that SHOULD be able to be picked up at local automotive store.

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post #13 of 30 Old 04-20-2009, 07:23 PM
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Quote:
Originally Posted by barton664 View Post
I was shop supervisor and lead fabricator and welder for a marine exhaust shop here in ft laud. That's why I moved here. Then I got injured keeping something heavy from killing 2 of my employees. So after 8 months of phys rehab I was allowed to go backto work in sales. Now I am 100% and back to normal type work. But thanks. My work ethic usually makes me excell inost things I do. Btw I am a certified master tig welder as well as mig and stick. 6gr tests if ya wanna try one
"back to normal", "master tig and stick", if it wasn't for you saving folks in this story, I would have to have some fun with this. If you ever want to see some profoundly ugly welding, I can show you that!!!

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post #14 of 30 Old 04-20-2009, 07:41 PM
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bro, weld that thing.but do find someone that knows how to do a nice weld and done.

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post #15 of 30 Old 04-20-2009, 08:01 PM
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Quote:
Originally Posted by sike View Post
"back to normal", "master tig and stick", if it wasn't for you saving folks in this story, I would have to have some fun with this. If you ever want to see some profoundly ugly welding, I can show you that!!!
You can have all the fun you want. I have w2's and MRI's and at least 5 eye witness's.

Funny thing. Unlike some when I claim something I 99% of the time have proof. Soooo knock yourself out.



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post #16 of 30 Old 04-20-2009, 09:08 PM
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Quote:
Originally Posted by barton664 View Post
You can have all the fun you want. I have w2's and MRI's and at least 5 eye witness's.

Funny thing. Unlike some when I claim something I 99% of the time have proof. Soooo knock yourself out.
Like I said in the private message, it was just some fun with words, nothing more. Obviously hit a soft spot, which I'll have to remember for later use. But, this time, no offense was meant, just some teasing. Again, when you use the word normal it is asking a lot of "us" not to tease you. It would be like me using the word, which makes my friends laugh.

In reality, I always mean it to tease, except if the subject is my X.

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post #17 of 30 Old 04-21-2009, 12:17 AM
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If it isn't too much of a stretch to get the slip-on to be bigger than the header, you could try using a "pipe stretcher" (not sure what it is called). I saw one in harbor freight while looking for a cheap come-along. I don't know how much give your slip on has. Probably not enough...

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post #18 of 30 Old 04-21-2009, 12:22 AM
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Quote:
Originally Posted by alinosa View Post
If it isn't too much of a stretch to get the slip-on to be bigger than the header, you could try using a "pipe stretcher" (not sure what it is called). I saw one in harbor freight while looking for a cheap come-along. I don't know how much give your slip on has. Probably not enough...
it is called a "swedge"...



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post #19 of 30 Old 04-21-2009, 06:43 AM Thread Starter
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Sounds like I ought to find a good welder. Thanks for the replies ya'll.

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post #20 of 30 Old 05-06-2009, 07:24 AM Thread Starter
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She's alive!!!


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post #21 of 30 Old 05-06-2009, 08:49 AM
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Nice, Congrats.

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post #22 of 30 Old 05-06-2009, 09:23 AM
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Just an observation - my 900rr header had a 3-bolt flange for the muffler to attach. Why's mine different?
btw - low slung single exhaust rules.

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post #23 of 30 Old 05-06-2009, 09:33 AM Thread Starter
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Quote:
Originally Posted by gpzTurbo View Post
Just an observation - my 900rr header had a 3-bolt flange for the muffler to attach. Why's mine different?
btw - low slung single exhaust rules.
I cut the flange off is all.

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post #24 of 30 Old 05-06-2009, 11:11 AM
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ohhhhhhhh. that would explain it. duh.

post a sound clip, will you

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post #25 of 30 Old 05-06-2009, 11:15 AM Thread Starter
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Sure. A co-worker has one of those flip cameras.

You'd think my iphone would do it, since it does almost everything else, but when it comes to normal stuff it should do it doesn't.

I love apple.

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post #26 of 30 Old 05-06-2009, 04:40 PM
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Excellent! Looks great. Glad you were able to get it sorted out. Did you have an exhaust shop make an adapter?

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post #27 of 30 Old 05-07-2009, 09:05 AM Thread Starter
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Quote:
Originally Posted by marylandmike View Post
Excellent! Looks great. Glad you were able to get it sorted out. Did you have an exhaust shop make an adapter?
Well the guy cut off the "slip in" part of the exaust down to the "cut outs" (where the clamp would have been fitted over an slip on style app) in it, then took that "slip in" pipe on the exhaust can and kind of "flared" it out so it fit inside of the header near perfectly, and then tig welded it.

Cost me $125 for the weld job as I had it done on the bike, would have been about $100 less if I'd taken him the header and can but I didn't one to remove the header a second time. The guy put the bike up in the air to work on it, i.e. electric winch way UP in the air over his table, haha. I didn't see it but I don't like to think about my bike dangling eight feet in the air but it worked out!

Total cost for full stainless exhaust system, about $225.
$90 header w free shipping, $178 for can, $125 for welding minus $170 for exhaust sold.)



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post #28 of 30 Old 05-07-2009, 09:28 AM
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That really looks great and wow $225

How do you like the sound? In my opinion its a little louder and deep at idle, fairly quiet cruising on the highway, but really has a nice roar when you get on it around 5K rpm.


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post #29 of 30 Old 05-07-2009, 09:45 AM Thread Starter
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I don't think it's louder than the 4-1 2bros pipe I had, but it's certainly deeper lower tone at idle that sounds wicked. Freeway cruising is fine, engine feels a little flat at freeway cruising though, around 75, going to break down and buy a pc3 one of these days!

Need to do those block off plates too.

It just never ends.

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post #30 of 30 Old 05-07-2009, 11:03 PM
 
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Beware of reduced ground clearance if you get into twisties hard. Looks very nice!

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