Hybrid Revisited

[mossy1200]

Design for street legal (just)reverse cone mufflers.



Dont drill the baffle end plate very large at first then use tapper drill bit to enlarge at the end .You may end up with it close to full size.
You can make the baffle yourself with thin wall steel plate.This will enable you to match the size .
First cut the rectagle shape.Then drill small holes.Then use old philips screwdriver to punch the holes so they have jaggered x shapes.
The jags are important.Once baffle is made with end plate slide it up the front half of cone slightly further forward than the cone itself.
Then weld on the rear cone.
The formula that get good results is outlet 20 % smaller than the widest point and 20% larger than the baffle tube.
You can buy cone shape drill bits that you can use to open the baffle end plate up until the tune and sound get to desired level.
This is the basic design used on classic drag bikes.
NOTE half the back pressure is created by the reverse cone effect of reduced outlet size.If its has to much back pressure you can cut some off end so best to start at 30% reduction then trim as desired.

George is going to love playing with this one also.

[cad600]

You will still need a custom mid pipe made to deal with the header. Here is an idea for a shorty can. Granted I didn't have to deal with the swingarm but I still had to have a pipe made to put the can where I wanted it. Then I just bent a small piece of steel to make a bracket and attached it back to the rearset (bracket is not shown).







There are some other ones out there like the M4 and Two Brothers... Hell, even Yamaha makes a performance shorty can for the R6 that doesn't look too bad. The biggest thing to do is get the mid pipe custom made. That way you can put the can in the angle and location you want it to be in. When I did this, my biggest fear was that the can was going to stick out too far.

[mrfreeze5]

You will still need a custom mid pipe made to deal with the header. Here is an idea for a shorty can. Granted I didn't have to deal with the swingarm but I still had to have a pipe made to put the can where I wanted it. Then I just bent a small piece of steel to make a bracket and attached it back to the rearset (bracket is not shown).







There are some other ones out there like the M4 and Two Brothers... Hell, even Yamaha makes a performance shorty can for the R6 that doesn't look too bad. The biggest thing to do is get the mid pipe custom made. That way you can put the can in the angle and location you want it to be in. When I did this, my biggest fear was that the can was going to stick out too far.

I saw pics of that can last night and I freaking love it. But I could do without the chrome.I also saw the video clip and love how it sounds. A single bend custom midpipe is easy, that wont cost much at all, its getting 2 custom midpipes with 5 or 6 bends each that I cant afford tight now.

What bike is that for? R6?

[reelrazor]

You can make the baffle yourself with thin wall steel plate.This will enable you to match the size .
First cut the rectagle shape.Then drill small holes.Then use old philips screwdriver to punch the holes so they have jaggered x shapes.
The jags are important.Once baffle is made with end plate slide it up the front half of cone slightly further forward than the cone itself.

I have made quite a few baffles....I use round tubing of the correct diameter and then make the center section (leaving an inch or so on each end) square-ish in a vise. You can then use a hacksaw or cutoff wheel to cut slots across the 'corners' of the sqaure-ish pipe you now have..and then you can dent one side of each slot with a drift punch so that you have a louvered effect on each set of slots.

[Genesis]

this is good to see, I need to get mine done damit.

[cad600]

What bike is that for? R6?

Yep, it was for an '06 R6. Great pipe. Try to find an automotive muffler shop. And stick around while they do the work. I wet to 2 places. The first was a moron. The second did the job right. For them to create a 2 - 1 pipe shouldn't bee that difficult.

[mrfreeze5]

What bike is that for? R6?

Yep, it was for an '06 R6. Great pipe. Try to find an automotive muffler shop. And stick around while they do the work. I wet to 2 places. The first was a moron. The second did the job right. For them to create a 2 - 1 pipe shouldn't bee that difficult.

Ive got the 2-1 collector for the header, thats no problem. in fact, its in the backyard drying with a fesh coat of paint alongside the shorty. im going to stick the shorty on for now until I can afford that scorpion one I think. And considering theyre both R6 pipes, it will just be a matter of swapping cans. Ive got a good shop in mind if I need any custom exhaust work.

[cad600]

If you already have the 2-1 pipe, then your almost finished. Seriously ask them if they mind you help during the process. The second person I worked with allowed me to show him and hold the pipe in place to make sure it ended up in the place I wanted it. I rode the bike there and unbolted the Yoshi pipe from it to do the mid pipe. It really is the only way to do it.

Take a look around eBay for a deal. A got this pipe new for $150.

[mrfreeze5]

Guage harness is all finished! Some careful studying of the wiring diagrams, a lot of solder and shirink tube, an extra FZR wiring harness and guages for plugs, and a whole mess of patience brings this:



in addition to this, there is a wire for the tach, not shown, and the speed sensor plug. The only modifications necessary to the stock harness installed on the bike was to wire tap the 12v always hot wire leading to the ign switch for constant power to the clock in the guage. Otherwise everything plugs in as it should, and even neater than stock since all the plugs will fit under the tank. There should be 0 wire connectors outside of the front of the frame. I need to get some heavy duty wrap for the wires as i did not have enough shrink wrap, and was not sure of the exact configuration until i was done. I wont use electrical tape, but can hopefully find some of that fibrous tape they used from the factory on the harness. I have 3 wire harnesses, one of which(that came of my bike originally) is in bad shape, so was a prime candidate for harness plugs. I stole one plug from the harness which I believe is for the oil pressure switch to plug into( the 2 prong green one) since it matched the low level plug on the YZF tank, color and fit. I also robbed my busted and broken stock guages for plugs. I am SOOOO glad i didnt throw them out a while back. I almost did.

It turns out that I made a poor decision based upon looks over function. My speedo is a 2800 series, which comes in black or silver. The 2900 series is chromed, but also has a temp guage. I didnt get it because I wanted black. Oh well. So I dont have a temp readout. Im goign to have to figure something out for that. A warning LED or something. I dont want to be wondering if a radiator pipe is going to blow on my leg. Another thing that this guage does not have that the stock setup does is the speed switch, which kills the turn signal over 35mph I believe in case you forget and leave them on. So i will have to be mindful of my signals, which may not be so easy considering the led is so small. Ill just have to build good habits I guess...

When i ordered my guages, I ordered one with an addition indicator LED built in. Mine has turn signals, birghts, oil, N, and a extra indicator for hazards. Its a nice bright red LED in the middle. Now, of course, the FZR does not have hazards, so this is a perfect one to use for the YZF low fuel LED! So my low fuel sensor is completely integrated directly into the guage wiring harness and seems to work great. The real test will be when I actually fill the tank. This will work for me until I can figure out a way to swap in a fuel level sender for the built in gas guage. but its better than what I had with the fzr. the only warning was running out of gas, and flipping to reserve. What sucks is when you forget and are already on reserve. I did not enjoy walking my bike through the crosswalk to the gas station like a bicycle. At least I was already on my way there.

[mrfreeze5]

Shred: youll like this. This guy did on his VF700 what I was planning on my hybrid. Mine would have a few more bends and be a little cleaner, but its nice to see someone actually do it. This is my ultimate goal with the exhaust, but I want to get new cans first, plus the cost of the mid pipes are going to make the whoel endeavor pricey, but Ill probably do it eventually. I dont want mine sweapt back as much though.

[shredex]

yea, you would be able to do that to because of your headers.
thats one of the ideas that i had as well.
i wouldnt even mind just having what iv got now but on both sides.
it would make my bike run better because there would be restriction of small pipe anymore

[Genesis]

Freeze, It is funny you mention the extra harness, that is specifically why I got a r6 harness, to rob from it what I could to update the FZR harness and for the extra plugs. its looking good. I wish I could bring my Bike into My house..... That would be great for working on it.

[shredex]

yea, iv been trying to get r1 harness for the plugs so i can wire everything up right.
BTW, you can use a tiny flat head screwdriver like the ones for glasses to pop the clip that holds the wires in the connectors loose. i put the fzr switch connecter onto my r6 control so it bolts on, but if I ever wanted to, i can put the r6 connector back on with no signs of tampering because i dont need to cut any wires.


and yea, your house is air conditioned.
once i have my own place, ill have a nice piece of furniture in my room as well.

[mrfreeze5]

Freeze, It is funny you mention the extra harness, that is specifically why I got a r6 harness, to rob from it what I could to update the FZR harness and for the extra plugs. its looking good. I wish I could bring my Bike into My house..... That would be great for working on it.

I had half a r6 harness.i robbed the connectors on the headlight harness to use with my R6 nose. I wish I knew what the hell I did with it though, I think I threw it out when I sold the nose/headlights. I kinda need the headlight connectors now. but luckily Ive got 3 FZR harnesses. i know where 2 came from, Im not sure about the third, but its nice having spare parts, relays, connectors, etc. And if it comes to it, if I need to replace the harness for any reason, the only mod I have to do is tap one wire, otherwise the harness is stock.

Electrical work is so tedious and I had a lot of it. Having it in my living room is very convenent. Beats the hell out of working on my cramped patio in the sun with no room to move. And if I need help or need to look something up online, or need to pull up pictures or diagrams or whatever, my cpomuter is right here. And just taking time to sit and stare at the thing is a good way to work through problems for me. I wish I had done this a long time ago. The dog doesnt like it very much though. There's not much room to play with her squeekie.

[mrfreeze5]

I finally put my collector on the header and mocked up the stealthified R6 shorty can. I think it looks great. I didnt think I would like it. I still need to paint the exup shield. I need some high temp gloss black paint. Im going to have to get a different midpipe made, but its no big deal, it only needs one bend really and to adapt size for the can. Im making an adjustable link to hold it to the rearset. I will be wrapping the whole exhaust in black wrap. i havent decided if Im going to wrap the can too, at least to the rivets for the tip.