2005 GSX-R Exhaust MOD!!!

Well Boys and Girls my pipe came in, and unfortunately for you, my excitement prevented me from taking any pics before my father and i had the whole thing cut apart and shortened... haha but i put together detailed pics to show you what we did.

1/ Unscrewed the allen head bolts at the tail section and removed the beauty cover

2/ Ground the weld off the heads of the allen bolts on the next section ( then removed them )

3/ Ground the whole lip where the aluminum outer was bent around the inner section of the pipe

4/ Slid out the whole inner stainless section

5/ Cut 7 1/8" off the entire pipe

6/ Cut the main exhaust tube to length through outter stainless ( just cuz if i had to cut it i only wanted to do it once, and i had to cut it to free it from the middle divider )

7/ Cut the middle pipe shorter ( still in stainless section )

From this point on I have yet to complete...

8/ Re-weld on the endcap with exhaust tip

9/ Apply high heat silicone on top of outter rim of endcap

10/ Bend the aluminum outter case back around the endcap ( over the high heat silicon ) <-- acts as a gasket so no fumes leak out

11/ Send it out and have it bead blasted and powdercoat ( not sure what color yet or if i will just leave it aluminum )

12/ Polish end caps and reattach them to muffler

13/ Bolt to bike muffler mount

14/ Fabricate a stainless steel adaptor to mount to stock head pipe. allowing me to retain the stock headpipe incase my bike were to fail emissions testing i can throw the stock crappy one back on.

and since this thing got shortened it should sound louder then stock but quiter than open header ;D
plus if has fiberglass and steel wool looking stuff around the outter shell.

Overall Id say suzuki makes a kickass stock muffler... three chamber and well built, ( now two chamber )

Ill post more as soon as I get more done ( hopefully tomorrow, "tuesday" )

so here are the pics i promised ;D










So far i have $45 invested in this muffler shipped to my door, and the labor it took us to cut it apart.
Ill add a tally when finished to show how much i spent on everything as it comes up... so check back frequently as i will be updating often. and yes is is a little scratched up ( its used ) but im gonna bead blast so it will fix all blemishes.