So for the last year I've been wanting a 2 into 1 exhaust. My problem is I'm a cheap basstage so there's no way I'll spend $500+ on a set of pipes.

And so it begins...
Before


I sat down and looked at the bike and tried to visualize how I was going to do this (yes beer was involved). I figured I would keep the stock front pipe, I kinda like how it looks. Its the rear pipe thats gonna get "worked" on the most. It looked like all I really needed was 3 "U" bends to get it done. I want the muffler to sit about half way between the 2 stock mufflers.

I ordered 3 mandrel bent pieces of exhaust tubing from JC whitney. Two of them are 1 3/4 and one is 1 7/8 inches. The 1 7/8 is for the 2 into 1 collector. The tubing prices were $14.99, $20.99 and $23.99. Geez those trucks drive slow when they have parts on em.



I had a scrap piece of 3/16 x 1 bar stock laying around. Figured that should work to make the bracket to hang the muffler.



Next, the 1 7/8 u bend for the 2 into 1 collector. I went with the larger size so the top U bend will slide in a little ways. I figured it would make a stronger joint and be easier to weld up.




Then I welded a short piece of 1 3/4 tubing to connect to the muffler. Here it is welded and cleaned up some.



I had to fill in the muffler cross over pipe "hole". I cut it out with a hacksaw and welded in a patch.



Got the bracket for the muffler done and mounted it with the collector. The muffler is a stock one that I cut the end off and pulled the baffle out. I tossed it in the trash and made a new baffle. I had a pair of Rush slip ons on the bike a few weeks ago. When I worked over the old stock mufflers (knowing this 2 into 1 was coming) I had to put them on for a while. I can see it starting to come together now.



I cut the rear exhaust pipe close to the O2 sensor and slid a U bend into the collector so I can see where to cut the U bend from the rear exhaust pipe. I'm starting to get excited at this point.



Cut the last U bend and tack welded it on.





I used a cheap fiberglass blanket to protect the bike while I did all of the spot welds.



Here it is all welded up. Ill clean the welds up later. I had to get it on the bike to start it and have a listen.



Here it is on the bike with it running. You can see just in front of the muffler the fresh pipe is starting to discolor. I am planning on painting the pipes (and a fresh coat on the muffler) with VHT 2000 degree flat black paint.



I hope the weather is good enough to get in a nice ride tomorrow so I can see how she runs.

Peace

 

Nice work!

 

Nice!

 

Brother that is BadAss !! You need to post a video of that sumbitch runnin.
Very nice work man I need a welder at home, having one at work is nice but I need one at home I feel helpless. I feel the need to create!!!

 

thats just frigging awesome man

 

i'd say that deserves to be in the under $50 list even if you went over a few bucks

 

wow nice work.

 

Man that looks awesome, nice job

 

Good job, looks pro

 

Nice job