"Tweaked" 801 stock muffler

[Tom]

A couple of pics how the 801 stock muffler can be "tweaked" with a removable custom-made db-killer; it's still work in progress.

 

[toast449]

Holy hell that must have been a lot of sanding and filing to get that fit that snug inside and out!

 

[Tom]

OK, you know what you're speaking about.
Yes it was indeed a lot of work to fabricate the adapter ring to fit it that snug. It took me some hours; but finally it works fine.

 

[Tom]

An additional pic of the short db-killer; now with some screws to fix the pipe in the adapter.
After a first short test with the modified muffler I'm very satisfied; I will give it a try on my next daytrip.

 

[Tom]

Here some short videos:

With the stock db-killer:

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Without any db-killer:

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With the short custom db-killer:

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[Tom]

On today's daytrip I tested the short db-killer; it's raspy and not too loud; it's perfect to me.

 

[Tom]

Today I noticed that the pipe of the db-killer suddenly stuck a couple of millimeters out of the muffler.
I checked it; wondered that it was quite difficult to remove the db-killer; and that's what I've found; definitely not what I've expected.
The melting temperature of aluminum starts at about 600°C; the exhaust gases are too hot.
The adapter-ring made from 20mm aluminum doesn't work.

 

[Tom]

Today I started fabricating a new adapter-ring; now made from 10mm steel.

 

[Tom]

Now with some heat resistant coating added to the adapter-ring...

 

[Tom]

Today I reassembled everything; to seal the db-killer I used some additional exhaust mounting paste; ready for the next daytrip.

 

[Tom]

Back from another daytrip; everything worked fine and I'm very pleased with the result!

 

[blue_monkey]

Was it fairly straightforward to remove the stock baffle? You mentioned drilling around the metal plate... is there enough room for a dremel with a disc cutter? Thanks.
BTW, your engineering is very impressive

 

[Tom]

Thank you!
I did it by drilling the sheet metal around the stock DB-killer; it's made from stainless steel, but not too thick; drilling worked fine, but I don't think it will work with a Dremel.
Afterwards I did some grinding and some filing to smoothen it out; I used a straight-grinder.
At all, with some proper tools it's not too difficult.

 

[blue_monkey]

Thanks for replying. I only have basic tools but I think a drill and file should do the trick.

 

[Dhd12]

Tom,´´At all, with some proper tools it's not too difficult´ And obviously the skill to use them.

 

[Tom]

Tom,´´At all, with some proper tools it's not too difficult´ And obviously the skill to use them.

Yes, your right; some skills are of course quite helpful...

 

[Tom]

Thanks for replying. I only have basic tools but I think a drill and file should do the trick.

With a file instead of a straight-grinder it may take a little longer, but it should also work without a problem.

 

[mk88]

Ehi Tom,

Where did you find a more original exhaust?

 

[Tom]

Ehi Tom,

Where did you find a more original exhaust?

On the internet...
Someone who bought his 801 with an Akrapovic sold his stock muffler to me.

 

[blue_monkey]

How loud is the standard exhaust with the baffle removed, Tom? Is it easy to live with day-to-day?