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post #1 of 80 (permalink) Old Feb 20th, 2010, 8:46 pm Thread Starter
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My 2 into 1 Exhaust project

For as long as Ive owned my SS I've pondered what to do about the stock stamped header crossover. The passages left by the stamping process leave what I would describe as a bloated "D" shape. It can't be helping that these passages only have, what I would guess to be 50-60% of the surface area of the 1.5 pipe in the rest of the system.

The obvious answer was a spag. system. Equal length headers, Ti pipe, perfectly tig'd. Sexy. But alas...... I can't justify the cash given It's a street bike. I have other items on my wish list that I'd rather spend the dough on.

Then I saw this 4v exhaust.........


Right here, not too long ago.

https://www.ducati.ms/forums/showthre...ghlight=header

Thought about this.... as I'm no where near a pro welder.

I do ok, but I dont have access to a tig (that's where I could spend that spag. system $). Couldn't do it......I just think mandrel bends are the way to go.

So I started looking for a fleabay header as my test subject. Didnt find one and intended to look again.

Then a friend decided he wanted to go 2 into 1 on his M900 track bike. I quickly volunteered figuring it would be a good ramp up to full crossover replacement that I wanted to do. He said he would bring it to me when he had time to wrestle it off.

Last week the header arrived....and I promptly cut the left exhaust out of the cross over. Leaving enough of the stock section to keep everything realitive to each other. Leaving this...

DC13

95 900(944)SS/SP #006
73 Triumph Bonneville 750
10 Triumph Thunderbird 1600
75 Suzuki T500

Last edited by DC13; Feb 21st, 2010 at 12:31 am.
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post #2 of 80 (permalink) Old Feb 20th, 2010, 9:05 pm Thread Starter
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Cut a few angles into the right shapes......

Got them all trimmed and dry fit .....

DC13

95 900(944)SS/SP #006
73 Triumph Bonneville 750
10 Triumph Thunderbird 1600
75 Suzuki T500

Last edited by DC13; Feb 20th, 2010 at 9:22 pm.
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post #3 of 80 (permalink) Old Feb 20th, 2010, 9:13 pm Thread Starter
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After lots of careful work with the mig and lots of grinding and I got this........


DC13

95 900(944)SS/SP #006
73 Triumph Bonneville 750
10 Triumph Thunderbird 1600
75 Suzuki T500

Last edited by DC13; Feb 21st, 2010 at 12:32 am.
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post #4 of 80 (permalink) Old Feb 20th, 2010, 9:37 pm Thread Starter
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I'm pleased with my results. I only have (1) 1.5" pre bent 90, wire for the mig and 2 cut off wheels into it. I figure he owes me $10 in materials.

Holding the stock steel stamped section next to the finished 2 into 1, you can see the difference.


Here is the whole thing, with the stock can for display. He's hunting up an aftermarket can to cut up to finish it up. The stock monster cans are apparently a nightmare to even core.


What do you guys think? I'm not thin skinned.......just looking for feedback.

--DC--
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post #5 of 80 (permalink) Old Feb 20th, 2010, 9:44 pm Thread Starter
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Just couldnt resist while I was uploading pic's

--DC--

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post #6 of 80 (permalink) Old Feb 20th, 2010, 10:27 pm
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It looks great DC. I like that fact that your cuts in the original were well thought out as they keep the stock dimensions. The mde up bits are well formed and keep the very improtant fluid dynamic appearance of flow. The fact that the pipe opens up in diameter just after the junction makes me think that the back pressure should not dramatically increase with your new set up. Keep us posted as to how it sounds and the effect on torque/hp. Brad.
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post #7 of 80 (permalink) Old Feb 20th, 2010, 11:58 pm
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Shop smart.......shop S Mart.......

09 R1
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Riding hard and sloppy - the Johnny Gan way!
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post #8 of 80 (permalink) Old Feb 21st, 2010, 12:27 am Thread Starter
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Quote:
Originally Posted by neuroduc View Post
It looks great DC. I like that fact that your cuts in the original were well thought out as they keep the stock dimensions. The mde up bits are well formed and keep the very improtant fluid dynamic appearance of flow. The fact that the pipe opens up in diameter just after the junction makes me think that the back pressure should not dramatically increase with your new set up. Keep us posted as to how it sounds and the effect on torque/hp. Brad.
Thanks

I try to have a well thought out plan. Mostly as insurance against not being especialy skilled.

Its going on an M900 trackbike so some SS heads with bigger valves and new carbs are being installed as well. Once we get all the new parts together we will spend some on the dyno and start tuning. If needed, my tenative plan is to increase the outlet to around 2". I'll certianly post whatever I figure out(assuming I learn something).

--DC--

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post #9 of 80 (permalink) Old Feb 21st, 2010, 12:29 am Thread Starter
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Originally Posted by Slo-Moe View Post



Shop smart.......shop S Mart.......
........and a hair trigger.

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post #10 of 80 (permalink) Old Feb 21st, 2010, 8:08 am
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It's certainly far more simple than what my welder friend did on my exhaust. The plus is that an ordinary slipon will fit. I can see this becoming a regular product or service also.
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