Replacement exhaust system

How have you made your GTS go quicker?

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rooyenan
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Postby rooyenan » Thu Apr 01, 2010 11:15 pm

heinlein wrote:You need a twin brother to work on the MicroSquirt while you work on this.


No way!!

That would be really unforeseen :lol: :lol: :twisted: :lol:

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Re: Exhaust resurrected for Easter!

Postby 24c » Fri Apr 02, 2010 6:30 pm

24c wrote: Unfortunately I have to go to work, otherwise it'd be a wrap tonight.

Took me a little longer, but this is the modded version to let the rear brake lever work! :oops:

The first one looked nicer, just got to TIG it up now, and polish... sod it...it's not for my bike! :P :wink:

Image

This is the Thunderace engined GTS1000 version, so it's deeper than normal, but the belly pan still fits. This will be the basis of the replacement system, except it will have a straighter exit, and just use a common slip on can, like an R1 or similar. That way everybody can accommodate their taste and own noise levels

EDIT Just noticed the Lambda/oxygen sensor bung is not on this picture, but will be when I weld it up.
Last edited by 24c on Fri Apr 02, 2010 11:47 pm, edited 2 times in total.
I've just started riding the GTS again, and it'll be changing

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Postby heinlein » Fri Apr 02, 2010 9:11 pm

Looks good and the slip on seems sensible. Just out of curiosity do you know how much this weighs compared to stock?
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Postby Chris Pinard » Fri Apr 02, 2010 9:41 pm

Stunning piece of kit Mike,probably weighs half what the original was. Lovely job.

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Replacement exhaust weights

Postby 24c » Fri Apr 02, 2010 11:41 pm

heinlein wrote:... do you know how much this weighs compared to stock?

I don't know how much the OEM cat & downpipes weigh offhand, but I do remember weighing them in the past. The set up in the picture weighs 4.4kgs or 9.7 lbs, and my titanium Blue Flame end can, that I have used on the red and blue GTS1000 weighs a lot less, nearer 2 kgs max. So you have to say the full weight of a replacement system will be around 6 kgs or sub 14lbs.

IIRC the stock silencer weighs a whopping 6.8 kgs, and an aftermarket Gazelle silencer/end can with link pipe to the cat weighs 4.7kgs.

Chris Pinard wrote:...probably weighs half what the original was...

Looks like you are not wrong with that estimate. :)

Next phase is to make another for a slip on, but try and reduce the costs. Also I must look at making four separate headers/downpipes, as this will make fitting easy for everybody. At the moment, you have to disconnect/separate the front swinging arm...which is a hassle.
I've just started riding the GTS again, and it'll be changing

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Postby Flydave » Sat Apr 03, 2010 1:39 pm

Great job Mike !
God bless James Parker !
1998 GTS1000A Blue

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Re: Exhaust resurrected for Easter!

Postby 24c » Sat Apr 24, 2010 1:32 pm

24c wrote:The first one looked nicer, just got to TIG it up now, and polish... sod it...it's not for my bike!


Finally got round to finishing this, only get one day in seven to play at the moment. To be honest, it needs a little more work, more polishing etc, slight tweak to the final bend after the collector, before I make the final version for the GTS.

Image

Awaiting some feedback from the local tube benders, as to what they can do for me, and talked it over with the stainless steel welder/fabricator... Will start a jig once, I know what these can do. Definitely looking at four separate downpipes though, as pulling the front arm away is more work then it needs to be.

Will be using larger primary/headers/downpipes to suit higher performance applications, but it will not be detrimental for stock ones either.

PS Update, based on the feedback so far, it'll be less than £300 (UK pounds), which is more than I thought initially. :(
I've just started riding the GTS again, and it'll be changing

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Replacement exhaust fitting

Postby 24c » Sat Apr 24, 2010 5:59 pm

Well guys, this has to be the easiest way to fit a one piece exhaust... jack it up with an engine crane like this

Image

undo front swingarm bolts and pull the arm out of the way, and just strap it up to something nearby, like this and this.

Image

Image

and when it's done...it looks like this.

Image

Total time probably less than an hour and a half.
I've just started riding the GTS again, and it'll be changing

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Postby heinlein » Sat Apr 24, 2010 7:10 pm

Damn that's pretty. Do you have a clue how much it will cost to ship to the colonies?
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Postby 24c » Sat Apr 24, 2010 7:33 pm

I reckon insured surface mail, via water will be the cheapest...so hopefully less than $50 ... absolute max, and hopefully cheaper or airmail for that.

I could do a group buy, and ship to one point..but I can assure you postage will not be marked up, I will do it as cheap as I can, but it has to be insured, as it would only take one bad mailing to wipe out the "profit".

Incidentally, my take on all these replacement items, is the "profit" funds more. The next item I have looked at is the indicator pods, but the process I can economically use for the lenses is UV vulnerable. The paint can protect the bodies, but I was also hoping to use LEDs for these and have dual wiring aka split inputs for you USA guys that need running lights too. The other thing I was going to make them symmetrical, so one side would do both... slight aesthetic compromise though. At least you could keep your originals and drop your bike all day long. :P

PS Still a designer at heart...f**king sad really! :oops:
I've just started riding the GTS again, and it'll be changing

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Postby 13blades » Sun Apr 25, 2010 1:46 am

Absolutely Stunning!!!
94' GTS1000, 93' TDM850, 77' XS750

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Postby 13blades » Sun Apr 25, 2010 1:46 am

Double post :oops:

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Postby omnivore » Sun Apr 25, 2010 3:36 am

Have you tried to contact Hindle exhaust in Canada? Their headers are individually attached, and justthe spigots bolt to the head. The downpipes each spring mount onto each spiggot, then the collector spring mounts onto the bottoms of each downpipe. And their stuff is all thin walled mandrel bent stainless. If you got a group order, I can't imagine them not wanting to sell you a bunch of them, even if i's the FZR1K or ThunderAce headers. Shoudl all work,no?
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(OT)

Postby 24c » Sun Apr 25, 2010 6:50 am

omnivore wrote:...Should all work,no?

There is no reason why it won't work, but my motive is too help a really nice guy, who employs a few guys, not far from me, stay in business.

He is a specialist precision welder, and with the downturn, and the obsession with "higher" UK production costs. The thinking from these bean counters is everything is cheaper if you take production to China and import it, but the reality is, it isn't like for like. Small order runs are no cheaper, quality is assured, and it maintains other folks quality of life, after all who wants to work in a supermarket doing promotional sales work. (That's what happened to a lad that my son knows).

The end game is to get this guy to make stainless steel exhausts, not just for GTSs, but other bikes and classic cars too. I suppose it's a karma thing... bit like buying milk from a farmer that delivers, rather than going to the supermarket and buying half gallons/2 litres.
I've just started riding the GTS again, and it'll be changing

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Karma

Postby heinlein » Sun Apr 25, 2010 7:37 am

I like your way of thinking. Are you sure your name isn't Earl?
“Calling upon my years of experience, I froze at the controls.” Stirling Moss


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