Wilsons Sandbox

----- Original Message ----- From: "Sonny Bulla" To: "KLR650 Group" dsn_klr650@yahoogroups.com> Sent: Wednesday, May 13, 2009 8:52:27 AM GMT -08:00 US/Canada Pacific Subject: [DSN_KLR650] Exhaust end cap Hey, I seem to remember a discussion on here awhile back about modifying the stock exhaust can and adding an end cap similar to ones found on sport bikes but, search as I may, I can't find it now. Does anyone know where such end caps (3" dia. or smaller) can be found? I checked e-bay and find 4" diameter ones and some the seller won't reveal the diameter of (and won't reply to questions). Thanks, Sonny '02 KLR650 [Non-text portions of this message have been removed]

On May 13, 2009, at 12:03 PM, Jeff Khoury wrote: > I did something similar. > > I went down to home depot and bought a 2" bimetal hole saw and a > piece of 1" dowel. I drilled longitudinally through the dowel and > fitted it over the drill bit when it was installed in the hole saw > to keep it concentric while drilling. A lot of pressing and sawing > later, I pulled out the secondary baffle. I then went to Pep Boys > and bought a 1 7/8" chrome exhaust tip and cut it to length with a > sawzall, then was off to my local muffler shop to get it welded in. > > After that, it was a matter of surface sanding and the application > of a little hi-temp matte black paint and it looks great. Sounds > great, too. It's not that much louder but a LOT deeper, actually > sounds like a dirt bike now. I think it's still under the 93db limit. > > If it were me, I wouldn't saw any bigger than 2" after looking > inside the can. The packing and tubular screen on the inside is 2" > and if you go too far, your saw will catch on it. In addition, > even if you put a 3" tip on, you won't get any better flow because > of this internal design. > > [Non-text portions of this message have been removed]

> > Very cool, that's the post I remember! But, someone else posted > something about the pre-made end caps. Let's see if that one surfaces. > > The 3" diameter I was talking about is the mounting flange diameter > not the opening. > > Thanks, > Sonny > '02KLR650 > > > On May 13, 2009, at 12:03 PM, Jeff Khoury wrote: > > > I did something similar. > > > > I went down to home depot and bought a 2" bimetal hole saw and a > > piece of 1" dowel. I drilled longitudinally through the dowel and > > fitted it over the drill bit when it was installed in the hole saw > > to keep it concentric while drilling. A lot of pressing and sawing > > later, I pulled out the secondary baffle. I then went to Pep Boys > > and bought a 1 7/8" chrome exhaust tip and cut it to length with a > > sawzall, then was off to my local muffler shop to get it welded in. > > > > After that, it was a matter of surface sanding and the application > > of a little hi-temp matte black paint and it looks great. Sounds > > great, too. It's not that much louder but a LOT deeper, actually > > sounds like a dirt bike now. I think it's still under the 93db limit. > > > > If it were me, I wouldn't saw any bigger than 2" after looking > > inside the can. The packing and tubular screen on the inside is 2" > > and if you go too far, your saw will catch on it. In addition, > > even if you put a 3" tip on, you won't get any better flow because > > of this internal design. > > > > > > > > [Non-text portions of this message have been removed] >

On May 13, 2009, at 12:03 PM, Jeff Khoury wrote: > I did something similar. > > I went down to home depot and bought a 2" bimetal hole saw and a > piece of 1" dowel. I drilled longitudinally through the dowel and > fitted it over the drill bit when it was installed in the hole saw > to keep it concentric while drilling. A lot of pressing and sawing > later, I pulled out the secondary baffle. I then went to Pep Boys > and bought a 1 7/8" chrome exhaust tip and cut it to length with a > sawzall, then was off to my local muffler shop to get it welded in. > > After that, it was a matter of surface sanding and the application > of a little hi-temp matte black paint and it looks great. Sounds > great, too. It's not that much louder but a LOT deeper, actually > sounds like a dirt bike now. I think it's still under the 93db limit. > > If it were me, I wouldn't saw any bigger than 2" after looking > inside the can. The packing and tubular screen on the inside is 2" > and if you go too far, your saw will catch on it. In addition, > even if you put a 3" tip on, you won't get any better flow because > of this internal design. > > [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

> Forgive me if this has been posted. I know many KLRistas hit the secret sauce. > > What's Inside WD-40? Superlube's Secret Sauce? > http://www.wired.com/science/discoveries/magazine/17-05/st_whatsinside > > Jim Fortner > Plano, TX > > > ------------------------------------ > > List sponsored by Dual Sport News at: www.dualsportnews.com > List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html > Member Map at: http://www.frappr.com/dsnklr650Yahoo! Groups Links > > > > >