Stock Exhaust Modification
by
Bert

This winter I kicked off the final mods, I just got them finished and on the bike, believe me, this is what you want to do.
Here is the step by step guide, pictures are posted below.

Step 1:  Remove cat box from the bike, cut it in 2 along the weld- take the left side of the weld,to cut along, as seen in driving direction- and remove the cat matrix completely, reweld the 2 half back together.

NOTE:  Don't touch the perforated pipes in the catalytic converter, as they balance out the cylinder pressure.

Step 2:  Now take the muffler, remove the aluminium sleeves and all parts you can possibly remove, and open the box along the welded line.  I used small grinding disks on a Dremel mill and it was pretty easy.  You also need to mill out all of the spot welds that keep the center walls in place - top and bottom.

Step 3:  After using the dremel, remove the top half, then empty the bottom half completely, TAKE IT ALL OUT.

Step 4:  Place a new solid partitioning wall with 2 57mm diameter holes.   Drill out the existing exit pipes to 57mm and make sure they line up with the new partitioning wall.

Step 5:  Make up 2 perforated tubes from perforated stainless steel sheet- weld a bit of solid tube on each end and place this into the muffler - from exit holes to partitioning wall- and weld up.  Fill up the space arround those with Glass matt and glass wool.

Step 6:  Now replace the top lid and weld off all arround, including the spots where the old walls used to sit.  That is it!

It took me about 35 hours of work, bit by bit, and about £50 in materials.  The sound is deep and low, but not to noisy.  The styling of the bike is intact.

You might have to adjust the fuel setting as the engine could run too lean if you don't.  Your dealer can do this no problem.
(editor's note:  many people have installed full exhaust systems without remapping.  As always err on the side of caution and have a qualified mechanic check and adjust the mapping as necessary.)

Update:  I ran into some Mark 2 Lotus Elise-Exige fuel filler rings, and guess what, it looks like the Lotus designer had my bike in mind when he designed those things.  They fit my modified MTS stock exhaust perfectly.  Pictures are included below.

 © 2006 WolfCentral Productions

You are Visitor Number: