A Call To All Great Exhaust Builders

[Mashermoto]

HOT DIGITY DOGS

Sorry about yelling so loud, but I think I found a workable solution for all wayward XS11 fellers wanting a new exhaust setup



Here it is...SuperTrapp Universal muffler 443-2217. This is some nice quality stuff



And this is what I call free flowing



It slides perfectly up the MAC 4-2 headers, which allows me to set the end length right between the rear foot peg and rear axle just like I wanted



Front vew looks like they were made to go together.



And look at this...the SuperTrapp muffler mount fits perfectly with the OEM exhaust mount hole That means it will be rubber mounted There may be a way I can make the clamp mount on the back side, but if not I'm happy with the front mount. A nice chrome bolt will help dress it out. And in real life the color difference between the clamp and muffler isn't that noticable. Funny what a camara will do to things

So Wooo Hooo It worked



So now all I have to do is solve how to fix this exhaust flange, knock the rust off the headers and give them a coat of flat black high heat paint, and bolt this thing up

I'm happier than a tick on Dracula

[T99Ford]

That looks awesome! Nice legwork. I am glad your were finally able to reach some resolution!

[bikerphil]

Nice bro. I also run a Supertrapp 4" can, but on a Mac 4-1. You're gonna love it. If for some reason you get some vibration in the high RPM's, lose the rubber mount and make it solid. BTDT

[xs11lover]

Looks good!

[crazy steve]

Originally Posted by Mashermoto

So now all I have to do is solve how to fix this exhaust flange, knock the rust off the headers and give them a coat of flat black high heat paint, and bolt this thing up

I'm happier than a tick on Dracula

For that bad exhaust flange, have you thought about just gooing it with some silicon? That high-temp copper-colored stuff should do the trick.

I've seen guys use this on custom header flanges and it worked there.

And I like the muffs; these look like something that could be there and not so 'adapted'....

'78E original owner

[TopCatGr58]

Hey Steve,

How's about cutting off the whole flange flush, and then getting another piece of pipe from an exhaust shop or such, put a flange on it, and then slip it into the header pipe with a press fit, or sealant, or weld? JAT!?

T.C.

[tinman905]

Looks very nice but what did it cost for the pair?

[crazy steve]

Originally Posted by TopCatGr58

Hey Steve,

How's about cutting off the whole flange flush, and then getting another piece of pipe from an exhaust shop or such, put a flange on it, and then slip it into the header pipe with a press fit, or sealant, or weld? JAT!?

T.C.

If I were doing for myself, I'd build it back up with weld; but not everybody has a wirefeed...

'78E original owner

[yamahansolo]

you could just order a build your own header kit from jegs or summit... they are cheap and you can also get mandrel bent peices as well...

i like the super trap. it looks good.

still i love the kerker the best!!! if it ever goes i'll try to do something similar with the st muffler....

there is a bike in one of my street fighter mags and he used a st type muffler that has the rings and a closed endcap and he made it face forwards so the end cap was into the wind... they tested the bike riding it and said that with the cool air hitting the closed end it allowed the exhaust to escape faster due to the cooler air hitting it... it sounded interesting..

[trbig]

I'm with Tinman... How much?


Tod

[Mashermoto]

OK...I'm back.

TR and Tin,

Actually I don't have a cost for the pair because I only bought one. When I measured the clearance under the foot peg mount I could tell it was going to be close. So I purchased one just to see how it was going to mock up.

The one pictured I got on Ebay for $130. The seller had it on a buy it now for $150, but when I contacted him about it he offered to lower his buy it now post. For a stainless steel model, that was a great deal SuperTrapp has them listed for $259.

http://www.supertrapp.com/product_se...t.asp?CatID=30

Summit Racing has an Ebay store that offers them for $195 plus $12 shipping. Just do a search for Supertrapp 443. The lowest I've seen them on the internet is $177.

Summit's store also has the flat black regular steel 449 series for $140.

So, nobody is going to save money by going this route, but crap, at least you can have a system that is truely free flowing, rebuildable, available all day long, very good quality and most importantly, looks Sexxy

Yamahansolo,

The answer is yes and no Yes I can order the mandrel bends, but no I can't weld them together As noted in the beginning of this post I purchased some mandrel bends to mount those ZX10R cans, but did nothing but burn holes when I tried to weld them Thus, my plea for somebody to just build a frick'n system for us to buy

My case is a little unique that I've got a project that started out as a bike in a box three years ago. I've been working on it for about a year now. The exhaust system that came with it was the rusted and worn out MAC 4-2 system pictured above. So I had to have a replacement. That's when I found out just how limited the supply for the XS1100 is. There are some systems out there like the occassional Jardine can systems found on Ebay or MAC 4-1 systems and 4-2 turn out systems that are still available new. The MAC 4-2 taper tip will be available in about six more weeks...that is if MAC still cares to. And that's just about it.

I don't want to anger anybody about my choices, but my anal obsessive compulsive self just has to have something a bit more sporty and compact looking than what is being offered. As well as the fact that I started this search 10 months ago last April I finished rebuilding this engine about 4 to 5 months ago and I really want to get it fired up.

When the eagle lands I have lots of pictures of back cut transmission gears, big bore pistions, exhaust porting, seat modifications, and other goodies to show ya

So, I think the pratical application for this set up is for they guy that has a usable set of headers, but a crapped out set of mufflers, or just wants to upgrade an existing set of mufflers. But if money is an issue and you are happy with the looks, there are complete systems you can buy for the price of two SuperTrapp stainless steel mufflers.

[Mashermoto]

Steve,

What is that copper goo stuff you mentioned I've thought about making something that would look like a large thin washer and weld it or glue it over the existing flange

Just how hot is the exhaust gasses from an XS11 as it exits the head That is what concerns me about using a glue.

TC,

I could always cut one of the flanges off this Kerker header and have it welded in place



I've hoped I could do something about the holes in these headers and salvage the system, but this set has a lot of holes and those header tubes are real thin

[crazy steve]

Originally Posted by Mashermoto

Steve,
What is that copper goo stuff you mentioned I've thought about making something that would look like a large thin washer and weld it or glue it over the existing flange

Just how hot is the exhaust gasses from an XS11 as it exits the head That is what concerns me about using a glue.

The stuff I use is made by Permatex and just called 'High Tempature'. The tube it comes in is copper-colored, as is the silicon sealant in it; any auto parts store should have it. I've used it on damaged exhaust flanges (with gaskets) and never had a failure. I've also seen it used with NO gaskets on several race car headers where no gasket was available and it worked great there too. The only downside to the stuff that I've seen is it's only good for exhaust joints, as it has to have the heat to cure. Use it other places and it won't set up.

A permanent fix would be to cut off the broken flange and machine a new 'ring' to fit over the pipe, then weld it on (which is how the factory pipes are done), but that won't be lo-buck if you have to pay to have it done...

'78E original owner

[Mashermoto]

Well I had another bit of good luck to keep this project going

I have a friend who has a welding business that shot some wire feed beads along the damaged area. So next I'll grind and file the surface area flat.

That Permatex might come in handy to fill in any little imperfections.

I'll post pictures later of either a success story or failure story.

[Mashermoto]

Ladies and Gents, I come bearing good news...I believe I have a success story to tell



To make a long story short, I ended up at a friends welding shop that has one of those 230v Lincoln wire feeds with gas He fixed the flange by shooting a series of small beads along the damaged area.



When I got home I used a file and resurfaced the flange front and side. So that problem is gone



Next came the paint.



I used the VHT high heat header paint in flat black. The color came out real good.



Next came the muffler mounting. But first I had some clean up to do. I noticed the inside of each clamp slot needed to be deburred. This is the only flaw I found so far with the SuperTrapp muffler



Here is the front...



Side...



and rear view

I'm extremely pleased with this set up so far. I have a muffler on order from carshopinc.com and should be here within a few day. Then I can finish the other side and post some more pictures.

For those of you interested, carshopinc.com had the second muffler for $177 plus $13 shipping. I think that is about as good as it gets for online shopping. I have a friend at work that is a card carrying NHRA drag racer. They get discounts on auto parts from a lot of places. The same muffler would have cost him $172 with no shipping costs. So the price I paid is good for us non-card carring guys

As far as a member here offering to build and supply XS1100 exhaust systems, maybe this is the answer. the 4-2 headers are just two pipes into a y-pipe with a 2.25" collector. If someone can just build that with an easy pleasy price tag, the mufflers can be found all day long and are a direct bolt on

Later.