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post #1 of 10 (permalink) Old 03-09-2012, 07:47 AM Thread Starter
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Shortening Exhaust

The time has come to repack my mufflers and while they are apart, I was thinking about shortening them up just a bit. Obviously a band saw or chop saw would be best. Unfortunately, I don't have access to those. Anybody have success with any other cutting tools? Hack saw, dremel, etc? I don't want to butcher it, but I'm trying to make due with what I have access to.

Thanks.

"Like a junkie trying to get his hands on the next fix,
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post #2 of 10 (permalink) Old 03-09-2012, 11:13 AM
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You can use a dremel but it may take awhile. Just measure a ton and use a tapeline to keep you going straight.

Is this the factory exhaust?

2001 #62. Ohlins rear/valves, Micron high mount, HyperPro damper, SharkSkinz, Tyga billet triple clamp, Tyga Carbon Fiber fender and hugger, Ti bolt/custom subframe/alien motion 8 cell diet, 15/41 520, COP conv. PCIII, Venhill lines, modified air box, turn signals in headlights...<deep breath> ZG Touring windscreen, Tech G rear sets, CRF450 rear master w/HRC cover, Tokico 6 pots w/V-pads, CRG Bar end mirrors, PSR Shorty levers-use only clutch, wanna-be basic racer paint, Roman Gold PC wheels
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post #3 of 10 (permalink) Old 03-09-2012, 11:40 AM Thread Starter
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I thought about my Dremel.

2 Bros. Titanium High Mount

"Like a junkie trying to get his hands on the next fix,
those of us who seek the thrill of speed and danger will
do anything to get those glands pumping out that juice."
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post #4 of 10 (permalink) Old 03-09-2012, 12:24 PM
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Shouldn't be too hard. Measure twice cut once Definitely will want to use the larger reinforced disks. The hard ones are the factory exhausts. Last one I did was for a Ninja 250 and it gave my saws all a run for its money (they have all kinds of wizardry in those little 250 mufflers!)

If you wouldn't mind...could you share the inside diameter of the high mount pipe where it meets the mid pipe and inlet diameter of the muffler? I am looking for a way to piece together something, so far it's a PITA.

2001 #62. Ohlins rear/valves, Micron high mount, HyperPro damper, SharkSkinz, Tyga billet triple clamp, Tyga Carbon Fiber fender and hugger, Ti bolt/custom subframe/alien motion 8 cell diet, 15/41 520, COP conv. PCIII, Venhill lines, modified air box, turn signals in headlights...<deep breath> ZG Touring windscreen, Tech G rear sets, CRF450 rear master w/HRC cover, Tokico 6 pots w/V-pads, CRG Bar end mirrors, PSR Shorty levers-use only clutch, wanna-be basic racer paint, Roman Gold PC wheels

Last edited by Hig; 03-09-2012 at 12:27 PM.
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post #5 of 10 (permalink) Old 03-09-2012, 12:40 PM Thread Starter
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Yeah, I'll take some measurements. Are you looking for the ID of the muffler inlet, or the ID of the Midpipe outlet?

"Like a junkie trying to get his hands on the next fix,
those of us who seek the thrill of speed and danger will
do anything to get those glands pumping out that juice."
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post #6 of 10 (permalink) Old 03-09-2012, 12:45 PM
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I'm looking for the ID of the muffler inlet and the ID of the midpipe inlet. I'd like to use the highmount pipes on an akra header...

Thanks a ton

2001 #62. Ohlins rear/valves, Micron high mount, HyperPro damper, SharkSkinz, Tyga billet triple clamp, Tyga Carbon Fiber fender and hugger, Ti bolt/custom subframe/alien motion 8 cell diet, 15/41 520, COP conv. PCIII, Venhill lines, modified air box, turn signals in headlights...<deep breath> ZG Touring windscreen, Tech G rear sets, CRF450 rear master w/HRC cover, Tokico 6 pots w/V-pads, CRG Bar end mirrors, PSR Shorty levers-use only clutch, wanna-be basic racer paint, Roman Gold PC wheels
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post #7 of 10 (permalink) Old 03-09-2012, 01:24 PM Thread Starter
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Gotchya. Will do.

"Like a junkie trying to get his hands on the next fix,
those of us who seek the thrill of speed and danger will
do anything to get those glands pumping out that juice."
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post #8 of 10 (permalink) Old 03-09-2012, 02:06 PM
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I burned through a 3in cut off wheel when I cut down my Ti Jardines.

Stock up on cut off wheels for the dremel, I'm sure they will work but they are like $7 for a pack of 5
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post #9 of 10 (permalink) Old 03-09-2012, 02:58 PM
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Here's the discs I use for various destruction:

I was thinking about it and James is right, you might burn through a few. Might be able to "line out" the cut with the dremel and take it nice and smooth with the hacksaw. There would be much less "walking" with the saw if you made the dremel cuts first. Not sure I have the patience to do this with a dremel (but I have the determination..)

2001 #62. Ohlins rear/valves, Micron high mount, HyperPro damper, SharkSkinz, Tyga billet triple clamp, Tyga Carbon Fiber fender and hugger, Ti bolt/custom subframe/alien motion 8 cell diet, 15/41 520, COP conv. PCIII, Venhill lines, modified air box, turn signals in headlights...<deep breath> ZG Touring windscreen, Tech G rear sets, CRF450 rear master w/HRC cover, Tokico 6 pots w/V-pads, CRG Bar end mirrors, PSR Shorty levers-use only clutch, wanna-be basic racer paint, Roman Gold PC wheels
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post #10 of 10 (permalink) Old 03-09-2012, 03:01 PM Thread Starter
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Could also put a 4.5 cut off on my grinder, but it might be hard to control as well.

"Like a junkie trying to get his hands on the next fix,
those of us who seek the thrill of speed and danger will
do anything to get those glands pumping out that juice."
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