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Discussion Starter #1 (Edited)
Hey All,

Planning on chopping down my stock (98-zx6r) can this weekend, looking for some input into which process has been tried, as I've found a couple different how to's

The majority follow one of two systems:

1. Cut it in layers, outside can first, then packing, then inner tube etc.
--> DIY - Stubby your Exhaust. Not 56K Friendly. - Custom Fighters - Custom Streetfighter Motorcycle Forum

2. Hacksaw right through all:
GUIDE: How to stubby an exhaust can. - Honda Motorcycles - FireBlades.org

Any input for my particular exhaust can?


Additionally, I can't find an exhaust diagram anywhere, the service manual only shows the CA KLEEN version. :(
Can anyone provide, or explain the layout inside this bad boy?
--> Don't want to start cutting and do something I cannot undo.

Any advice would be hugely appreciated!

:king:




BEFORE PHOTO:
 

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I have done it both ways. one on my kfx400(atv) and made a shorty on my kx250(dirtbike) preferred method for me was the first. do it in sections. cutting though the whole thing with a hacksaw makes a mess of things. same end result but spent more time bending baffle back strait and had to use new packing cause the hacksaw makes a mess of it. good luck. not to hard to do. remember pics when your done!!
 

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Discussion Starter #3
Thanks!

Currently in the process of chopping the bad boy down.

Slow and painful process I am realizing.

Will post pics soon!
 

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Discussion Starter #4
Well,

Guess the old adage "measure twice.." is spot on, ended up cutting just passes the first wall, since the outer layer was too short, ended up having to cut through the flow chamber tubes.

This thing is essentially one big chamber, single small tube, then atmosphere.
Probs going to be noisy as shit, but decided to finish the project, as anything's probs quieter than no muffler.

Here's pics so far for anyone who's following.



Work Bench in progress + Leftovers




Shell Chopped and painting in progress




Innards Chopped Down




Any point cleaning this thing? Or drilling little holes to help with noise?



Im sure it's too short. haha.
Anyone know if lining the inside with the leftover fiberglass can help with the noise?
--> Maybe rip is so it's loose and super (lightly) packing the empty space?
------> Enough to let gasses through, but try and muffle noise?
 
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