I got my hands on an extra set of Vee mufflers from a friend, and the conditions were that I do something to make my bike louder. I took the mufflers to my friend Luke's shop and we hacked them a bit today.
First thing you have to do is take the heat shield off the muffler. The 12 and 6 o'clock hex bolts have threadlocker from the factory so it takes a little effort to crack them loose.
Next step..cut the muffler with a bandsaw. This was the first time i've ever attempted to hack into a Vstrom muffler. I've done it on my R1 but that required no cutting, just drilling out rivets. So we just decided to cut just inside of the big bead on the front side of the muffler, less than an inch away.
Luckily on the first attempt, we cut into the perfect place. The peashooter fell out as the saw passed through it, and we exposed the front of the baffle. We made educated guesses where to cut based on the visible spot welds on the outside of the can. Here's what was left. The plate around the pipe was loose and we were able to pull it out with ease.
Here's what it looks like with the plate out
Next we went ahead and cut the back side of the muffler with the bandsaw. As you can see we cut about halfway in between the bead at the back and the bracket for the heatshield. We based this upon visible spotwelds on the outside of the can.
After we cut that out, we discovered there was a catalytic converter in that big ugly midpipe. Make sure to clear out that fiberglass packing (the stuff between the 2 outer rings) with a screwdriver because this part needs to be welded later. We had cut far enough away not to damage the honeycomb and we expect to see a red glow through the muffler when ridden at night time.
The next step was to hammer the baffle out. After banging on it with a hammer a few time, we realized there was a spot weld that we hadn't cut through.
So we drilled that out and it was all good. The hole would be filled when welding the pipes back together. After hitting it with a mallet a couple of times (hitting the back side of the muffler, so the baffle would slide out of the front side) the baffle slid out a bit.
The baffle is wrapped with fiberglass so make sure to use gloves and not to let any of it get into your lungs. Here is the muffler completely disassembled.
The rest is pretty simple. Line up the front cap and tack it into place. The perfectly oval can will have been warped from banging and sawing, so after you line up one side perfectly and spot weld it, use a c-clamp reform the oval so you can spot weld it flush on the opposite side. We put about 6 spot welds around the circumference of the can, then laid down the bead.
When welding the front cap and mid pipe back on, make sure not to mix it up and make sure to get it as close to the original position as possible, or else it won't mount correctly on the bike and/or the heat shield won't bolt on.
Here's the muffler all back together.
And here it is front the front. Much better look without the peashooter isn't it?
Here's the catch..i haven't had time to put it on the bike to see how it sounds. Who knows maybe it'll be great, or too loud, or too farty. I dunno. But i'll definitely get a video camera and do before/after as well as cruise, accel, and decel if I can. If it sounds good, there is a possibility Luke will be taking orders on this for a couple hundred bucks a pop if anyone's interested. But for now, it's just a project to kill some time. If anything you got to see what the inside of those big fat heavy mufflers looked like. Also, i believe they dropped about 4.5 lbs in weight for each can, but I'm not 100% certain. Thanks for reading.