Just recently a 2008 sport silencer came up on ebay, I bid on it and won it for £40 ...bargin
It has a slightly larger exit bore than my 2007 tube type silencer and is to my mind better looking.
It is a welded construction with a decorative end cap held on by 3 off M6 cap head screws.
The outer stainless sleeve has been rose welded to the mounting bracket.
I set it up on my Bridgeport mill and carefully drilled(11.5mm dia) out the rose welds leaving the inner bracket not quite broken through with the drill point, the sleeve then slid off, I then marked a datum line down the length on the silencer to help me align the two halves on assembly later.
I used a 2mm wide cutting wheel and split the silencer where the tapered and parallel parts were welded.
I then removed the catalytic matrix and drilled 3 off 20mm dia. holes in the tail section. ( I clamped it rear end down and drilled them with the Bridgeport again)
Then my workmate welded the two halves back together.
As it was now a little shorter I drilled the inner bracket with the 4 drill points out to 6.8mm and tapped it M8 this allowed me to slave the outer decorative skin and the outer mounting bracket to the main silencer and permit a small amount of movement to get best position.
Then back to my friend ....remove one bolt at a time and weld up.
Finished article looks like standard ........sounds very much better according to guys I have ridden past and those who have followed on behind, I get the impression the bike accelerates a lot more easily.
My 2007 Sport with updated unfettered silencer.
It has a slightly larger exit bore than my 2007 tube type silencer and is to my mind better looking.
It is a welded construction with a decorative end cap held on by 3 off M6 cap head screws.
The outer stainless sleeve has been rose welded to the mounting bracket.
I set it up on my Bridgeport mill and carefully drilled(11.5mm dia) out the rose welds leaving the inner bracket not quite broken through with the drill point, the sleeve then slid off, I then marked a datum line down the length on the silencer to help me align the two halves on assembly later.
I used a 2mm wide cutting wheel and split the silencer where the tapered and parallel parts were welded.
I then removed the catalytic matrix and drilled 3 off 20mm dia. holes in the tail section. ( I clamped it rear end down and drilled them with the Bridgeport again)
Then my workmate welded the two halves back together.
As it was now a little shorter I drilled the inner bracket with the 4 drill points out to 6.8mm and tapped it M8 this allowed me to slave the outer decorative skin and the outer mounting bracket to the main silencer and permit a small amount of movement to get best position.
Then back to my friend ....remove one bolt at a time and weld up.
Finished article looks like standard ........sounds very much better according to guys I have ridden past and those who have followed on behind, I get the impression the bike accelerates a lot more easily.
My 2007 Sport with updated unfettered silencer.
