Cat bypass

I am looking to do some work on my exhaust... I missed out on some D & D's on Ebay and am kicking myself for it. In any case, I have been toying with the idea of welding up my own Cat Bypass... Right now I have a set of Off Road Mufflers... just 2 on the right side, and none on the left. They sound good, but I want more, and I dont want a cat anymore. Any tips on where to get a cat bypass for a good price? Or any tips on how to weld one up? I am pretty good with a welder.. I just dont want to do anything that is going to really mess with my tune. I don't have a Tuneboy yet... bought the bike used.. I just want my bike to be louder and not have to worry about ruining anything.

Cat Box

Jay, I'm picking up a set of jardines tomorrow and was going to put my cat bypass and drilled out silencers on eBay as a complete set. They sound great. The higher you rev the more the rocket sounds like an expensive Italian sports car. Will also have Uni's up for sale.

let me know before you put them on ebay... I will buy the bypass for sure... this way you avoid the ebay fee.

D&Ds

PolarisJay13 said:

I am looking to do some work on my exhaust... I missed out on some D & D's on Ebay and am kicking myself for it. In any case, I have been toying with the idea of welding up my own Cat Bypass... Right now I have a set of Off Road Mufflers... just 2 on the right side, and none on the left. They sound good, but I want more, and I dont want a cat anymore. Any tips on where to get a cat bypass for a good price? Or any tips on how to weld one up? I am pretty good with a welder.. I just dont want to do anything that is going to really mess with my tune. I don't have a Tuneboy yet... bought the bike used.. I just want my bike to be louder and not have to worry about ruining anything.

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You probably would not be happy with the D&Ds you missed out on, they are rather mild sounding even under hard acceleration they are not very loud.

Tbucket said:

You probably would not be happy with the D&Ds you missed out on, they are rather mild sounding even under hard acceleration they are not very loud.

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WHAT.......I can't hear you.....

If the bypass slips through your fingers, Staintune makes one and so does Triumph. It's not being a good welder that makes the bypass (I'm certified), it's the tube bender.

Hey Jay, If you decide to start making those cat bypasses at a good price you might have some buyers, like ME. I have the TORs also with the cat.

"(I'm certified)"

No one mentioned anything about nuts.

RocketDaryl said:

"(I'm certified)"

No one mentioned anything about nuts.

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My nuts......what about 'em?

I'm AWS Certified pipe, tank and pressure vessel, all positions.....and no, I'm not doing anything kinky at ES. We'll leave that to George.

I'm a low hydrogen guy.

my plan is to start making them if I can.. you are right about the bends Flip... they are expensive.. i need to get a madrel. I spent my senior year in college designing exhausts...if only I had a spare rocket to throw on the dyno.

Muffler man......

PolarisJay13 said:

my plan is to start making them if I can.. you are right about the bends Flip... they are expensive.. i need to get a madrel. I spent my senior year in college designing exhausts...if only I had a spare rocket to throw on the dyno.

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Don't compromise....Midasize

Designing exhausts in college huh....Sounds like a bored Mechanical Engineering student. Bet you've heard of Pridgeon & Clay before?

You need a nice Baliegh CNC through mandrel tube bender. You'll have to be careful with the metallurgy. It's hard to pull that tight radii without cracking the material. A 3 roll former won't cut it. you'll wind up with a constricting id. That's why the Staintune Cat Bypass is so expensive. They are pulling 3 series in tight radius bends with little constriction. I imagine the reject rate is pretty high. Of course they are in Oz so they can deal with European suppliers and get quality material. Domestically, the material is ****. The only half way decent 3 series material comes from Car-Tech. That's where I get mine and it ain't cheap.

You can't fabricate the bypass from AKDQ or even 10X because the heat/cool cycles plus the expansion and contraction will stress fracture the fabrication. It will crack at the weld point which is where the metallurgy will change. It has to be stainless and the less parts, the better. Better brush up on handling Thoriated Tungsten Electrodes too and getting consistent dye stain free welds.

You have quite a few physical and mechanical obstacles to overcome but if you can pull it off and be competitive, I'll buy one, better yet, I'll sell 'em for you.