Hawk exhaust mod/hack complete
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Well I decided to gut the cat on my Hawk. Just cut out a "window" and it pretty much just popped out. Welded the "window" back in, checked for leaks and painted. I also got froggy and made a new insert for the muffler. Went up to 1 1/2 inch pipe. Made the insert using EMT conduit and a 4" square electrical box cover (being an electrician stay with what you know). Sounds deeper and a little louder but not much louder. Can definitely tell a difference in power as it gets to 55 faster/easier and cruise's at 50 effortlessly. I need to get a long drill bit and drill some holes in the baffle in the muffler to free up some more flow and then will probably re-jet again. Pretty good mod for under $20. Here are some pics.
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Re: Hawk exhaust mod
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If you get a chance, could you post photos of the insert that you made? |
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I see everyone cutting windows in the cat and gutting it. Can't you just cut the cat out and weld up a piece of exhaust pipe? I know I'd end up with stitches trying to dig those things out.
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I cut the pipe after first weld. Scratched some crows feet marks before I cut so I could line it back up. Used a tire tool to punch out baffles in muffler. It's a bit louder but worth the trouble. Combined with new jets and open up air box ALOT, I can hit 62 mph pretty easy. Accelerates up hill better. I can cruise 55-58 easy. Made it pull stronger for sure.
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https://www.facebook.com/photo.php?f...6&l=5755794f96 |
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http://i67.tinypic.com/1okp5f.jpg http://i66.tinypic.com/25sadq8.jpg Here's where I "made" it. :p https://www.amazon.com/dp/B001654JK0 I just wish it were exactly as pictured on Amazon because it would have made it real simple to clamp a screen to the part that would have extended into the muffler. Here it is installed: https://www.facebook.com/photo.php?f...3&l=cbb9f2f6d4 |
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Don't go overboard as I did, I think 3 holes would have been enough but I have even more than you can see here: http://i68.tinypic.com/1r9flh.jpg |
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OK, here is the insert I made. Welds look like crap. My auto darkening welding helmet didn't darken on the first arc and from then on all I could see was a red spot where I was welding. It sticks but it ain't pretty but NORMALLY no one will see it. I still need to de-bur the holes and add a spark arrestor screen for when I go on National Forest land.
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Luna t... I often wondered if you could get away with a 3 way cut and bend the window open for access. Then just 3 cuts to weld closed . I won't know till I get in there and do it.
Luna t.. you are far too humble, the fact is job done ! Results are what counts :tup: |
BlackBike... I'm not sure 3 cuts would work but it never hurts to try. The cat material is glued/stuck in several spots all the way around so bending might be difficult. I just used a dremel with a cut off wheel (actually used about 4 wheels) to make the long cuts and my hack saw to make the two end cuts (across the radius). The cat material came out stuck to the "window" I cut out and I just used a screw driver to pry it off there.
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LT, thanks for taking the time to share your exhaust surgery with us. Your method is exactly what I would do if I had a cat to excise. I might also try BB's suggestion of cutting three sides only, with a score to relieve the section to be bent.
I really like the exhaust tip concept. You might decide to try another version that borrows from 2LZ' design, which has a plug in the inlet end of the tip. That forces exhaust to enter the tip through the small holes on the sides, which can be tailored to suit your needs (and it'll pass a coat hanger test). I've fabricated similar mufflers before, and my way is to use a little math. Calculate the area of the ID of the header and then calculate how many 1/4" holes would be required to equal the same area. Drill that number of holes and try it. I wouldn't drill holes any larger than 1/4", so that sparks can't easily find their way out. |
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