Emgo reverse cone mufflers? 80-84051

[850 Combat]

Talkinaboutshaft put pea shooters on his 850G. I saw it at the OC Vintage bike day show once. He did it without welding. He cut back the housing and clamped to the inner pipe. Haven't heard from him in a while.

Here is the thread

http://www.thegsresources.com/_forum/showthread.php?t=172875

These "Dunstall" copies really don't look bad, but they definitely don't look much at all like the real thing.

[GS1000G Shopper]

I worked on this project some today. The Emgo mufflers are basically the same diameter as the pipe where I cut off the rusty muffler. I'm going to use a short 2" OD pipe to go over both pipes, weld it to the new muffler and then use a band clamp to hold the muffler to the pipe. The heat shield will cover this. I made an L shaped bracket and used 2 x 5/16 bolts in the slot on the new muffler. This way I can use the stock mounting point. Appearance is not too bad. I'll try & take some pics as I make more progess, I'm doing a few other things to it right now.

[GS1000G Shopper]

I found that what I needed were a pair of 1.75" straight pipes to mount the mufflers. Advance Auto had these, they are about 6" long. I ended up cutting about an inch off of each muffler and then about the same off the new pipes. I ground down the welds where I cut off the mufflers, and hammered the new pipe in place. Pushing the new muffler into place, it makes a decent seal w/o a clamp. The stock heat shield will just about cover the 1.75" pipe. I need to find some 1.75" band clamps to finish up the job.

EDIT
Make that 1.87" Accuseal clamps. I found them at Verocious Motorsports for about $5 each in aluminized steel, and under $8 each in stainless. Shipping was reasonable at around $10. I've dealt with them on some car turbo projects and they are a reliable vendor. I'm having second thoughts as to cutting down the muffler. Basically I trimmed it back about 1/2" so the slot in the side of it is gone. This leaves less "meat" to clamp onto.

Here are some pics. I have an MP3 sound file of idle and up to 4K RPM, and converted it to a WMV file- there is no picture. I had to do it this way since the forum won't accept sound files and Photobucket is photo/video only. It is an MP4 file on Photobucket.

Sound clip

Rear view:


Bottom side:


Top view with L bracket:


1.75" pipe w/o heat shield in place:


With heat shield in place: