http://i660.photobucket.com/albums/u...eden/002V2.jpg

http://i660.photobucket.com/albums/u...eden/001V1.jpg

http://i660.photobucket.com/albums/u...eden/003V1.jpg

i will try to do a diagram tonight to show where I did the cuts.
I put a large cut in both sides of the silencer just after the inlet pipe using a nine inch grinder.
This gives you another weld to do but means you can hacksaw out the last of the cat easily as it strongly welded in.
There is a central baffle plate that separates the inlet chamber with the cat in it and the outlet chamber with the two baffles in it.
If I was doing another pipe I would remove the whole upper section of the exhaust in one go as this would give you better access to the whole of the box for not much more welding.

looks a great job... how is the sound/tone of exhaust now

decatt
 

The sound is good, not that loud but it now sounds like a big single rather than a neutered cat. You have to do the AIS mod or it pops like hell on the over run.

Well done the pics of the way you cut it will be helpfull if I try and take the same route, cheers

Looks a good job mate.:bravo:

nice job! good write up, thanks.

Random question about your R&G tail tidy.....

Are both those lights brake and tail lights...or is one just a tail light and one just a brake light? Also do they come away from the black backing plate easily? (just screwed on?)

cheers

Hello, Yes both units are both tail light and brake light.
The LED assemblies are attached by a couple of 3mm screws but there a bit crap and corrode up easily.
One complaint I have had with the R&G tail Tidy is that the LED's point up to the sky and if your following you dont really see when the brake light comes on. I will stick a bit of packing behind the lights when I get a chance, to 'dip' them a bit.
The R&G is definately a lot lighter than the stock unit which weighs a lot. Im not that keen on the shape of the lights and have seen some good modified tail units on this forum.
Still doing the sketch of the exhaust and will post it this weekend.

Decatt the exhaust
 

Ive attached my drawing of the exhaust internals. Please excuse the quality but I need to sharpen my crayons.
Hope it give you an idea of whats where and which bits to cut out.
My mates got an XTZ and If he wants his pipe done I will get a photographic diary whilst doing it as it makes a lot more sense.
The perforated tubing used in the baffles was supplied by the excellent folk at PJ Engineering (1 &1/4 inch stainless steel)
the also supplied the outer tubing which fits over the performated tubing perfectly and finishes off the out side of the pipes really nice.
Happy welding!

http://i660.photobucket.com/albums/u...sieden/IMG.jpg

Also started on mine today

http://i806.photobucket.com/albums/y...013/DeKat3.jpg

http://i806.photobucket.com/albums/y...013/DeKat4.jpg

Monday the welding will be done

Put it back on the bike today
Disappointed, it's like the grump is gone, hollow empty noise ???