Homemade silencer
 

Hi everybody!

This is my first post, but I thought it would be nice to share my little project with others. =)

Since all silencers for the Tenere are rather expensive I decided to build my own.
I've posted this on a couple of other communities, first it's translated from swedish and then it's copied from advrider.com so there may be some confusion. If that's the case ask me and I'll try to make things more clear. =)
If you don't feel like asking then you're at least able to look at the pictures. =P

Here it goes:

Since the silencer i nearly finished (some final modifications and a "paintjob" left) I'll post all updates in one post =)
It's copied from another community and manually translated from swedish

First "sketch"
I'm now more interrested in making it from sheet metal which will make a "edgier" look, the best part about that idea is that it'll require a lot less welding compared to a silencer made of both parts of pipes and sheet metal.
Shape: The hexagonal look of the original, but in one can.

The question is if I should try to make it "splitable" so I can easily open it and modify its inside.

Update: 2010-11-14

[pic of two design options]
alt1: easier to access for internal modification
alt2: probably easier to seal properly and less prone to break open

Blue text: Rivets
Red text: Weld


[Pics of the original XT660Z for comparison]


2010-11-14
[pic from the service manual showing the original exhast]

The "original setup"

Sketch (gotta love MS-paint =D ):
[A crappy sketch made in paint =P]



2010-11-18
The design idea is from a XR650R-silencer. The end plugs kan be seen here: http://forum.soe.se/showpost.php?p=358618&postcount=312
A friend of mine has that silencer with the louder "plug" and it sounds just about loud enough.


2010-11-21
Just a short update:

http://img812.imageshack.us/img812/91/imag0083p.jpg
Making a jig (is it called that in english? http://www.advrider.com/forums/image...eadscratch.gif )

http://img89.imageshack.us/img89/183/imag0085n.jpg

The current "sketch"
http://img19.imageshack.us/img19/9665/namnlswi.png




2010-11-22
Modification of the pipe that connects the silencer with the remain part of the original exhaust

"preview":
[outer tube held to place for a sneakpeak]


2010-11-23
A more accurate sketch:
[CAD model]



2010-11-23
The shape of the camfered endpiece before its shaped:
[CAD-drawing]



2010-11-23
Latest CAD-sketch
http://img832.imageshack.us/img832/2549/namnlst2.jpg

Todays work:
http://img842.imageshack.us/img842/1671/imag0093c.jpg

Comparison
http://img38.imageshack.us/img38/8587/imag0095d.jpg



2010-11-25
Miniupdate

The other wall is bent (again an uncertainty with english http://www.advrider.com/forums/image...eadscratch.gif )

And a couple of not too relevant pics

http://img197.imageshack.us/img197/6822/imag0106yb.jpg



2010-12-05
A small amount of work done today:

http://img34.imageshack.us/img34/607/imag01170.jpg



2010-12-10
Time for a small update

[Pic of interior design at that moment]

Left to do:
- Sealing it up
- Weld the chamfered endpiece to its place
- Making a bracket for the silencer
- Use the jig to get the "connecting pipe" welded in the right angle
- Soundcheck
- Possible post soundcheck modifications
- Painting
- Putting on the �bercool decal on it =D

2010-12-11
Update

PANIC!!!

I've run out of welding wire =(

Kvar att g�ra + lite omstrukturering


2011-01-09
Update

A few steps forward:

http://img684.imageshack.us/img684/8...ag0187i.th.jpg
Weight savings that are really hardcore racing cool, or something...

http://img839.imageshack.us/img839/5...ag0191j.th.jpg

http://img232.imageshack.us/img232/6...ag0194g.th.jpg



2011-01-14
http://www.youtube.com/watch?v=NJ0Z1gK2xkk

http://img146.imageshack.us/img146/9273/imag0195m.jpg

Whats left:
- post soundcheck modifications (some internal work and sealing it properly, by welding it)
- Painting
- Putting the �bercool decal on it

http://img828.imageshack.us/img828/4486/imag0200x.jpg
I guess the gasflow was a bit stronger than I anticipated

Todays work
http://img4.imageshack.us/img4/5893/imag0202i.jpg
Left side

http://img337.imageshack.us/img337/2226/imag0203k.jpg
Right side

http://img135.imageshack.us/img135/318/imag0204n.jpg
Assembled

The sound level has improved, it's acceptable now I guess, but I'll work more to make it more silent

Tomorrow (probably) I'll modify the other side of the interior wall in a similar way

A video clip where you can see the AIS working =D

http://www.youtube.com/watch?v=FI7fJlEcu2E

Close to being finished now:


http://img220.imageshack.us/img220/4445/imag0207p.jpg

http://www.youtube.com/watch?v=S3SPX355Lnw

Only exterior work left, like grinding down the welds a bit and painting it

Aparently there a restriction in the amount of pictures per post so I've deleted som pictures.

Great write up...Nice work!...... be great to see the finished project. Interesting how its made and put together.

Thanks :)

If anyone really wants to see the deleted pics they can be seen in these three posts:
http://www.advrider.com/forums/showp...postcount=3482
http://www.advrider.com/forums/showp...postcount=3493
http://www.advrider.com/forums/showp...postcount=3495

thats a great job you are doing there, how much weight have you saved ?

Great job Erik!
So good to see talented craftsmen in this forum! :YouRock:

Nice job mate, interesting design.

I only saved about 1,5kg, I think.
Next time I remove the silencer I'll try to see if I can find a somewhat more accurate scale.

Is there anyone here who knows the weight of the original silencer? :)

I think its 5,4 kilos.
I made mine at home and lost 3,2 kilos...

I checked the original which seemed to weigh 5,5 and mine was about 4kg.

Though I've got a lot of grinding left to do so I may save a few grams :tongue3:

Good to see you on here Erik.