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:


Making a jig (is it called that in english? )



The current "sketch"





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


Todays work:


Comparison




2010-11-25
Miniupdate

The other wall is bent (again an uncertainty with english )

And a couple of not too relevant pics





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





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:


Weight savings that are really hardcore racing cool, or something...







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



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


I guess the gasflow was a bit stronger than I anticipated

Todays work

Left side


Right side


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://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.

__________________
Previous bikes:TS50 - RD125LC - XT250 - ZXR750L3 - BMW 650 Funduro - BMW 1100GS - XT660Z Tenere

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 ?

__________________
Ride On :tenere:Camel 2008XT660Z
harvey mushman did it in the dirt Uma 1994 TT250R

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

__________________

Nice job mate, interesting design.

__________________
Click here to join the XT Supporter's scheme

Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946