build custom exhaust VN800 - Kawasaki Vulcan Forum : Vulcan Forums
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post #1 of 13 (permalink) Old 08-02-2016, 12:48 PM Thread Starter
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build custom exhaust VN800

OK so I have my 800 pretty much the way I like it for now, only things I have left to do this season is design and install a custom exhaust and maybe get the bike painted if budget allows, anyway I have been looking at all the alternatives on the market for our bikes and I must say they are impressive for sound but are kinda lacking is original design, to me a great looking exhaust is as important as a great sounding exhaust.

I know I am going to get slammed but the one I like the most is the Harley Fatboy design as pictured below, with our Vulcan having similar lines (at least mine does now after some suspension work and bolt ons) I think this would be a great looking exhaust:

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My next selection is the Highway Hawks slash cuts:

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I am working on a photoshop of the FatBoy exhaust on my bike and will post it when it done, guys help me out here post pictures of your aftermarket or custom build exhausts systems, thanks.

2002 VN800 as it is now, stock exhaust de-baffled

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2002 VN800B, 6" DYI forward controls, EPA system removed, baffles removed, DYI lowered 2 inches in rear , 2" riser, mustang solo seat, re-geared to 18T/42T, scooterized and re-jetted carb, chrome rear fender rack, led headlight, old school leather saddlebags, billet chromed foot pegs, ISO hand grips

Last edited by jfl1960; 08-02-2016 at 02:00 PM.
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post #2 of 13 (permalink) Old 08-02-2016, 04:25 PM
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you in usa?

Thunder Mfg teardrop 40's K&N 170MJ 48PJ 2.75turns DynoJet Needle DNO106 2nd notch V&H Cruzers Aeromach risers Michelin Commander IIs Wix 51358 filter 17T/40 Sprockets, 2357 rear bulbs
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post #3 of 13 (permalink) Old 08-02-2016, 07:42 PM Thread Starter
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Canada eh!

2002 VN800B, 6" DYI forward controls, EPA system removed, baffles removed, DYI lowered 2 inches in rear , 2" riser, mustang solo seat, re-geared to 18T/42T, scooterized and re-jetted carb, chrome rear fender rack, led headlight, old school leather saddlebags, billet chromed foot pegs, ISO hand grips
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post #4 of 13 (permalink) Old 08-03-2016, 11:21 AM
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did your bike ever have a scootworks belt drive on it? are you on the east coast? or Ontario, I might know of your bikes history or might not, depends where you are at, maybe your 2002 B is a different bike than I am thinking of

Thunder Mfg teardrop 40's K&N 170MJ 48PJ 2.75turns DynoJet Needle DNO106 2nd notch V&H Cruzers Aeromach risers Michelin Commander IIs Wix 51358 filter 17T/40 Sprockets, 2357 rear bulbs
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post #5 of 13 (permalink) Old 08-03-2016, 01:05 PM
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I made a 2-1 exhaust for my 05 800 Classic a couple years ago. Mine had no baffles, but should not be too hard to install some if you like. I did double wrap the head pipes because the heat from he rear pipe was burning a hole through my jeans, the 2nd wrapping stopped that. Could also made/buy custom heat shields to prevent this.
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2005 800 classic
2012 Voyager ABS
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post #6 of 13 (permalink) Old 08-03-2016, 01:19 PM Thread Starter
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Nope never had Scootworks belt drive, thought it would be cool and looked into it but found not worth the hassles in the long run, Scootworks are historically slow on delivery times and the belts are unavailable anywhere else, they also seem to be unreliable with modded bikes snapping belts under heavy throttle, and I am a throttle whore so not a good combination, the chain is messy but strong and easily replaced on roadside if need be, and I have a cheap spare with me at all times. Re-geared to 18T front and 40T rear gave me same drive ratio as the belt drive, better on highway.

This bike is from eastern Canada, at least that's where I bought it and where I live, Cape Breton, Nova Scotia. Bought it from a dude in North Side East Bay, Cape Breton NS. Have had it since May 2015. Was basically bone stock when I got it.

BTW just scored this set of 2003 anniversary FatBoy pipes for $80.00 Canadian delivered, was told these were removed from the bike at the dealership and replaced with V&H Pipes, they look brand new inside and out, owners kept the pipes and is now clearing out basement I found them on Kijiji. Can't wait to get started, for $80.00 I couldn't even get enough tubing to do an exhaust let alone chromed and with heat shields and already formed bends, this is going to be interesting..

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2002 VN800B, 6" DYI forward controls, EPA system removed, baffles removed, DYI lowered 2 inches in rear , 2" riser, mustang solo seat, re-geared to 18T/42T, scooterized and re-jetted carb, chrome rear fender rack, led headlight, old school leather saddlebags, billet chromed foot pegs, ISO hand grips

Last edited by jfl1960; 08-03-2016 at 04:04 PM.
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post #7 of 13 (permalink) Old 08-03-2016, 01:28 PM Thread Starter
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Quote:
Originally Posted by rick View Post
I made a 2-1 exhaust for my 05 800 Classic a couple years ago. Mine had no baffles, but should not be too hard to install some if you like. I did double wrap the head pipes because the heat from he rear pipe was burning a hole through my jeans, the 2nd wrapping stopped that. Could also made/buy custom heat shields to prevent this.
Nice, that looks slick,most exhausts I see for our bike do not flow with the lines if you know what I mean, they do the job but look like there was little to no thought put into the design, yours definitely flows and that and that's what I am after, great job and I am now torn between what I had in mind and what you did. Thanks for the pics.

2002 VN800B, 6" DYI forward controls, EPA system removed, baffles removed, DYI lowered 2 inches in rear , 2" riser, mustang solo seat, re-geared to 18T/42T, scooterized and re-jetted carb, chrome rear fender rack, led headlight, old school leather saddlebags, billet chromed foot pegs, ISO hand grips
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post #8 of 13 (permalink) Old 08-03-2016, 11:18 PM
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Quote:
Originally Posted by jfl1960 View Post
Nice, that looks slick,most exhausts I see for our bike do not flow with the lines if you know what I mean, they do the job but look like there was little to no thought put into the design, yours definitely flows and that and that's what I am after, great job and I am now torn between what I had in mind and what you did. Thanks for the pics.
With the tubing and having it bent, plus the 3"x24" exhaust tip I used as a "muffler", I had about $50 into it plus 2 packs of exhaust wrap. Total investment was less than $100. I used all of the stock front tubing. The rear tube is where I used new stuff. The welds are not the prettiest, but I did this with a wire feed gasless welder, and know I would be using wrap to cover them.
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2005 800 classic
2012 Voyager ABS
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post #9 of 13 (permalink) Old 08-04-2016, 06:39 AM Thread Starter
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Quote:
Originally Posted by rick View Post
With the tubing and having it bent, plus the 3"x24" exhaust tip I used as a "muffler", I had about $50 into it plus 2 packs of exhaust wrap. Total investment was less than $100. I used all of the stock front tubing. The rear tube is where I used new stuff. The welds are not the prettiest, but I did this with a wire feed gasless welder, and know I would be using wrap to cover them.
very nice, how does it sound any sound clips you could share?

2002 VN800B, 6" DYI forward controls, EPA system removed, baffles removed, DYI lowered 2 inches in rear , 2" riser, mustang solo seat, re-geared to 18T/42T, scooterized and re-jetted carb, chrome rear fender rack, led headlight, old school leather saddlebags, billet chromed foot pegs, ISO hand grips
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post #10 of 13 (permalink) Old 08-04-2016, 06:01 PM
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All I can say is LOUD! I have since bought another set of stock pipes and removed only the rear most baffles, it tended to drone on long rides were now it mellows out at speed. I could have probably put baffles in it but got a set cheap. Its very close to the stock pipes without any baffles as far as sound goes. I do still have this system and may reinstall with baffles later.

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2012 Voyager ABS
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