Custom Devil Dual Underseat Exhaust System

Well, the first 2/3 of the topic was missing due to the forum crash, so here it is again from the top, sorry we lost all the other member's comments alonng the way, you guys make a great cheering squad!!!

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Well, I FINALLY :cool: booked out to the garage and started ripping and tearing the bike down for the exhaust project.

First thing on the menu of course was to remove all the tail plastic plus the stock undertray and battery box:

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This left me with a jumble of wires and such to deal with:

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Later, later. Let's start making stuff!

Next thing I did was to reinstall the tailsection plastic and hang the mufflers to get an idea of how everything would sit:

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Triple exhaust anyone?

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Width is good, about the same side-to-side as the later, smaller Dia. WOLF cans:

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They don't stick out much more than the Micron does, I'll wait to see how they sound before I decide to shorten them (or not):

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Yeah, I know, they need to be shifted to the right a bit. A man can only do so much with ZipTies:

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I decided to make the undertray in two pieces, one upper and one lower. The upper one sits aft of the round crossmember and mounts atop the subframe rails like so:

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The notches on the sides are for the passenger seat, so the appropriate bits sit flush with the subframe rails when the seat is installed. The notches toward the bottom of the pic are for the riders seat, so the two hooks can still hook underneath the round crossmember.

Here, the upper portion of the undertray has been drilled and riveted into place, fixing it to the subframe:

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I felt if I mounted it atop the framerails in this manner, it would leave me maximum clearance for the cans, moreso than the WOLF undertray pics I've seen to date. I plan to attach some aluminum angle to the underside of the upper part of the tray to enable me to hang the cans from with some band clamps. This is where using 1/8" Al sheet will begin to make sense as it will be a stressed member so to speak, holding the weight of the dual cans.

Now to do something about the forward portion. It needs to run underneath the subframe rails to provide clearance for the rider's seat pan. The plastic seat pan dips below the upper rails and would not clear if the forward tray were mounted up top. Here is the vacancy that needs to be filled. There's an old kid's snowsuit protecting my CF hugger so it doesn't get marred while I'm messing about:

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This is the simple piece I wound up with, 1 bend and cut narrower at the leading edge to clear the lower subframe rails. it's clamped in place as part of the fitup and in preparation for drilling and riveting:

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It will be riveted to the subframe and to the remains of the stock battery box which has been trimmed and rotated forward to allow more clearance for the Y-pipe that will connect the two mufflers.

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I'll have to make a small vertical filler piece to close the gap and have that welded in place to join the two levels of the undertray. Don't want to invite water and road grime through that huge opening, but the Hugger and the dual cans, they should block at least some spray.

I'm planning on removing the whole works this winter and having it powdercoated. For now, it'll stay as raw aluminum. B)

Next, I made templates of the sidepanels to check the fit:

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Clamped in place in preparation for riveting:

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This sucker ain't goin' nowhere:

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View from the outside, note 3/4" Al square tubing behind the steel plate that the R/R mounts to:

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Template and the actual cutout:

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Clamped in place for riveting:

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It's actually starting to look like something now:

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RH side view:

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Various shots showing how the forward portion attaches to the battery box:

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I may yet wind up modifying the undertray similar to this pic for more clearance:

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Next on the list is to make a slight mod on the forward portion of the undertray for more clearance and then fab the hanger brackets for the twin cans plus a rear support bracket for the taillight housing.

After that, I'll take the bike to Edmonton to have the custom up-pipe and Y pipe fitted. It'll look something similar to the WOLF plumbing except it'll be a 2" splitting into two 1.5" at the Y.

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I went another few rounds with the bike today. In the end, the bike won.

More about that later.

First order of business was raising the front portion of the undertray to allow greater clearance for the Y-pipe going into the mufflers. I gained 3/4" of clearance Versus the previous iteration.

Next, I set about fabricating supports for the taillight. I had read reports of the tailsections vibrating and cracking, so I made this contraption using the stock rubber grommets from the plastic undertray:

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I finalized the mounting brackets and got one can clamped in place:

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The problem arose when I installed the second can. The rear portion is spaced well, but the fronts are too close together.

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I'll have to remove them and space the leading clamps apart, possibly with some washers between the inner part of the T-bolt clamp and the drop mount.

Elevation and symmetry look good, just have to get the leading edges of the cans spaced apart 1/4-3/8" or so.

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I also got in touch with the guy who's going to be doing the custom connector pipe for me, and I'm taking the Viffer in on the 26th.

Can't wait to hear the V-4 roar from 2 mufflers at once!

Or as my wife so eloquently put it: "You paid 350 bucks for new mufflers so your bike could fart out the back instead of the side?"

Now the plate bracket is all finished up, the Micron has been removed, and the bike is currently in the shop getting the custom Y-pipe fabricated.

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Hey, I picked up the bike today and am very pleased with the workmanship.

Bike isn't really any louder than with the Micron, which is great. I didn't want the entire MotoGP grid every time I thumbed the starter button!

I didn't have my own camera there when I picked the bike up, but one of the local VFRdiscussion.com members had kindly snapped some shots for me and here they are:

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Here's two more I shot with my own camera, they're quite a bit sharper:

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Videos:

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:thumbsup:

Jet-Hot coated headers:

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Black ceramic coated undertray and subframe:

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Can't wait for spring! :cool: :music:

veefer800canuckCan't wait to hear the V-4 roar from 2 mufflers at once!

Or as my wife so eloquently put it: "You paid 350 bucks for new mufflers so your bike could fart out the back instead of the side?"

LOL!!

:lol:

Rob: Nice fabrication work. Highly impressive, and it ended up sounded great. Thanks for posting up with so many pictures and the video. :thumbsup:

Rob you did a fantastic Job on the mod A-1 stuff brother :thumbsup:

Could you take a picture of your hugger so that I can see how it mounts up or where it is bolted? Thanks

Can you tell me how many inches you have between your hugger and the pipes when its on the side stand? Any rubbing issues? Ever ride 2 up? Thanks, trying to set up my undertail.

SLO97VFRCan you tell me how many inches you have between your hugger and the pipes when its on the side stand? Any rubbing issues? Ever ride 2 up? Thanks, trying to set up my undertail.

I'll take a measurement tonight when I get home from work. There is a slight amount of rubbing if, for example, I hammer a set of railroad tracks riding two-up. Other than that, it's fine.

veefer800canuck

SLO97VFRCan you tell me how many inches you have between your hugger and the pipes when its on the side stand? Any rubbing issues? Ever ride 2 up? Thanks, trying to set up my undertail.

I'll take a measurement tonight when I get home from work.

Sorry for the delay, I measured and there's about 2.25" between the hugger and the Y-pipe before the dual cans.

You will probably be thinking "BUT, there's about 5" of rear wheel travel!!!"

Yes, but that 5 inches is directly vertical from the rear axle.

And the spot where I have ~2.25" of clearance is ~11 inches forward of the rear axle.

FWIW, there's approx 21" between the swingarm pivot and the rear axle.

Thanks for that! How much would you say you have from the top of the tire to the mufflers? I think I may just have to run without my hugger for mine to work. I only have about 3-3 1/2 inches from top of tire to muffler right now. If I flip the eccentric I pick up an inch but run into other issues -( chain riding on top guide rails & slight hitting of center stand if too loose ). Maybe Ill get this figured out yet..... Is 5 inches the magic number I am after from top of wheel you think?

There is perhaps another 1/2" without the hugger, but then, hugger brands/mounting locations/years of VFR are all different.......

I realize that this was a while ago but I hope you're still up for questions. I was wondering what you did with the PGM-FI UNIT that mounts in the tail section under the passenger seat? Now that you have had it out are you having any heat issues with either the seat or the wiring?

Thanks

mini

miniI realize that this was a while ago but I hope you're still up for questions. I was wondering what you did with the PGM-FI UNIT that mounts in the tail section under the passenger seat? Now that you have had it out are you having any heat issues with either the seat or the wiring?

Thanks

mini

Hi Mini, the ECU has been relocated to the LH side of the tailsection, under the plastic, aft of the R/R.

As for the heat, there is a bit of heat when stopped in traffic on a hot day, but the ceramic coating on both the pipes and the subframe/undertray helped a lot.

Wow! Awesome write up. I'm going to attempt this but with a few alterations to the undertray I think. We'll see how it goes. I do have a quesiton regarding the Devil pipes, what length and diameter are they? I assume they work well but I'd like to find pipes the same size as yours to make the system easy. I will be riding two up and I want to ensure I minimize the rubbing as much as possible. I don't know where I'll find a muffler guy to make the Y-pipe and mid-pipe but I'm sure there has to be someone who can help around the Boston area. Thanks again for all the detailed informaion.

Just a thought, would one of the GSXR, R6, Ninja Moto GP slip-ons work? They are shorter, have baffles (although small) and are relatively cheap and would look bad-ass mounted as duals. here's a link to one on ebay.

ebay megaphone

Man great job just awesome.. :biggrin: the guy that built the pieces could build a header system?? the connector pipes look great nice finish just awesome...I one day will attempt to get a true header made for a 6th gen with the expansion pipes between the down pipes like an araknapovic showing wields like a dirtbike prociruit pipe..until then i will dream ...

Very nice wokmanship it looks great!

Open your EBAY Store. Looks Good

Thanks guys, it looks even better now that the undertray has been welded up (the rivits are still there, just had all the seams welded solid) and also the entire undertray and subframe are ceramic coated in heat-resistant flat black.

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That's Hispanic Slammer standing behind the bikes, not smiling and waving. wink.gif

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There's an old school part of me that would love to see four reverse cone megaphones coming out from the rear of a VFR.

I know this is a dinosaur thread but did you notice any performance gain after your header was Jet Hot coated? I called to inquire and the salesman claimed a 300 degree drop in skin temp and a 10% power gain.10% seems like a pretty big number...... I still want it, I'm just curious if you gained any power. Thanks :)

Ask the salesmanto put in writing he will reimburses the cost of coating and 2 dyno runs to you if the dynocharts (one before and one after coating) donot show 10% increase.... :laughing6-hehe:

Dutchy

Ask the salesmanto put in writing he will reimburses the cost of coating and 2 dyno runs to you if the dynocharts (one before and one after coating) donot show 10% increase.... :laughing6-hehe:

That's a good idea, maybe I can get him to do a custom map for an "after" run, lol He can reap the benefit of a big increase and I get my bike to run better! Sounds good to me, I don't know if he'll agree though, lol..... ;)

I coated mine, and I dont know if it really improved the HP, but it def dropped the temps a bit. Oh, and it looks awesome too... that helps

xerox

I coated mine, and I dont know if it really improved the HP, but it def dropped the temps a bit. Oh, and it looks awesome too... that helps

Sold! Lol I wanted Orange but they don't have it here. Funny, I would think there would be a demand for the Chevy guys :/ lol I think I'm going to go with the sterling though. Do you have pics of yours anywhere and VFRD? TIA

I have no idea about power gains as the bike was not dynoed before/after.

I know that with the highmount Micron that was on there before, I dynoed 100.6 HP, but that was a couple years before I put the new exhaust on.

The bike has not been to the Dyno since, but if I get an opportunity, I'd try it again.

I know it would not be comparable, two different dynos, 4 years apart, etc, etc.

But I'd do it anyhow say, if a local dealer were having an Open House ot similar and had the dyno trailer parked out front for ~20 bucks a pop.

All I can say for sure is that, seat of the pants, the bike feels as strong as ever, and I've owned her since 2000.

Somebitch!!! That looks good! Great work.

Thanks guys! :)

Hello to all. Honored to be a part of this community. I've had a 2000vfr for a year now. I absolutely adore my Vfr. So to get to the point. Does u know where I can get a D&D can in gta(greater Toronto area)? As well in the aluminum models, do the black & silver sound the same? By now thanks.

Check out the Ontario VFR Mailing List. I just sold a D&D muffler to someone there for their VFR.

http://www.vfr.on.ca/club/mailing_list.html

Very nice fab work!!

Veefer800Canuck

:thumbsup:

Jet-Hot coated headers:

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Aaah! Gorgeous! I'm sold on it.

Sorry to dredge up an old thread, I was just linked to this thread by Veefer. That is exactly what I want!

do you remember what the diameter of the cans were? thinking of going down this road someday :wheel:

I could pop out to the garage and measure them if you like.

they are smaller in diameter than most.

yeah i am interested to know, ive been eye balling a pair of Dan moto titanium cans that a buddy has left off of his z1000... they're 2" inlet which seems like it may be a hassle but maybe they sell smaller inlet/diameter cans

OK, BRB.

3.341" diameter, 16.75" length (canister body only, excluding inlet and outlet spigots)

Inlet spigot I.D. for the cans is 1.625"

Veefer800Canuck

OK, BRB.

3.341" diameter, 16.75" length (canister body only, excluding inlet and outlet spigots)

Inlet spigot I.D. for the cans is 1.625"

awesome thanks so much for the prompt info :)

Looking at Dan moto cans are 3.54" around and a sleeve length of 11.8" with 2.02" inlets... Length and inlet seem ok but wondering if the cans are too large in diameter to fit in there side by side...

FYI:

They said they do custom specs too in case anyone was wondering... It's $305 shipped for 2 cans custom made with titanium sleeves, the carbon should be a little cheaper. $275 for their standard spec cans. Good email response time too, especially for Hong Kong or where ever.

it doesn't sound like much, but that's an extra centimeter for both cans combined.

I can have a look and see if they might fit, but it would be really close, if at all.

Veefer800Canuck

it doesn't sound like much, but that's an extra centimeter for both cans combined.

I can have a look and see if they might fit, but it would be really close, if at all.

its more food for thought anyhow no worries on looking, im looking at photos and it looks as if the cans will fit but i would have to stagger the mounting clamps if they were that size. When i get around to it i will probably shell out the extra $30 and make them 3.25" around with a 1.5" inlet and their standard 12" length

Daword, there are some GPR silencers on EBAY right now and they have an 80mm outer diameter. That's 3.15 inches, so they ought to fit fine. Don't know what the inlet ID is though.

Anyhow, just tossing that out there:

http://www.ebay.com/itm/EXHAUST-SYSTEM-GPR-HONDA-VFR-800-RC-46-TILL-2001-GPR-TH-/250846524659?pt=Motorcycles_Parts_Accessories&hash=item3a679e34f3&vxp=mtr

Bet they sound good too with the size. Little 'spensive but thank you for the update and thoughts :)

You might contact the seller and see if they would give you a Bro Deal if you bought two of them???

This looks amazing! Great job! Really cleans up the tail and shows off that SSSA!!!

Thanks DM.

The bike has changed a LOT since I started this thread ages and ages ago, but the exhaust system is still going strong with no issues!

I'm really glad I took the time and effort to get it all worked out on the bike, it has totally been worth it.

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Sorry to drag this back - looking for info to help me in a decision. Questions will be for all those who have designed/built a custom underseat setup.

Long term I want to replace the stock exhaust setup on my gen5. I love the underseat look as it show off the single side swing arm and why in the past I have owned 2x gen6's.

If I don't go underseat then it will Staintune high mount. Question time.

1. Have you made rear suspension mods to give extra clearance for the underseat setup?

2. The cans/slipons you chose what length and outside diameter are they?

3. With the info above in question 2 did you shorten them to fit them? Or unmodified used as delivered?

4. If you were to do it again would you do anything different?

For me an underseat conversion is a long term project.

Again this is for those that have done this before aka Veefer800Canuck, sa1713 and others.

Thanks in advance Mike from New Zealand.

Hi nzeder

I'll answer your questions as much as I can, I'll have to take a quick measurement of the cans when I am at home.

1: Yes, I raised the rear ride height as much as possible by shimming the upper shock mount, so that the lower shock eye was as close as possible to the suspension dogbone, without hitting.

2: measurements needed

3: No, did not shorten them at all.

4: I really like the outcome, I don't think I'd change anything, aside from perhaps having the pipes fabricated from stainless steel.

Hello nzeder,

My response is about the same as Rob's:

1. Have you made rear suspension mods to give extra clearance for the underseat setup? No, as my WP shock is ride height adjustable and my original settings work.

2. The cans/slipons you chose what length and outside diameter are they? I used Jamma Lazer Xtreme stainless steel cans. They are about the same diameter as Rob's which is about 76mm and the lengths (I used a non-matching pair) are 330mm and 355mm.

3. With the info above in question 2 did you shorten them to fit them? Or unmodified used as delivered? I used the Lazers as delivered.

4. If you were to do it again would you do anything different? Nope. I am extemely pleased with the outcome.

My up-pipe was made by a local fabricator who can replicate it upon request. He can add length to the outlets if you are unsure of the total length needed. All you will have to do is a final measure and cut.

Let me know if I can help with your mod.

Jim

Veefer800Canuck

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This is the best looking 5th gen I've seen by far. Great work!!

Thank you kind sir!

I have long winters and a big toolbox. Idle hands and all that.........

sa1713

Hello nzeder,

My response is about the same as Rob's:

1. Have you made rear suspension mods to give extra clearance for the underseat setup? No, as my WP shock is ride height adjustable and my original settings work.

2. The cans/slipons you chose what length and outside diameter are they? I used Jamma Lazer Xtreme stainless steel cans. They are about the same diameter as Rob's which is about 76mm and the lengths (I used a non-matching pair) are 330mm and 355mm.

3. With the info above in question 2 did you shorten them to fit them? Or unmodified used as delivered? I used the Lazers as delivered.

4. If you were to do it again would you do anything different? Nope. I am extemely pleased with the outcome.

My up-pipe was made by a local fabricator who can replicate it upon request. He can add length to the outlets if you are unsure of the total length needed. All you will have to do is a final measure and cut.

Let me know if I can help with your mod.

Jim

My answers are (not surprisingly, since we used the same fabricator!) very similar to Jim's.

1. Have you made rear suspension mods to give extra clearance for the underseat setup? No mods, apart from the fact that I have a Penske, which is adjusted as high as it would go w/o interference w/swing arm (IIRC). I used to have a Harris carbon fibre hugger, but it did get munched between the tire and the end cans, so I chopped it considerably. Perhaps a little more rear ride height wouldn't have hurt...

2. The cans/slipons you chose what length and outside diameter are they? My Lasers were intended for an early CBR600RR, I think. Sorry, I don't have the specs handy.

3. With the info above in question 2 did you shorten them to fit them? Or unmodified used as delivered? Standard.

4. If you were to do it again would you do anything different? Can't think of anything right now. I had Dan make me some "dB killer" inserts, and wanted him to make me some "race" inserts, but given how loud the system is with the "road" inserts installed, I don't think I would be using them anyway.

I've uploaded a short video clip to my gallery, so you can hear it in action. (Sorry for hijacking your thread, Rob!)

Ciao,

Yes thanks for the reply's and slight highjack :biggrin: all that info is good to know - sounds like everyone with a custom underseat setup has some form of suspension mod/height adjust-ability. Love all your guys bike, Rob, Jim and John a credit to you all. I can only assume the old wolf setup if no suspension mods were required would have been very small diameter end cans.

I will start my own thread once I start on a underseat exhaust project - I just have 2 others that need to be finished before I start - one of which I need to move on (reads sell to raise the $$ for the other + the VFR mods)

Cheers guys

Mike

One of the things I wish was different on my underseat exhaust is the profile of the up pipe in the section immediately in front of the rear wheel.
I don't know if it's feasible to do, but if a fabricator could bend/pound the up pipe into an oval profile in that section, it would go a long way towards solving cleareance problems, particularly with huggers.

Man I wish it was possible to rig something like this up for the 1200F, great work! (I only assume it's not possible since nobody has done it yet?)

ggathagan

One of the things I wish was different on my underseat exhaust is the profile of the up pipe in the section immediately in front of the rear wheel.

I don't know if it's feasible to do, but if a fabricator could bend/pound the up pipe into an oval profile in that section, it would go a long way towards solving cleareance problems, particularly with huggers.

My 6th gen Remus system leaves just barely enough room to clear the hugger. I can't even get my little finger in between. It's never rubbed but is definitely a tight fit.

iamzombie

Man I wish it was possible to rig something like this up for the 1200F, great work! (I only assume it's not possible since nobody has done it yet?)

Thank you Zombie.

The exhaust system is surviving nicely. No packing burnout or anything. Cans still look great and the sound is like a proper V-4.

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Very nice work.

:fing02:

Dusty thread alert! Cough cough!

Like classic bikes, some threads never go out of style . . .

The GL800RR and Seb's street fighter, I never get tired of looking at either of them.

Got dang that is sexy!!


Sent from my iPhone using Tapatalk

Did a re-read on this thread... Still - great review on all the work Rob.  :fing02:

mello dude, 2017-06-03 at 8:06 PM

Did a re-read on this thread... Still - great review on all the work Rob.  :fing02:

Dusty thread alert, haha. 

Pleased to say its all still working just fine! 

IMG_6912.MOV

Veefer800Canuck, 10/26/2014 at 9:23 PM

Thank you Zombie.

The exhaust system is surviving nicely. No packing burnout or anything. Cans still look great and the sound is like a proper V-4.

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I thought the bike look awesome in red but Wow.  The color combo you put together here is incredible.  That's the way the Honda should have sold it from the factory.  Nice job.......

15 hours ago, alwaysaware

I thought the bike look awesome in red but Wow.  The color combo you put together here is incredible.  That's the way the Honda should have sold it from the factory.  Nice job.......

Thanks!

i spent all winter of 2009 obsessing over the paint scheme!

Great work on this mate. Had an old wolf exhaust on a previous bike and would love to go down the same route as you did. Here in Poland, we don't have great affordable options (zl vs. euro/pounds) and a dual aliexpress akrapovic can setup is being researched... so thanks for the dimensions! 

Have to ask, did you do any tuning after the setup? Do you, or anyone, know if going from one can to two, without "special" VFR cans, could be detrimental to performance? My mechanic friend was saying that with my current aftermarket + a new pipercross air filter, I should have some custom tune done for long term reliability. Guessing two cans would change the dynamic that much more? Perhaps a stupid question, just not familiar with the relationship between it all. 

Thanks! 

dozyproductions, 9/25/2019 at 1:07 AM

Great work on this mate. Had an old wolf exhaust on a previous bike and would love to go down the same route as you did. Here in Poland, we don't have great affordable options (zl vs. euro/pounds) and a dual aliexpress akrapovic can setup is being researched... so thanks for the dimensions! 

Have to ask, did you do any tuning after the setup? Do you, or anyone, know if going from one can to two, without "special" VFR cans, could be detrimental to performance? My mechanic friend was saying that with my current aftermarket + a new pipercross air filter, I should have some custom tune done for long term reliability. Guessing two cans would change the dynamic that much more? Perhaps a stupid question, just not familiar with the relationship between it all. 

Thanks! 

Hey thanks! 
 

no, the bikes fueling is totally stock

no power commander or anything 

it runs just fine, no issues at all