Also for whats its worth, I am no longer using the expanded metal. I liked the sound but not totally satisied. so I bought generic exhaust pipe. It was 1 7/8 diameter. then used a transition to 2 1/4 at the end that was cut on an angle to fit against the end cap.
One pipe was left straight. the other has several 1/2 inch holes in it midway down the pipe.
The straight pipe is louder with a higher frequency. the other pipe is deeper but quiter.
I have moded these time and time again, trying to get the best sound. Also even though they are piped the way they are, they both have 4stroke race baffeling material in them. It helps keep the outside of the can cooler. If not, it gets super hot.
It's the original size of the factory cans. I didn't cut them down and the cat is still in place.
I have to figure out how to post a video so be patient.
Also the trick is to design each can to the sound or tone you want by trying different inner pipe designs.
I learned that if u want loud pipes u will lean more towards a straight pipe design, but with a few holes in the pipe for some sound absorbsion.
I noticed that a straight pipe is loud but has a higher pitch. The more u allow to baffle the sound from the holes, the quiter but deeper tones.
So I have 2 pipes that are not the same for the best sound that I liked. I used large screws to hold the end cap on the pipes so I could disassemble and redesign the inner pipe and baffle with ease until I was happy.
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Awesome post! Thanks. Just got this done, the stock baffles comes out alot easier if you drip some WD40 into the gap and let it settle. Mine practically slipped right out after a few taps with the vice grip method.
Took me around 5 hours all up...but that's because I didn't have all the tools and I cut/measured/re-cut my perforated steel tube from a 1 meter tube. Ended up costing me around the same as if I just bought the race baffle kits on eBay 'cept those are already cut to size and angle. If you get the precut kits, removing stock exhausts should take about 10mins (seriously easy!!!) and u'd probably spend an hour or two drilling out the rivets and spot welds, then it's smooth sailing from there.
Apparently the 05's uses a 2" perforated tube, and the 07's use a 2.5"... That's the only difference between the year models.
Oh another advice, get some washers with 5mm internal hole diameter. The factory baffles are what the stock rivets rivet to, you'll be removing those and the holes on the titanium skin are way too big to rivet again, that's when you'll need the washers, glue it to the inside of the titanium shell and rivet against the washers instead. The black cone also has a 5mm diameter hole so the washers will be a perfect fit. That's what took me a while because I can't find the right washers so I had to use 3/16" washers and drill it out with a 5mm drill bit. Warped around 20 washers before I finally got my 8 good ones.
I finished my conversion today, used 50mm pope with 3mm holes. Right now it seems unbelievably loud. Maybe things will settle down? This mod is nice and stealthily though so thanks to all the contributions in this thread