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post #91 of 105 Old June 8th, 2015, 07:48 AM
 
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Re: Triple Pass Universal Muffler Install

I have the parts arriving today from Summit Racing to duplicate machinistika's exhaust setup. The 17909 muffler and resonator. Total cost was $104. I also picked up a can of high temp heat paint to black it all out. I will post a video after the install.

As far as preliminary data - I download a free sound meter in my android phone and was getting about 95db at idle in the drivers seat, 110db steady driving. I will report back my findings after I complete the install. Another thing I did while the bed plastic is off was add a full aluminum heat shield with dynamat on the top side. I checked the sound level at idle with just it laying over the motor (no bed installed) and the sound level dropped to 89db just from that.
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post #92 of 105 Old June 8th, 2015, 07:24 PM Thread Starter
 
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Re: Triple Pass Universal Muffler Install

Quote:
Originally Posted by PA_Probe View Post
I have the parts arriving today from Summit Racing to duplicate machinistika's exhaust setup. The 17909 muffler and resonator. Total cost was $104. I also picked up a can of high temp heat paint to black it all out. I will post a video after the install.

As far as preliminary data - I download a free sound meter in my android phone and was getting about 95db at idle in the drivers seat, 110db steady driving. I will report back my findings after I complete the install. Another thing I did while the bed plastic is off was add a full aluminum heat shield with dynamat on the top side. I checked the sound level at idle with just it laying over the motor (no bed installed) and the sound level dropped to 89db just from that.
Interested to see how this works out for you guys using the added resonator. I had concerns about exhaust restriction with just the muffler, but they didn't amount to anything. Will be curious if you see more engine heat with the added resonator. My only means to check for excessive heat was if the radiator fan seemed to cycle more than before or more than my buddy's machine when we rode together. With just the universal muffler the answer was no.

Da Blue Toad
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post #93 of 105 Old June 11th, 2015, 08:50 AM
 
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Re: Triple Pass Universal Muffler Install

An update on where I am with the exhaust fabrication. I have everything mocked up as far as fitment. I found that the resonator hits the reservoirs on my YZ450 rear shocks that I am running. The rear body\bumper frame extension limits how high I can place the resonator. I have it removed and will be cutting out the angled portion of that bracket and fabbing something else to all for the clearance I need. My plan is to have the muffler, u bend and resonator removeable out the passenger side if I ever need to. I will be welding the pieces together tonight and should get an idea of the sound level.

Here are some pics that I have taken thus far.
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post #94 of 105 Old June 13th, 2015, 07:10 PM
 
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Re: Triple Pass Universal Muffler Install

I got everything welded together and took it for a ride today. I am very pleased with the results. Sound levels were reading 80-82 decibels at idle and about 90-95db at my usual pace of 10-15mph with the kids in. The first ride I took myself, I had to go about 200yds down the paved road and thought something was wrong with my RZR because it was making a funny sound. But it was just the sound of the tires on the road that I normally don't hear. The idle and low RPM exhaust tone is that of an econo car (low and powerless) which is what I figured it would be. It is quieter which is the main thing I wanted. There is a raspy tone\buzz that shows up between 4500-4800rpms. Not a deal breaker as I am usually just below that level while cruising. If you go WOT, it actually sounds pretty good IMO. There is a loss in throttle response from what my right foot could tell. The little hills that I usually just gave a little more throttle on took just a little more to reach the same speeds. I am happy with it. The ride was much more enjoyable with family. I saw about twice as many deer too. I do need to add a hanger to the drivers side end of the glass pack. It was hanging lower than I expected after the ride was over. You will notice that I still have my rear sway bar on. I have a Vent Racing 2+2 cage on back of my RZR so it can be a tad top heavy and I like that the sway bar helps with that, so I will not be removing it. There was no paint rubbed off the pipe after the ride so I don't think it ever impacted the pipe.

I will post videos with audio tomorrow. Hopefully they give a true representation of what it sounds like. I will also compile a detailed list of parts that I used. I think it was a combination of noise eliminating projects that I completed to knock the sound levels down to what I wanted. Headers wrapped, full heat shield with dynamat, and the exhaust modification.

Here are the pics. Take an easy on my amateur welding skills. I use my dad's welder about twice a year so they are what they are - crappy.

Here is my final list of parts I used. I had access to a welder so I did not need as many clamps as listed. With my setup, I can take the clamp off the stock pipe to 17909 muffler connection and my elbow tail pipe and slide the main muffler assembly and glass pack out the passenger side above the tire.

Everything was ordered from Summit Racing
(1) - Walker Exhaust 17909 - #22.97
(3) - 1 3/4 Clamp - PTE-H7174 - $5.91
(1) - 1 3/4 U-bend - PTE-H7023 - 13.97
(1) - 1 3/4 Connector - Walker 41926 - $3.97 (used wider side only to sleeve over elbow)
(1) - JEX 1 3/4 inlet Glasspack - JEX-A3018S - $19.97
(1) - 1 3/4 Elbow - WLK-41000 - $6.97
(2) - Exhaust Hangers - WLK-35103 - $11.94
(1) - Rustoleum Black Heat paint - 248903 - $6.97
(2) - 2" Exhaust Clamps - WLK-36145 - $9.94 (I welded most of my connections so I did not need these)

Total cost - $102.61
This puts you over the $100 mark and qualifies you for free shipping.

Quick overview of assembly:
Start by cutting of 1.5"-2" off each end of the tailpipe and glasspack. I did this to shorten things up overall. Leave enough pipe to fit a clamp on when assembling everything.
I cut slots on the inlet end of the muffler as it was a tight fit to get it over my stock exhaust pipe.
Slide the new muffler on and clamp it with a 1 3/4 clamp.
Cut your U bend in half at the middle of the bend.
Now you have 2 peices, take one half and stick the cut end in the muffler.
Take the other half and stick the cut end in the glass pack.
Mark a line on each where they overlap and cut off the excess.
Now take the 1 3/4 connector adapter and cut the wider end off to use as a coupler for the u-bend pieces. I welded this section of pipe up on mine as I thought it would look thrown together with all the clamps it would need.
Attach the bend pipe to the glass pack.
On the exit end of the glass pack I used an elbow. However the elbow was the same diameter as the glasspack so I used a straight peice of 1 3/4 pipe form the U-bend I cut off and slid it inside the elbow and the glasspack. I used a 1 3/4 clamp here as well. I needed this tailpipe to be removable so I could slide it out through the frame.
Then swap the stock spark arrester to the end of the tailpipe.
Attach exhaust hangers in location that you feel will support the exhaust well. I mounted one in the middle of the bend between the muffler and glasspack and one where the tailpipe comes off the glasspack.
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Last edited by PA_Probe; June 16th, 2015 at 08:50 AM.
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post #95 of 105 Old June 16th, 2015, 06:37 AM
 
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Re: Triple Pass Universal Muffler Install

Here are the videos I recorded of the exhaust. I will try to get some drive by style videos too.
https://www.youtube.com/channel/UCKN...YsiT5wee7I-k7A

Walk Around

Idle and 15mph ride

0-50 MPH

Last edited by PA_Probe; June 17th, 2015 at 08:30 AM.
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post #96 of 105 Old June 17th, 2015, 08:21 AM
 
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Re: Triple Pass Universal Muffler Install

Additional Videos on my Youtube Channel

https://www.youtube.com/channel/UCKN...YsiT5wee7I-k7A

Last edited by PA_Probe; June 17th, 2015 at 08:29 AM.
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post #97 of 105 Old June 30th, 2015, 10:08 AM
 
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Re: Triple Pass Universal Muffler Install

I'm about to dive into this one this week, I think, all the parts arrived yesterday.

I'm doing this to a '12 rzr 4. Do I need to pull the bed? If so I want to heat shield it while I'm in there. Guess I'll pull the swaybar as mentioned.

Toad et al,

Where did you guys mount the hanger where it won't melt? Picture would be great...

I'm also dynamatting the panels between the back seats and the engine/belt etc, covering the two big holes under the seats where noise can come through, and maybe filling that area with some sort of batting, though I suspect it will be a huge water/mud sponge..

Greg
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post #98 of 105 Old June 30th, 2015, 10:23 AM
 
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Re: Triple Pass Universal Muffler Install

Pulling the bed was easy. Only takes about 10 minutes. It is easier to work with it out of the way. If you are doing the full heat shield, it needs to come off anyhow. The peice of aluminum i used was from Lowes. it was 24x48 and cost $38.

I did not remove my rear sway bar. There is enough room to leave it there. Some people remove it because the ride is better without it but I have a 2+2 rear cage and like the stability it gives me.

I mounted one hanger from the U bend part of the setup and it is bolted through the angled frame rail above the new muffler. My pics are a couple posts up.

I put a second hanger on the drivers side right after the glasspack and it bolted to the square bar that is under the bed. I put it on after I put the plastic\bed back on.

I ran out of dynamat or I would probably have done the back seat panels like you are doing.
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post #99 of 105 Old June 30th, 2015, 10:25 AM
 
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Re: Triple Pass Universal Muffler Install

Quote:
Originally Posted by PA_Probe View Post
Pulling the bed was easy. Only takes about 10 minutes. It is easier to work with it out of the way. If you are doing the full heat shield, it needs to come off anyhow. The peice of aluminum i used was from Lowes. it was 24x48 and cost $38.

I did not remove my rear sway bar. There is enough room to leave it there. Some people remove it because the ride is better without it but I have a 2+2 rear cage and like the stability it gives me.

I mounted one hanger from the U bend part of the setup and it is bolted through the angled frame rail above the new muffler. My pics are a couple posts up.

I put a second hanger on the drivers side right after the glasspack and it bolted to the square bar that is under the bed. I put it on after I put the plastic\bed back on.

I ran out of dynamat or I would probably have done the back seat panels like you are doing.
Thanks, I'll just pull the bed. Do you have a link to the shield you built? I'd like to see pictures!!
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post #100 of 105 Old October 21st, 2015, 06:08 PM
 
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Re: Triple Pass Universal Muffler Install

Found it for $49.84 At Rock Auto. Thanks For The Tip bluetoad7. Newbie here with RZR 800

RockAuto Parts Catalog
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post #101 of 105 Old April 4th, 2016, 07:40 AM
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Laughing Re: Triple Pass Universal Muffler Install

I did this Mod this weekend and I am super happy with the results. Thank you PA-Probe and bluetoad7 for the instructions and pics.
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post #102 of 105 Old April 4th, 2016, 07:54 AM
 
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Re: Triple Pass Universal Muffler Install

Nice job.
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post #103 of 105 Old April 4th, 2016, 10:23 AM
 
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Re: Triple Pass Universal Muffler Install

Did you guys actually use the 'U' bend in your installs? It looks like you welded 2 90 degree pieces so you could get the length right between the Walker muffler and the Jones glass pack. Just curious...
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post #104 of 105 Old April 4th, 2016, 12:01 PM
 
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Re: Triple Pass Universal Muffler Install

I cut the U bend directly in half. Then I used a small piece of larger pipe to sleeve\join those 2 pieces together. You may be able to get a couple 90 degree elbows at the parts store and make them work but the U bend has a smooth mandrel bend. And there isn't alot of space to do a big sweeping turn between the muffler and tire.
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post #105 of 105 Old May 15th, 2019, 07:36 PM
 
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Re: Triple Pass Universal Muffler Install

Thanks Bluetoad7 , I did this to my 09 RZR 800 and am very pleased with the results.
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