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Old 04-27-2006, 11:50 AM   #11
Wicked Wanda
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If any of ya'll want to sell me your canister (actually only need the canister cover and tailpipe end) if it's in good shape (no scratches please), drop me a PM with a price. I'll be interested in purchasing for reasonable $$'s.

The rounded tip of my tailpipe is starting to discolor very slightly - can use chrome cleaner but eventually that will wear out it's welcome too.

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Old 04-27-2006, 05:09 PM   #12
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Originally Posted by croach1
You don't have to cut off the canister. I just removed all the baffles from the big 4" pipe. Now I have the headers going into the pipe and it is open.

The sound is pretty good. Not as nice as the drag pipes I had on, but this fits with my forward controls.

What forward controls do you have? Where your pipes cobra drag pipes? I just put mine on, but alos want to get some forwards... Just wanted to know if I'm gonna have issues.... Okay that's a loaded question, anyone that knows me, knows I already have issues...
There are 10 types of people in the world, those that know binary, and those that don't....
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Aero Pipe Mod
Old 07-11-2006, 09:39 PM   #13
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Exclamation Aero Pipe Mod


Honda Shadow Aero Pipe Modification

Tools Needed:
Various Drill Bits (working up to desired size)
Drill bit extentsion
3 or 4ft. 1" pipe

Sine I have gotten a bunch of E-Mails asking what I did, I thought I would make a How-To. This modification is to increase the sound and possibly the power of a Honda Shadow with stock exhaust. The stock exhaust on the Aero has a "2 into 1" exhaust. Which if you look more closely it has 2 pipes into one muffler but inside the muffler are 2 pipes that run through it. Here is a diagram of the internals of the stock exhaust:

On the back side you should see two one inch openings. Each of those has 3 baffles inside. One at roughly 6 inches, 1 foot, and one and a half feet inside the muffler. Depending how loud you want it to be is how many holes you should drill and how far. I wanted my loud as I could make it without having to re-jet it. I like the amount that I drilled the pipes because it's loud and sounds good at full throttle, but idle and some throttle it is quieter but it does not have that tinging sound that some bikes have when they drill out the baffles.

What I did
First, I drilled the inside of the exhaust pipes out. I used a small bit with a extension on it and drilled around the inside of the pipe making about 8 holes. I then worked up to the next size until I got to a 1/8 (The largest I had). There was then some metal left hanging and this is where the pipe comes in. I took the pipe that fits perfectly inside the 1" exhaust holes and knocked out the remaining part of the baffle. I repeated this for each of the baffles till I got to the curved part of the exhaust. And then I repeated this for the second of the two exhaust pipes.

I then checked the sound and wasn't bad, but I wanted to go louder. If you are content with the sound you should leave it. As you can see from the diagram, there is one pipe in the middle that helps in muffling and transfering the exhaust. So I drilled small holes at 3 o'clock and 9 o'clock. This creates the straight pipe effect. The exhaust now doesn't have to take a single path. I then simultaneous would drill the holes at 3 o'clock and 9 o'clock bigger and deeper. The deeper you go it seemed like the louder it got. I would use your judgement and drill the amount and size hole for the sound desired.

Some Observations
Some of my observations. Just drilling the pipes not only did not destroy the muffler, but it also did not create any cackling. After drilling out the pipes I increased my gas mileage 2-3 mpg. And there was a noticable performance increase. I drilled out my old Rebel 450 and there was backfiring, but when I did this on the Aero there was basically none. I have over 15,000 miles on my bike and it has backfired about 2 or 3 times, which it might have done anyways.

Thanks again for all your help Keith! I had an opportunity to take my pipes off on Wednesday night and drilled out the baffles. As you had stated.. it was not that difficult to do.I did as you said.. I used a small drill bit all the way around and then used a larger bit to make it easier to hit out. After that I used a pipe to knock them out and then a grinding stone to clean out the rest.After that I drilled out three smaller 3/16" holes through each baffle and had the pleasure of riding it yesterday. It was 44 degrees here in Minnesota yesterday and I brought it out for a short ride and it sounded so much better thanks to you! I now know what you mean about it sounding almost stock at idle and at cruising speed, but when you crack it open.. WOW it sounded great. My son says it sounds more like a chopper now. I was a bit nervous about doing it because I did not want it to sound like my buddies who's sounded tingy and cheap, but I am very happy with the results. It sounds like a much bigger bike and again I thank you so much for all your help.
2004 Shadow Aero
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Old 04-20-2007, 05:57 PM   #14
Shadow Junkie
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Using this guide, I went so far as to neatly "gut" my pipe to the point where there's nothing rearward of "baffle B", and it sounds and runs great!
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Old 04-20-2007, 10:42 PM   #15
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Hey matty I believe that you can get some ends (tips) for your stubbies from Vance and Hines, you might have to tweek em a little to get em to fit just right they have half a dozen to choose from, I believe they'll add some class to your mod, not that it isn't already classy..just a thought...ride safe, Mel

Last edited by mcvierh : 04-21-2007 at 08:15 AM.
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Old 05-10-2007, 07:52 AM   #16
Shadow Master
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Originally Posted by Matty1378
I have a aero 750 did both mods 1 and 2, and the bike really started to sound like shit. very loud and high pitched and on decel had a metalic sound to it. I was embararrased to rev her up. This weekend I took the ol' saw blade out and I cut The pipe right b4 where it goes into 1. It sounds like a monster now! I love it. I just need to tweak my carbs this weekend.

i made my cut before the can and left the 1 1/4" pipes that went to it, the rear cylinder down pipe is about 1" long and the front cyl. is about 1 1/2", got my friend to spot weld some 2 1/4" O/D exhaust tips from the autoparts store it sounds awesome and looks good, i'll post pics as soon as i find the cam

Last edited by NAL : 08-27-2007 at 10:59 PM.
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Old 05-30-2007, 12:36 AM   #17
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How would the exhaust look and sound if mufler was cut just before chamber "A" and 4" turn out chrome extension put on?
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Old 05-30-2007, 01:46 PM   #18
Shadow Master
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ok pics are in look in my gallery under aero 750 exhaust mod not finished but you get the idea
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Old 05-30-2007, 03:22 PM   #19
Shadow Junkie
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What did you do about jetting the carb?
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Old 05-30-2007, 04:20 PM   #20
Shadow Master
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You wont have too. If anything you'll have to turn out your air/fuels a bit
2003 Ace
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