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Aero exhaust on a Sabre
Old 06-18-2012, 06:21 PM   #1
rac3850
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Aero exhaust on a Sabre

OK, I'm a noob, so if this has already been covered, sorry (not really). I did a search, but nothing showed up.

Always liked the look of the Aero, just couldn't find one in my price range when shopping for a bike. Got my Sabre cheap (didn't run, bent rear fender). Zero $ to clean the carbs and get it running, just some elbow grease and about $80 in paint, and the rear fender was fixed (good enough anyways). Been trying to do budget mods ever since.

Never happy with my stock exhaust. Did the holesaw, didn't sound good to me. Made some glass pack inserts, which helped, but still didn't sound right (my buddy did this on his holesawed Suzuki M50 pipes and they sound great).


A set of 2 into 1 pipes was high on my wish list. Looked many times at V&H pro pipes, just couldn't get myself to spend the bucks. Always was told the Aero exhaust would not fit on the Sabre due to the front foot peg mount location (its true). But when studying some pics of an Aero I had a Eureka moment. It struck me that the front Aero pipe and the front Sabre pipe dropped to the same place on the bike when they straightened out. When I saw an Aero exhast system on craigslist, I took the chance.

Did this mod last week.

My Sabre pictured here has an Aero muffler, an Aero rear header pipe, and the original Sabre front header pipe. The Sabre front header is too short to reach the Aero muffler (which is forced into position by the rear header pipe). Believe it or not, I connected the Sabre header to the Aero muffler with an $8 chrome drain tube extension from Home Depot. No leaks. Have a little work to do for mounting the Aero heat shield to cover the 5" gap between the Sabre front heat shield and the Aero muffler shield - its held on now with a hose clamp. A simple chunk of angle iron was used for the exhaust bracket extension.

$100 for the Aero system, $8 for the drain tube, and $5 for a crush gasket. Seems like a budget way to get 2 into 1 and a unique look. It also sounds so much better than the hollow sounding, overly muffled stock exhaust. It looks long, but it is only about 1/2" longer than the "pig's snout" license plate light.

So, that's how it was done if anyone is interested.
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Old 06-20-2012, 11:02 PM   #2
gochisox81
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Well done man. If you got pics of the process post em. I got a buddy who has a Sabre that we are hole modding friday. If he doesn't like that, we may try this out. Pretty cool option.
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Old 06-21-2012, 06:08 AM   #3
rac3850
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If you got pics of the process post em. I got a buddy who has a Sabre that we are hole modding friday. If he doesn't like that, we may try this out. [/quote]


Sorry, I didn't take pics. It's almost a bolt on. When I get a chance in the near future (kinda crazy around here right now), I'll take some close-ups of the very few "fabricated" pieces and write up some step by steps. Basically, just a piece of angle iron, a small piece of 3/4" oak to use as a bracket spacer, the drain tube, plus some longer bracket bolts, a t-bolt clamp and a little exhaust sealer are all that's needed. The drain tube is a little short, so it isn't fully seated in the joints. It doesn't leak and its not going anywhere, but its not right.

This winter, I will replace the drain tube with a real exhaust adapter, just have to make it (I'll put the dimensions in the write-up), and figure out a heat shield attachment in one spot. For now though, I'm riding it.
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Old 06-21-2012, 12:29 PM   #4
rac3850
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Quote:
Originally Posted by gochisox81
Well done man. If you got pics of the process post em. I got a buddy who has a Sabre that we are hole modding friday. If he doesn't like that, we may try this out. Pretty cool option.
FYI, here is a thread that goes through a lot of steps taken on the stock exhaust. I did all of this, and still went to the Aero first chance I got.

http://www.hondashadow.net/forum/53-...0c-spirit.html
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