So since I have started chopping up so many VLX's I just couldn't leave all the exhaust chopped and wrapped. Don't get me wrong, I like the look of the chopped and wrapped exhaust, but sometimes you just need a little flare. I purchased a set of custom exhaust from someone else and although they were decent and it was a somewhat fair price, I had to ask myself why I didn't just make my own.
The front pipe is not so much of a problem, it is 1 3/4 and although it has a pipe in a pipe, it is pretty easy to fabricate, so the focus will be on the rear pipe. This is just the first stage and a pretty simple explanation as to where to start. The set that ordered from someone was done by using a washer to create a doughnut to step the stock pipe up to 1 3/4". Nothing exactly "wrong" with doing it that way, but not what I would consider the easiest and cleanest way. So here is how I did it. (It was 17* in the shop so I was in a hurry and had made one cut before I thought about you crazies and sharing the modification, so we'll have a rough start).
TOOLS & SUPPLIES:
Chop saw or angle grinder with cutting disc
Stock VLX pipes
1-1/2ID to 1-3/8 OD adapter ($2.99 O'Riley's)
1-5/8ID 1-3/4 OD sleeve ($3.99 O'Riely's)
Cut the rear pipe just before the bend. This pipe has has been cut down farther for final fabrication you will or can measure as you need to cut. Make sure you have enough for your exhaust mounting flange (I forgot to put that on when I tack welded everything together...good thing I am smart enough to only tack it up for test fitting, you'll see in the pictures to follow). You want to allow enough room to be able to fit a socket on your mounting bolts.
Again, I want to note, mine has been trimmed at this point...DON'T start this short or she is not going to be long enough and I know some of you guys are used to being told that but don't let it happen this time...
STEP TWO: Cutting the sleeves to step up to 1-3/4
Cut your 1-1/2ID to 1-3/4OD sleeve tight enough that the stock pipe will slide in to fit and weld.
Insert your 1-1/2ID to 1-3/8OD into the 1-3/4OD and tack it into place...
Now MAKE SURE TO PUT YOUR FLANGE MOUNTING BRACKET ON and insert the stock pipe and tack into place (as you will see here I forgot to do that, but it was 17* and and I was trying to hurry so I could be the iceapocolipse that was coming)...
You can buy 1-3/4OD pipe at your local auto parts store to build your exhaust. Mandrel bends are find if you are going to wrap the exhaust, the crinkles in the pipe will not be seen once you wrap them. If you want straight wall pipe you can order kits online for a fair price or go to your local muffler shop and tell them what you want. My local shop actually told me for about $60 he would make and weld the turns for me all I needed to do was take a wire clothes hanger and build a template of what I want.
As for chrome tips, I have found that there is a limited supply of 1-3/4 tips, I only found straight tips. So here is another little tip...
I bought this exhaust tip which the ends are 1-3/4. Tips are generally about $8.99 a piece, this was $13.99 and as you can see where I am going with it, by the time I cut it I actually saved a few dollars.
As you can see, and if your modding mind is anything like mine, I have a potential future collector for a 2 into 1 modification as well just from the "scrap."