The Exhaust for Full Size System Case Mod

[darcym]

So far, the CHEAPEST mod on the BMW R1150 R I've yet to complete.

First remove the stock pipe:


The parts with old pipe on the table (man that thing was heavy!). Total cost $9.68.


The pipe tip will fit pipes up to 2.25 inch, and it has a little curve and nice slant cut. It's not really thick or heavy, so we'll see how it weathers.


The adapter piece:


The adapter slips on over the pipe and lets me keep the original heat shield.


Then the new tip goes onto the adapter. I cranked the screws down until they dented the adapter and I used some loctite just in case.

Looks nice!


Wow!


Big surprise, it's not all that loud! The aftermarket pipes on my yamaha are much louder!

Next ... the full size left side system case!

[darcym]

Step 2: Full size left side system case. I got one on e-bay for less than $100! The guy had them advertised as a case from a K bike, but close scrutiny of the pics convinced me that it was either an RT or RS bag! And I was right! (whew!)

Here's the existing cases with city lids on:


Here's the difference the full size left side case makes!


But ... the left side case has to be modified with a new bracket for the lower mounting point.

Closer pic:


And the bracket will have to go here:


more to come ...

[munchmeister]

You're gonna love having all that extra room !!



Good lookin' bike, by the way.

[riceburner]

Does anyone know if there's a replacement footrest mounting piece that will put the supporting block in the right place??

Is the R1100S fitting very different??

[OU812]

I got a 1 peice bracket from a fellow member that made them. It was great, about $75, super strong and the supporting block mounted right on it. This was for my R1150R. PM me and I will give you his E-mail, If I still have it. Found his member name, flynlo. Give him a try!

[DJ Downunder]

Hey darcym...great job with the mod...and the pics...

DJ

[colinpollock]

Does anyone know if there's a replacement footrest mounting piece that will put the supporting block in the right place??

Is the R1100S fitting very different??

The more important question is... Does anyone know if there is a system case available that does not require repositioning the footrest, but allows for a non-existent or lowered pipe? Anyone got a part number?

[DJ Downunder]

The more important question is... Does anyone know if there is a system case available that does not require repositioning the footrest, but allows for a non-existent or lowered pipe? Anyone got a part number?

No...there isn't one.

You don't need to reposition the footrest on the case if you make a bracket that mounts off the original one..or use the exhaust lowering bracket foot.

DJ

[GeoffJ]

Nice mod. Why the 1.75 to 2-inch adapter? Seems the automotive aftermarket should offer a 1.75 inch chrome or stainless pipe tip. I mess around with old Corvettes. I might have some stainless tips in my parts bin.

[NHighCotton]

Nice mod. Why the 1.75 to 2-inch adapter? Seems the automotive aftermarket should offer a 1.75 inch chrome or stainless pipe tip. I mess around with old Corvettes. I might have some stainless tips in my parts bin.

I tried the 2" tip just for the looks and sound but, I noticed it seemed to vibrate more than using the 1.75 tip (lesser back pressure?), sound wise it was not that much of a difference, just more of a straight pipe canney sound.

[rdsmith3]

GeoffJ - It is difficult to find a good stainless tip in 1.75". You can find some cheapy chrome ones in that size, but I had trouble finding stainless.


Darcym - you changed your camera ISO from 200 to 1600 at some point in taking the pictures?

[R4R&R]

I found a mailorder place for the 1 3/4" chrome tip with a slight turn in it. If anyone likes I can dig up the link and re-post it.

Ideally I would like to have about a 45 degree bend in stainless steel but I haven't seen any when searching.

[BigC]

Looks great darcym! I think I used a 2.25" tip and adapter to fit it. It sounds deep and throaty like a stock can on a big sport bike. It's not overly loud at all but definitely has a voice when you crack the throttle.

I haven't replced the system case yet although that would make it look better as the void looks kind of silly. Actually I try not to use the bags...the extra weight slows me down

[darcym]

GeoffJ - It is difficult to find a good stainless tip in 1.75". You can find some cheapy chrome ones in that size, but I had trouble finding stainless.


Darcym - you changed your camera ISO from 200 to 1600 at some point in taking the pictures?

rd -- it was getting dark, and I was shooting a black case from inside the garage to the lighter outside ... and too lazy to go grab the flash while I was rushing to get the pipe back on. I need better light in my garage!

Geoff -- I couldn't find any pipe tips at the local auto store in the smaller size. The best thing though is it was so cheap that if I want to replace it later on with the right size, no problemo!

Still working on the right bracket adaptation ... will keep you posted.

[darcym]

Part 2 - finished the bracket for the left side system case.

Got lucky with some handy raw materials ... as you'll see below. First off I stopped at Home Depot and picked up a framing bracket that seemed just about perfect. The piece is a Simpson Strong Tie part number RTU2 and cost about a dollar. Brought it home and coolness it's almost the perfect size! Two #6 half inch machine bolts with locking nuts
and a couple of washers were all I needed to attach it to the bag. Backed it up with a little bit of Gorilla Glue, just in case. I figure the bracket isn't under a lot of stress, I didn't want to over-engineer it but can't be too careful.

Some pics --

Applying a little paint - hope it sticks:


here it's on the case --


here's the case lined up onto the footrest stop. As you can see the only drawback was that there was a little bit of space on either side.


So I was standing at my workbench wondering what I could use when I spied an old rubber sanding block. The black rubber pieces that I cut off the top of the sanding block looked like they would be perfect. They're even tapered a little bit so I could put the thickest part at the bottom of the bracket. Here, pictures show it better than I can explain:





I attached the rubber bits with some tiny wood screws and a little more Gorilla Glue. Filed down the little bit of screw that penetrated the interior and trimmed them a little bit more because I didn't get them on quite straight.



And there you have it! Success!


I also got some of these Quik Hinges for the bags for easy swapping out the lids:


I'd had the Kugler Klamps, but these are better I think. The trouble with the Kugler hinges is that you have to screw a bolt into the metal piece each time and besides it being quite a bit more labor you also run the risk of stripping the threads. I got the hinges on but too tired (and dark) tonight to take more pics, but they came out great.

[DJ Downunder]

Nice job....also pics showing how the quick hinges work would be good.

DJ

[OU812]

"flynlo" makes a bracket that leaves the footrest in place. It moves the mounting point for the pipe and the case rest. If anybody cares. Oh, and It's machined from solid aluminium?(spelling)

[NachtRitter]

Awesome mod!! One of the best looking cheap mods I've seen in a long time!

I took a very similar route; went to my local Kragen's for the tip and adapter, though I got a 1.75" ID to 2.5" OD adapter; this allowed the tip to slip snugly inside the adapter so I could drill holes into the adapter for the tip's set screws. This gave me a way to securely attach the tip to the adapter.

For the heat shield, I had to liberate 2 of the 4 legs that hold the shield to the clamp, and then with some bending I could use the clamp to secure the adapter as well as hide the joint between the tip and the cat.

End result is a very nice looking and very good sounding setup. Thanks very much for the great pics and clear instructions!!