Loud, deep and stock - stage3 C800 Exhaust Mod

Well that’s what I’ve been aiming for anyway. I started with holes bored in the backplates and through both middle plates. Then progressed to a debaffle, removing the backplates and the baffles themselves. I added silencer packing fibreglass to make the sound less high pitched. Now I have moved on to stage 3. Having already made a hole in the 2nd plates and left the holes where the baffle welds were broken, I decided to remove the plates all together as most of the pressure was lost here already. By doing this I would gain quite a few extra inches to increase the volume and add more silencing packing to deepen the tone. I removed both 2nd plates using a home made long chisel although a hole cutter with drill extension would do the job probably better. The resulting pipe is loud (much, much louder than stock) but to get that elusive deep tone I would need to add more packing. The previous debaffling stage left the exhaust note loud, deep on idle but rising sharply on acceleration. So here are pictures of how I filled the pipes on stage 3. I have included a video at the end of the resulting exhaust note

This is a mesh panel from B&Q. Cut one for each pipe to fit the circumference and exact length from where back plate was to the end plate inside





Silencer Packing from M&P (£5) one packet will do both pipes easily. Cut same size as mesh





Roll round spray can to get wide cylinder




Roll round mastic tube to get tight cylinder




Here are the two stages - you end up with 2 tight cyclinders




Roll the fibreglass around the tight cylinders and hold ready to insert




Insert the rolls into the pipe and push under the protruding bit at the back of the last plate




Fiddly bit - bend and hammer with piece of wood until the mesh is tight against the fibreglass and is tucked under the flange of the little lip where the original back plate was (it really will stay in place!) Then spray liberally with flat black HT paint




That's it. I really like the deep, loud tone which stays fairly consistent whether idling or revving. It could be a little louder. At the moment I will leave it as is as it seems to be getting louder on its own with use as the heat beds it down. I may cut some off the packing to gain more volume - we'll see. The fuel injection has handled the change admirably - a bit spluttery and poppy at first and then it suddenly accepted the new adjustment and the bike sounds happy and accelerates much the same as before. But now I ride with a lovely low growl. Here is the latest video after about 30 miles of this stage of the mod.



Finally - here is one of the endcaps I made from the old baffle and a new donut plate fixed together with exhaust paste. They could be exhaust pasted or stitch welded to the ends, sprayed black and return the pipes to a slightly louder, deeper stock appearance which could be useful for resale for example. I have not tried this out yet.


If anyone is interested in doing this mod - I can recommend it - you will love the unique deep cruiser sound, better than a lot I hear around. Its not got the pedigree of aftermarket but I got a great kick out of doing this one. Time of course will tell but one crack of the throttle will tell you, you have a throbbing exhaust back there - a long, long way removed from stock - if that's what you want of course.

Just watched the video - is actually deeper than the sound track - I think there was distortion coming from my camera - maybe too close. Will have another go soon.

Absolutely fantastic, what an excellent write up and modification done.
Although I am very happy with my Cruzers if I had seen this mod before I have no doubt I personally would for the time being at least have kept my cash in my pocket & still be running around with modified stockers in place. The tone is so much better than stock (in my opinion) and with the extra possibility of just popping the end cap back on makes this the almost perfect exhaust mod.

This will have to be known as the Bluesman Mod from now on

The Intruder wrote:

Absolutely fantastic, what an excellent write up and modification done.

Couldn't agree more an amazing A-Z instructional post and a lovely rumble

The Intruder wrote:

This will have to be known as the Bluesman Mod from now on

Well the "Bluesman Mod" will do for me, thats for sure, money is always at the heart of everything I do and I would love a bit more rumble coming from my bike
Thanks Bluesman

for the positive comments - I was unsure about bashing about my new bike but I find it so much more enjoyable to ride now. I have to learn how to ease off the throttle not to startle peope or horses though! Decided to shorten the packing to about half length as it was a bit too low on my ride today. Now it's a little higher but a bit less thumpy. It's quite easy to dial in your own sound with this mod. When I put the mesh back in I snipped the edges around the opening and made a bit of a trumpet shape. When you push it into the pipe it closes up and then snaps back to hold against the small ring where the back plate was. I positioned the packing half way down the pipe. This is open to experiment - open pipes back to the cat for higher, loud note and fully packed pipes for a low quieter rumble. It's down to personal preference (or neighbours!)

Made another video today - used another camera - much better sound. Still can't believe these are stock pipes!

Sounds nice

I love the fact that after the initial mod is done you can change the sound very easily to get exactly what you want