• 4 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     TE = 4st Enduro & TC = 4st Cross

  • Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

SMR511 Dual Exhaust Build Project

ascribner

ascribner

Husqvarna
AA Class
I will share my project (pain and frustration and momentary speckles of joy) as I progress through building a dual carbon exhaust setup for my SMR511. Keep in mind, I am working out of my garage and have no access to any fancy machines. A miter saw, bench grinder, normal rotary cutting tools, a tig welder (not in my garage, at my cousin's shop), and a little bit of imagination are the only things at my disposal.

I knew well in advance of purchasing this bike, that a dual exhaust would be a project. All motards should have dual IMO -- just my opinion.

The first part was figuring out how to mount the duals to the subframe. Mounting directly to the subframe would not give the needed clearance (and even with the aluminium spacers I installed, the fit is still a lot tighter than I would like. So after a bit of searching for aluminum, I found some spacers that would work. I welded the tabs to both sides Then test fit the mufflers (I am using different mufflers from what is pictured).

WP_20130113_007.jpg



WP_20130128_002.jpg


Now with the exhaust mounted, I have to figure out how to route my piping. This is the pipe I currently have.

WP_20130206_007.jpg


Without, ready access to a heliarch machine, I busted out my hillbilly "engineering" imagination and figured out how to mock up the mounting (since I cannot find a pipe expander that will handle 1.5 OD pipe) -- using a pool noodle! So the pipes are rough length and overcut. Once I start to TIG it, I will have to clean up the ends and cut to exact length. I should have access to a heliarch machine tomorrow and will hopefully have it done.

WP_20130211_001.jpg


Well, these exhausts are way too long. So off to the saw I go.

2013-02-24%2020.44.17.jpg


Now that everything is all cut and mounted, time to start the welding. First piece is the splitter.

2013-03-01%2018.31.03.jpg


All tacked up.

2013-03-01%2019.17.36.jpg


2013-03-01%2019.17.43.jpg


2013-03-01%2019.24.04.jpg
 
Project list

Modify subframe
Mount mufflers
Mock install (rough fit, cut pipes to approximate length)
Weld exhaust
Build modified rear mud guard
Build modified rear fender
Build modified side fenders
 
looks good man, I've built a ton of custom under seat exhaust in my day for my stunt bikes including my old husky. Its ton of work but no one else will have one thats for sure. Looks like regular mild steel? How do you plan to keep it from rusting? coating or wrapping the pipes?

10.JPG
 
R. Stephen said:
looks good man, I've built a ton of custom under seat exhaust in my day for my stunt bikes including my old husky. Its ton of work but no one else will have one thats for sure. Looks like regular mild steel? How do you plan to keep it from rusting? coating or wrapping the pipes?

View attachment 23220
Click to expand...

Sik man!

I am going to have it ceramic coated, but it is 304 stainless, not mild. Going to coat it though considering how close it will run to the gas tank. Also have to build a small carbon fiber heat shield and coat the underside of the gas tank with some heat reflective material. Last thing I need is the gas tank melting.
 
OP updated. I will post some more pictures after I finish grub'n and unload the bike from the truck. Still some work to do, but now everything is back to my garage for the carbon work. And the pipes off to the ceramic coater.
 
OK. 72db (according to the freebie Android app). Definitely needs to be tuned after the intake and exhaust mods. Will order a PCV later this month.


Walk-around

 
I am HIGHLY contemplating selling the dual pipes I built. I just swapped the header for an FMF megabomb and FMF is a piece of crap that is not the same specs as the OEM header and my dual exhaust setup no longer works. Yes, I am a bit pissed at the moment. If someone wants to take this off my hands for the cost I have into it, then now is the time to offer up. PM me if interested.
 
Tinken said:
I am not exactly sure why the FMF is crap? I run the FMF mega-bomb and it is the single best investment I have made into my 511.
Click to expand...

Hah, only because is does not have the same dimensional specs as the OEM header and I made my dual pipes to bolt to the OEM header...d'oh!
 
Oh, no it wouldn't. FMF only makes the mega-bomb to fit the TC and I believe the SMR is more of a long header like the TE's. The mega-bomb is really trick though because it gives you that long header low end torque at low rpm and short TC header top end. Can you cut and re-weld the mid pipe you made?
 
Tinken said:
Oh, no it wouldn't. FMF only makes the mega-bomb to fit the TC and I believe the SMR is more of a long header like the TE's. The mega-bomb is really trick though because it gives you that long header low end torque at low rpm and short TC header top end. Can you cut and re-weld the mid pipe you made?
Click to expand...

I am "working on it". I am going to just make a mid-pipe between the two that will slip over the FMF and slip into the duals. It is only about a 20 degree bend that I need, so I am trying to find someone that can make the ever so slight bend that I need (w/o paying a ton of money for one bend).

I was (obviously) not happy after I mounted the FMF based on my post about 10 minutes after mounting it.

(side note, most of my time has been working on finishing my Daytona 675 project, which is 90% complete -- just been avoiding spending money on bikes as I need a down payment for a house in the next few months).
 
ascribner said:
I am "working on it". I am going to just make a mid-pipe between the two that will slip over the FMF and slip into the duals. It is only about a 20 degree bend that I need, so I am trying to find someone that can make the ever so slight bend that I need (w/o paying a ton of money for one bend).

I was (obviously) not happy after I mounted the FMF based on my post about 10 minutes after mounting it.

(side note, most of my time has been working on finishing my Daytona 675 project, which is 90% complete -- just been avoiding spending money on bikes as I need a down payment for a house in the next few months).
Click to expand...
ascribner said:
I will share my project (pain and frustration and momentary speckles of joy) as I progress through building a dual carbon exhaust setup for my SMR511. Keep in mind, I am working out of my garage and have no access to any fancy machines. A miter saw, bench grinder, normal rotary cutting tools, a tig welder (not in my garage, at my cousin's shop), and a little bit of imagination are the only things at my disposal.

I knew well in advance of purchasing this bike, that a dual exhaust would be a project. All motards should have dual IMO -- just my opinion.

The first part was figuring out how to mount the duals to the subframe. Mounting directly to the subframe would not give the needed clearance (and even with the aluminium spacers I installed, the fit is still a lot tighter than I would like. So after a bit of searching for aluminum, I found some spacers that would work. I welded the tabs to both sides Then test fit the mufflers (I am using different mufflers from what is pictured).

WP_20130113_007.jpg



WP_20130128_002.jpg


Now with the exhaust mounted, I have to figure out how to route my piping. This is the pipe I currently have.

WP_20130206_007.jpg


Without, ready access to a heliarch machine, I busted out my hillbilly "engineering" imagination and figured out how to mock up the mounting (since I cannot find a pipe expander that will handle 1.5 OD pipe) -- using a pool noodle! So the pipes are rough length and overcut. Once I start to TIG it, I will have to clean up the ends and cut to exact length. I should have access to a heliarch machine tomorrow and will hopefully have it done.

WP_20130211_001.jpg


Well, these exhausts are way too long. So off to the saw I go.

2013-02-24%2020.44.17.jpg


Now that everything is all cut and mounted, time to start the welding. First piece is the splitter.

2013-03-01%2018.31.03.jpg


All tacked up.

2013-03-01%2019.17.36.jpg


2013-03-01%2019.17.43.jpg


2013-03-01%2019.24.04.jpg
Click to expand...


Damn would love to see this but the photos aren't showing! Anywhere else I could find them? Want to try and give it ago. Thanks.
 
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