Yamaha XS650 Cafe Racer: Custom Exhaust Muffler

Turning down aluminum for the custom exhaust baffle

Turning down aluminum for the custom exhaust baffle

In a previous post, we covered the welding of a set of custom exhaust headers for Danny’s Yamaha XS650 Cafe Racer build.  Of course, this is only half the story, unless you plan to run straight pipes, going deaf in the process.  Danny is fond of his hearing, so he decided he needed a custom baffle…

Custom Muffler for the Yamaha XS650 Cafe Racer Build:

Baffle end cap to fit inside the muffler housing...

Baffle end cap to fit inside the muffler housing…

There are plenty of slip-on baffles available for custom motorcycles, but the way this build has been going, if it’s a metal add-on, then Danny is making it on the Mill or Lathe.  A plan was hatched to use a muffler housing we had purchased out at Mid-Ohio, fill it with a custom made baffle, and slap it on to the end of the custom pipes.  Danny didn’t want the muffler to remain the length it was when we bought it, so he removed the stock end cap, cut off the stock mounting tabs, and chopped it in half.  It left it about 8 inches long, and ready for a custom baffle.

Exhaust components for the Yamaha XS650 Cafe Racer build...

Exhaust components for the Yamaha XS650 Cafe Racer build…

The next step was to turn down some end caps, which would slip inside the housing, and hold the expanded metal and batting in place.  This was a bit tricky, since the caps had to be turned to the specific size to hold itself into the housing, but also have a a thin wall inside for holding the expanded metal to shape.

The end caps were finished, and despite not needing to look pretty, since they will be inside the muffler, and covered with exhaust build-up, Danny made them look sharp.  The only issue left to solve was the internal diameter of the flange that came welded onto the muffler body.  The size was an exact match for the pipes, so needed to be cut off, and a new flange milled and welded to allow it to slip over the pipe.

A little polishing goes a long way....

A little polishing goes a long way….

The last steps will be to have some small tabs welded onto the body, allowing some springs to be attached to aid in securing the muffler to the pipes.  A job well done, and like most things on this bike, custom made by Danny himself.  Nothing better than finding a ratty bike part at a massive swap meet, and then turning it into exactly what you envisioned for your custom Yamaha XS650 Cafe Racer

3 Replies to “Yamaha XS650 Cafe Racer: Custom Exhaust Muffler”

  1. I can’t wait to see this bike completed and on the road. Straight pipes are only loud for the person behind you…….I never really notice when I am riding. Sorry for the noise but my XS650 sounds so good with the straight pipes, well to me at least, I can’t put on a silencer.

    1. Hey james! If you like cleaver, fabbed solutions, stay tuned. Any chance Danny got to head over to the mill or late, there he went. This XS650 will have some sweet bespoke parts for sure.

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