Bonneville America Forums Forums Technical Forums Exhaust Sidecar specific exhaust system?

I'm in the market for a new sidecar rig, my last was a '63 BMW with a Steib tub, classic but a bit long in the tooth. I want something more modern this time around.

I've seen a few Bonnies and Americas set up for chairs, and am getting ready to buy a 2014 America. Seems like another classic albeit one with modern underpinnings.

I'd like an exhause system that has a 2 into 1 collector exiting onto the left side into a quiet muffler. That would put it on the opposite side of the chair, and the quiet muffler (low mount) would make for a more comfortable passenger experience when hauling the wife or kids.

Any suggestions? Is there something available out there or am I looking at talking to the local muffler shops? I have a friend who works for a company that builds custom exhausts for trucks and cars, so I'm thinking of asking him to help but if there is someone out there already making such a system or can do so, I'm interested!

Otony

The problem with a two into one is the foot control bar that spans the frame right where the headers come down. I just finished reinforcing a set of foot controls so I can run some Thunderbike 2 to 1s but I still have some pipefitting to do with exhaust arrangement. Since only one cylinder is firing at a time, your choice of exhaust is unlimited. Any quiet factory silencer would work for you. I'll send you a picture of my modified foot controls when I get the gumption to go back out to the shop. My woodstove is out and it's cold out there right now.

Thanks Ryk!

I would think it would be easy to make one like the old TT pipes for the old twins and merge that into 1 pipe. That or the ones they use to make for the old bikes that go to one side similar to HD exhaust and merge that into 1. The foot controls shouldn't really be an issue for either set up as long as bent for our bikes configuration.

TT pipes are exactly what I'm attempting to mount, but when I cut out the center section of the footbar and I was getting deflection when I hit the brakes hard, so I welded in some 16 Ga plates that marries up to a couple of case bolts on both sides. The pipes came with the collector and upswept Thruxton silencer, but I didn't dig how that (the silencer) was going to look, so I'm playing with one specialty spare down the right side or two shortened Epcos with the exhaust going back into a one into two. I'll take some pictures if the whole experiment comes out looking good enough to be mildly proud of the results.

I understood your problem, I meant it shouldn't be too hard to bend headers in that style that clear the foot control mount. Could you have flattened the engine side of those headers to clear?

Well the ones I've acquired were meant for a Bonnie or a Thrux in the old TT style and flattening the headers a little just wouldn't work as their vertical (headers) and horizontal (footbar) centerline intersection are almost a perfect match, as in to a -1/8th of an inch.

The flattening was just an idea if they didn't need much. I figured that was what they were made for, I haven't seen any for our bikes.