Post by guest writer from globalmoto.net.

E-mail me at: info@GlobalMoto.net or call me at: (330) 289-9053.

I’ve been thinking/talking about this project ever since the folks at Yamaha brought us this stock header back in 2006

They certainly didn’t do us any favors with this welded on/unremovable boom box. If it were as simple as cutting it off and adding a Y-pipe I’d have done that a long time ago.

We experimented with it and found that it robbed the R6 of low to mid-range, right where the bike needs it most. Since we couldn’t get it to perform the way we wanted, I wasn’t going to put my name on something like that and the idea sort of “died on the vine.” I never stopped thinking about the idea and finally, we’ve built a better mouse trap.

Weights – 18 lbs for the OEM headpipe assembly with boom box (no muffler). After modification with our complete merge collector installed is 6 lbs, 9 oz. Weight savings of about 11 lbs, 8 oz.

Heat – There is a large difference in radiant heat with the boom box removed. The new modified system also cools down much, much quicker.

Please keep in mind that we DO NOT SELL A MID-PIPE. This is a header exchange program only! You send us a stock header that is straight with no cracks kinks or bends and we send you out an already modified stock header. It sells for $349, $20 for shipping. There are NO exceptions to this program. We are inundated with people asking to buy just the “mid-pipe” and do the modifications themselves. I wish it were that easy, it’s not.

We bought up some stock headers and have developed an exchange/core program. A customer can send us their acceptable stock header and we’ll send out an already modified header. Here are the details in the new modified header.

The merge collector unit will be a spring mount slip fit. Essentially we make a set of outlet spigots that get welded to the headpipe collectors. We join cut/grind down the OEM weld, and weld on these spigots so the essentially look more original/OEM. We then weld spring hooks onto the headpipe. The new Hamilton Merge Collector slips onto the outlet spigots and is secured with springs. The springs look trick, and also provide a little movement for the various differences that can occur from bike to bike. A little movement is also a good thing to prevent any possible breakage from binding.

The collector outlet also houses a CNC’d 304 series stainless steel 02 Bung to utilize the OEM closed loop system. The Merge Collector kit is very different from other options (from a pure engineering standpoint). It is a true merge collector that is blended (in the opposite way of theirs) for superior flow and seamless design. All thin gage 304 series stainless steel in A269 highly annealed tubing (the absolute best). All tig welded in a fully purged atmosphere using an argon/helium mixture. The production “main” collector tube will be vectored and mandrel bent in one piece. The secondary collector tube is also mandrel bent and blended with full merge cut for maximum flow/velocity. These are important details that add up to a very high quality product. In short, not some bogus Y-pipe! This will exit at the stock location 1.75 diameter and work with the OEM exhaust or any aftermarket slip-on. In addition, we’re going to offer an optional Race muffler kit with a 2.0 inlet adapter for a full blown race exhaust.

1) This is thin gage 304 series stainless steel in A269 highly annealed tubing (the absolute best). The stainless steel O2 bung that we use for it costs us $25 alone. I could buy a cheap steel one for a lot less but it’s not the right way to do it.

2) This is a true merge collector where the I.D matches exact to the shouldered O.D. of the pipe it meets up with. This is a far more involved process that has a clean, smooth internal bore, seamless design, and increases gas flow/performance. Simply welding it together (poorly, I might add) creates a turbulent effect inside of the header. This is simply exhaust manufacturing 101.

3) Look at the welds on the other products available?!! We are using a TIG stitch weld, a vastly superior method. These are TIG welded in a fully purged atmosphere using an argon/helium mixture.

4) Your not just getting a “mid-pipe.” Your getting a modified stock header that has been cut, grinded, and had a new set of outlet spigots that get welded to the headpipe collectors to accept the new merge collector.

Now I suppose I could MIG weld steel to the stainless stock header and then paint it black to hide the work. I could also cut angles on pipes and weld them together instead of having it vectored and mandrel bent. But I would never put my name on something like that. These are important details that add up to a very high quality product. If price is all you’re concerned with, then I agree, there are certainly cheaper options available. As the saying goes, you get what you pay for.

E-mail me at: info@GlobalMoto.net or call me at: (330) 289-9053.

E-mail me at: info@GlobalMoto.net or call me at: (330) 289-9053.