GS1200SS Banana Silencer and Muffler Bracket Fabrication

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The bike came in for inspection, and we’re installing a banana silencer and fabricating a muffler bracket.

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First masking, second masking—that’s how we minimize risk.
Before we start… should we go with ■ or ●? We’re torn between materials and design. We prefer something clean and understated.

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This time we’re going with a hanging-type design mounted to the rear suspension.
Since it’s a single piece, we chose a thicker pipe. By heating the pipe and bending it with an offset, we get dimension and depth—it looks better that way.
We welded the upper boss and let it cool.
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We positioned the lower side by fitting it to the actual bike, then welded it. We shaped the flange collar to be as smooth and organic as possible.
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We cut away the excess on the upper side and did surface prep and polishing before sending it out for anodizing.
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The smooth and organic muffler bracket is done. Positioning takes the most time, really.
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We made sure it doesn’t sag and doesn’t put stress on anything—clean and understated.
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We tucked it as far inboard as we could and it’s done. We sent it out for anodizing today, so we should be able to hand it over by the weekend.

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