I'll start off showing the result. I started with a 2002 ZX-9r. The mid-pipe outlet is 2 3/8" OD. SuperTrapp does not make an exhaust specific to this model, only universals of fixed sizes. I purchased a SuperTrapp muffler with a 2 1/2" ID, so the fit was a little loose. The muffler is designed for crimping the inlet, as I've done previously, so this is an alternative to that method.
The first stop was to Autozone for a 4" length 2 1/2" OD x 2 1/2" ID muffler sleeve and Permatex 101BR Ultra Copper silicone gasket. I cut the sleeve ID off, keeping the remaining ~1 13/16" length OD cone (see below). Next I made two length cuts to that, taking out about 1/4" (a single cut would have worked as well), turning the cone into a "C" shaped sleeve. A metal file was used to smooth out any rough edges on the muffler internals, sleeve, and mid-pipe outlet.
Everything is ready for a snug assembly. Just need to take it down for the rear set bracket TIG welds. Permatex will be used during final assembly to seal any air gaps between the three pieces. Let dry for several hours.
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I would let him drive mine for a day if i could just touch his with my index finger. lol.
2002 SuperTrapp fitted ZX-9r
The bike as it looked with its stock scuba tank size muffler.
Step 1 of 10
Unbolt chrome beauty ring and make cut right at the mid-pipe exit weld.
Step 2 of 10
Not all hack saw cuts end up straight. I had to try about four different angles.
More below.