Custom Muffler for Big - CC Sport Scooter!

[ace79]

I am also assistung my pal in doing a custom muffler for his Gilera Nexus 500 sport scooter. I bought him his current muffler ( GPR Italy, carbon - look muffler ) December last year, and until now, the perforated inner muffler tubing has cracked twice and the muffler packing have been replaced THRICE!!! He is obviously not happy with the durability of the muffler, and after some talk, we have decided to go the custom route. I have gone thru a few 'famous' local exhaust shops, and they are not interested in helping us achieve this. I hope fellow ZTHians can assist me in this matter. Basically what we need is :

- a muffler that will be used for a 500cc sports scooter
- requiring the use of custom exhaust mounts
- muffler design is preferably to be oval or triangle
- muffler body is either stainless steel or aluminium
- the muffler inside piping is straight, and perforated
- muffler packing must use Superwool ( check my thread down here also )
- muffler piping inlet ( which will go thru all the way into the muffler body
and exit at the back of the muffler ) size is about 1.8 inches.
- muffler length is about 19 inches ( but we're thinking of doing it shorter, any plus or minus points on this matter? )
- muffler fitment ( from bike exhaust piping to muffler ) utilises springs

Please do reply for any ideas, suggestions etc.