muffler mod (I aint got no time for these RK's)

[garyS-NJ]

I have some very nice condition Road King Mufflers for sale.

 

I'm such an idiot but eventually I get there anyway. I just had to do something with the oem muffs on my '84 XVZ12 and looked into modifying them (and ran a piece of 3/8" rod through each end punching through one baffle wall without much noticeable difference..). I then bought a set of road king muffs and a pipe bender and spreader.. worked out some short bent pipes that had the RK muffs in the right place (oh and BTW, I slipped them onto the collector for a listen and a very nice sound..). but then I was having a time spreading the galvanized fence pipe to fit the OEM collector copper gaskets... and so cut off one gasket and made gaskets from type K copper pipe realizing I needed type L or M and couldn't find a piece of that... ARGHHHH!!!! then I'm looking at a mounting bracket design, I bought 1/2" square steel tubing, and I decided that whatever I made would be mad ugly. Fed up at all the wasted time I went and kicked the dog and the next day I cut the end cap cones off my oem muffs and drilled 1/2" holes, and ran my 3/8" threaded rod (grinded pointy) through the baffles. Specifically: two holes through the center tube crossing through two baffle walls, then two holes through one baffle wall via two of the tubes observable via my 1/2" drilled holes.

 

As for the process: I used an angle grinder with cutoff wheel and carefully cut at the cone interface. then a sawzall to cut at the straight portion (see pic with tape mark). then the cone cover drops off and the sawzall to cut the tube short and angle grinder to smooth all edges.. then I marked I think 8 holes and drilled with a small bit and then a 1/2" bit. then I just leaned on the bit to cut sideways between pairs of holes (yes, a little ugly but I didn't have a metal bit for my jigsaw and sawzall blades too wide). and some files to round off the oval holes. from there looking into the oval holes, I could see two tubes (besides the center tube) that go through to another baffle plate. So I punched my 3/8' rod through the two tubes and the center. NOTE: I got lucky with my oval holes in terms of the pairs I picked which allowed me a straight shot to the two inner tubes (see pic). make sure you look into your 1/2" drill holes and pick pairs to oval accordingly

 

the muffs mount right up of course, look better chopped, and sound almost like the RK muffs. I was crossing my fingers hoping with the oem intake restriction, the opened muffs would not demand rejetting but I think it might be close as I hear a lot of popping out the pipes as it's warming and also some on cruise and deceleration. will see, gotta check the plugs, but it is probably close enough. I probably rejet and run open pipes next year. pics attached..

 

I'll sell the RK muffs for same price I got them, (cheap shipped on ebay).

[Bassett]

I have some very nice condition Road King Mufflers for sale.

 

I'm such an idiot but eventually I get there anyway. I just had to do something with the oem muffs on my '84 XVZ12 and looked into modifying them (and ran a piece of 3/8" rod through each end punching through one baffle wall without much noticeable difference..). I then bought a set of road king muffs and a pipe bender and spreader.. worked out some short bent pipes that had the RK muffs in the right place (oh and BTW, I slipped them onto the collector for a listen and a very nice sound..). but then I was having a time spreading the galvanized fence pipe to fit the OEM collector copper gaskets... and so cut off one gasket and made gaskets from type K copper pipe realizing I needed type L or M and couldn't find a piece of that... ARGHHHH!!!! then I'm looking at a mounting bracket design, I bought 1/2" square steel tubing, and I decided that whatever I made would be mad ugly. Fed up at all the wasted time I went and kicked the dog and the next day I cut the end cap cones off my oem muffs and drilled 1/2" holes, and ran my 3/8" threaded rod (grinded pointy) through the baffles. Specifically: two holes through the center tube crossing through two baffle walls, then two holes through one baffle wall via two of the tubes observable via my 1/2" drilled holes.

 

As for the process: I used an angle grinder with cutoff wheel and carefully cut at the cone interface. then a sawzall to cut at the straight portion (see pic with tape mark). then the cone cover drops off and the sawzall to cut the tube short and angle grinder to smooth all edges.. then I marked I think 8 holes and drilled with a small bit and then a 1/2" bit. then I just leaned on the bit to cut sideways between pairs of holes (yes, a little ugly but I didn't have a metal bit for my jigsaw and sawzall blades too wide). and some files to round off the oval holes. from there looking into the oval holes, I could see two tubes (besides the center tube) that go through to another baffle plate. So I punched my 3/8' rod through the two tubes and the center. NOTE: I got lucky with my oval holes in terms of the pairs I picked which allowed me a straight shot to the two inner tubes (see pic). make sure you look into your 1/2" drill holes and pick pairs to oval accordingly

 

the muffs mount right up of course, look better chopped, and sound almost like the RK muffs. I was crossing my fingers hoping with the oem intake restriction, the opened muffs would not demand rejetting but I think it might be close as I hear a lot of popping out the pipes as it's warming and also some on cruise and deceleration. will see, gotta check the plugs, but it is probably close enough. I probably rejet and run open pipes next year. pics attached..

 

I'll sell the RK muffs for same price I got them, (cheap shipped on ebay).

 

 

Hey how is this process holding up? Working well?

-Alex

[garyS-NJ]

Yes, of course the muffs held up well. I was riding yesterday. But since the muffler mod and concurrent with noticing an exhaust leak at #4 at the head ex port, I now have some popping (mostly when it's cold) at idle and low load cruise. I have the mix screws set at 2 and 1/8 turns out so I'm going to set them to 2 and 1/4 out then sync the carbs,.

 

those Road King Muffs are still for sale!