Anatomy of a Muffler

GeorgeS,

Thanks for all the great pics. Exhaust volume like a stock Harley - even with all that stuff gutted - wow.

1) Did you leave any baffles at all in there?

2) The cap at the back of the muffler - did you have to cut all the way around to get it off? All I see holding it is a little tack weld on the inside, toward the wheel. How else is it held to the outer pipe? And did you also have to cut it loose from the inner pipe?

3)Did you put the rear cap back on without all the guts? How did you make the edges look OK?

Thank you,

Jeremy

To answer few of your questions:

The End cone has an inner collor. its welded in three places. In order to get the end off with least amount of Damage I used a Dremel Tool with very thin cutting discs. Used up about 3 discs on each Muf.

The metal Is Soft, cuts pretty easy.

There are 4 baffel plats installed. Note the two small pipes pulled out of the middle section. Total flow goes thru them. The final pipe section you see removed is only exactly 1 inch diameter. Thats It.

Total exhaust flow exits thru 1 inch dia holes.

This is a spare set of muf's I bought on E-bay for $60, to experiment with.

They are back on the bike, initial test results are good. Sounds like a 4 cyl stock FLH, or pretty close, Deffinatly more power at high speed roll on from about 60mph.

I put in some Cone's but you could do something like the infamous Cherry Bomb aftermarket mufflers. Or whatever you can think of, almost anything is better then all that back pressure.

To re install the End Piece, I made a 1 inch wide inside coller, and just pop rivited it in place. I am still expeirmenting so want to be able to pull it appart for more work. I will weld the end cones on eventually.

To get the baffles out, I drilled lots of holes around the perimeter of each baffel, then chisled out the remaining metal. Took about 2 hours to gut each one cleaned out. If you try it, buy a Cobalt 3/8th 10 inch long drill bit. And a long narrow chisel.

Why did I do this ?? You might ask!! Well, I'm retired and didn't have anything better to do that week !!!

And I live in Seattle, and it was Raining Every Day that Week !!!!!

Great job George, just a couple of ?'s. Did u have to rejet or make any other adjustments? Looks like something I would like to undertake on my 83.

Once again, very informative and wonderful blow by blow illustration.

thanks

Dickie Self

It would be great if you could post a WMV file so we could hear them, George!