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Sportster Motorcycle Air intake, Carburetor, EFI, Fuel, and Exhaust Problems, advice and/or how tos for Sporster and Buell motorcycle carburators, Electronic Fuel Injection (EFI), Air Intake, Fuel and Exhaust.

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  #1  
Old 23rd May 2020
Hornsmith Hornsmith is offline
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Default Tapered Muffler Baffle Repair?

I recently acquired a super beat up muffler.
I'm actually going to put it on a Buell, not a Sportster, but posted it here considering I reckon they came on sportsters.
Back to the muffler. It is a 65231-65a muffler, and has some huge dents, is cut a few inches short, and had the Baffle drilled out. It cost me like 20 dollars, and I knew it was trashed. I don't mind that it's cut short, because it wouldn't fit on my project very well if it was longer. I don't mind the dents either, as my bike is gonna be quite the rat. However, I just started my bike up for the first time in a while, and it is very loud.
Is it possible to repair the baffles?
I don't see any hardware on the outside, and I guess they're welded in place. I can weld a wee bit, but I'm wondering if anyone else has done something like this, or if there are other solutions to this problem.
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  #2  
Old 23rd May 2020
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bustert bustert is offline
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if it is a blind baffle, it some times can be repaired with a welsh plug or freeze plug as some say.

Last edited by bustert; 24th May 2020 at 15:09.. Reason: typo
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  #3  
Old 23rd May 2020
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Default

Figure out how to insert one or make your own that inserts and will stay somehow in the pipe.

Home made baffle


You can also search lollipop on this forum. At the bottom of the page. I run em on my straight pipes on my 1980 XLS.
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  #4  
Old 24th May 2020
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very easy to install with a pipe or socket and extension. the very nature and shape of the plug pretty much locks it in place if sized right.
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Old 25th May 2020
Hornsmith Hornsmith is offline
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Huh sounds like something I can do. I'll see what's for sale, or maybe make something myself. Doesn't look to difficult at all
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Old 31st May 2020
Hornsmith Hornsmith is offline
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I have decided to cut up the exhaust and make a totally new system, reuse some of the bits. Thanks for the info, I got a new Baffle that I was gonna put in the old muffler, and I'm gonna end up using it in the new system.
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  #7  
Old 31st May 2020
duffy duffy is offline
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You can make a head pipe baffle (goes into the head pipe in front of the muffler).....I did that once on a set of Cobra pipes that were too loud for my liking.
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