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  #1  
Old 28th October 2018
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Default 77-78 OEM exhaust baffle removal

So I wanna gut the insides of my OEM 77-78 cannon sized muffler. It's too restrictive and sounds ridiculous.

Not sure how to go about this, never done it and don't wanna mess up the outside of it in the process.

Here are some photos of it and what is the best way to go about this.





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Old 28th October 2018
60weight 60weight is offline
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Rather than destroying this nice oem muffler,why not use a set of drag pipes
till Shes broken in? (Your new engine build)
Id say fill up the beer mug and relax.
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Old 28th October 2018
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It's not just that it's restrictive and sounds like krap - it's heavy and ugly.
Go to your nearest exhaust place. ask them to make a two into one collector for you. Get them to neck it down to 2 inches for you. You can now select a muffler that looks good and works better. I ran the spiral core Hot Dogs for years.But there are plenty of nice chrome aftermarket mufflers that you can pick from.
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Old 28th October 2018
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see if you can find a hole saw to fit inside there.
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Old 29th October 2018
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I modified this 2 into one. You have to cut the welds at the front. Then you can slide the whole baffle out. You still have to cut the three spot weld at the end. To keep simple, be ready to paint the whole reassembly black or send to be rechrome; I just paint the new front welds and pipes with aluminum paint and cover the modification with the heat cover. At the back, couple of screw to hold it. You will see, the holes in the baffle are on the small side.
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Old 29th October 2018
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Quote:
Originally Posted by 60weight View Post
Rather than destroying this nice oem muffler,why not use a set of drag pipes
till Shes broken in? (Your new engine build)
Id say fill up the beer mug and relax.
I really don't like the looks of common drag pipes. I like the look of this OEM exhaust better. Now XLR drags, that would be a different story, nice perfect curves and the look you can't beat. But they are hard to find and expensive when you do.

While I agree about not messing with obsolete OEM parts unnecessarily, these mufflers are cheap and many available on eBay.

I'll get another one and put it on the shelf so I got it.

Engine is broke in. I had 1000 miles on it before I tore it apart 4 years ago. 400 miles on it today.
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Old 29th October 2018
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Here you can see where I cut my pipe. I have removed the original silencer and replaced it with an 2,5" perforeted tub 12" long without packing, The bike run great and the sound is really nice.
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Old 1st November 2018
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Quote:
Originally Posted by 60weight View Post
Rather than destroying this nice oem muffler,why not use a set of drag pipes
till Shes broken in? (Your new engine build)
Id say fill up the beer mug and relax.
Dead on the correct answer.....
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Old 1st November 2018
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Repro XLR pipes on eBay for $200:

https://www.ebay.com/itm/Harley-Spor...8:pf:0&vxp=mtr
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Old 1st November 2018
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Straight pipes are not the answer for the street. No matter how bitchen they sound or how nostalgic or "correct" they appear.

Straight pipes suck!

Ideally a 2:1 pipe should terminate in a Venturi that leads to a megaphone. The Venturi enhances the scavenging effect and the megaphone allows the gasses to gradually slow down without getting in the way of the next pulse and also works as a check valve restricting reversion. A pressure wave will not travel backwards in a megaphone because it gets squished down.

They don't call me Ironhead Rick just because I'm hard headed
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