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Sportster muffler installation help! (Read 109 times)

skrapiron -FSO

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Sportster muffler installation help!
04/22/08 at 09:18:15

Hey guys, I finally got around to dropping my exhaust to mount up my sportster muffler in place of the stock one. I have one problem that I can't seem to find a work around for.

On the header end of the muffler, there is a 1" diameter hole, presumably for some kind cross-over hose. I have the muffler fitted up, but I can't seem to think of any suitable way to block the hole to keep gasses from leaking out the side, instead of through the baffles.

Short of taking it to Mr. Muffler and having them weld a piece over the hole, is there any way to block that off?

Everything I say is fully substantiated by my own opinion.

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 29692 Tucson Az Gender:	Re: Sportster muffler installation help! Reply #1 - 04/22/08 at 09:36:06 Looks like you bought the wrong muffler. We generally go for the ones without the crossover tube. But now, since youv'e already got it, how about an automotive engine freeze plug. See if you can find a 1" freeze plug and tap it into the tube?
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T Mack 1 - FSO

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Re: Sportster muffler installation help!
Reply #2 - 04/22/08 at 10:52:50

IMO, two choices.

First, sell it and get a Dyna muffler. The Dyna's have the cross over in the header not the muffler.

Or Second, seal it. Options, freeze-out plug welded on or squeeze the opening together and weld the resulting seam closed. The BIG question, does the cross-over opening/pipe hit anything under the bike??

Engineers design things, Technicians make them work.
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30% of being mechanical is confidence/30% is knowing to go slow when needed/30% is looking repeatedly at what you have/10% is dumb luck Wink

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skrapiron -FSO

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Re: Sportster muffler installation help!
Reply #3 - 04/22/08 at 16:05:41

Ok, the freeze plug worked.

I got one that was just a HAIR too small to fit over the opening, then persuaded it in place with my favorite tool, a 3lb hammer.

I used a regular automotive muffler clamp (like yours, T-Mack) and took it out for a spin.

WOW, what a difference. it sounds SOOO much better. Can't really say that the butt dyno detected any more get up and go, but I didn't run it on the expressway yet.

I'm planning on taking it to Mr. Muffler tomorrow and having them weld the pipe to the header and welding the freeze plug to the cross-over hose fitting.

Heres a pic of the pipe installed. No T-Mack, It fits with no clearance issues...

Everything I say is fully substantiated by my own opinion.

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steely

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Re: Sportster muffler installation help!
Reply #4 - 04/22/08 at 20:26:05

I would suggest that, since you are taking it to have it welded, you have them put a 10 degree adapter in place. Where you have it now will soot up the rear brake linkage in no time. It should cost you no more than $15 to have the adapter tube made, and will keep the exhaust more inline with stock. Should you want a heat shield to cover the adapter tube, there are plenty to be had on ebay for about $20.

1999 Suzuki Savage

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