exhaust flange broke

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Dec 2, 2017 | 06:01 PM

Big Panda

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From: Los Angeles

exhaust flange broke

So I was riding north towards the Grand Canyon along the 89A in AZ when I suddenly heard my bike get a bit louder. I asked my wife to look and see what was going on and she reported that the muffler had fallen off! Thankfully the mounting bolts held the back end on but the front of the muffler was dangling free of the header. Luckily we stopped at a navajo jewelry store and they gave me some super thin surgical steel wire and some copper wire to use to mend the exhaust system temporarily.

After I get home and have time to take things apart I find that the flange on the header side of the exhaust pipes has almost completely broken off, save for one very small piece at the bottom.

So here is what I want to know:

Is this fixable with a weld? I feel like it isn't because its such a small thin piece.

Since I will most likely need to buy a new set of exhaust pipes I want to buy a black set. I'm having trouble finding black exhaust in anything besides short pipes/drag pipes. I'm not really looking for that much sound, I'm happy having pipes coming out the back.

I found this set:
https://www.jpcycles.com/product/713-410

It says that it is for big motor builds (110 ci or larger) or forced induction. Mine is neither of those but it says it will fit my bike. Is it OK to use even if its meant for larger motor bikes? Any downsides to using it on my bike?

I found these however the bike came from the factory with a dual exhaust that had the pipes connected, and these aren't connected, should I stay with the connected pipes or can I get these and just put the black exhaust wrap over them for a cheap option?

I am also fine using black exhaust wrap over a cheaper exhaust system.

I find it pretty difficult to search through the ocean of HD parts to find the right stuff for my bike!

Any hints, tips or tricks would be appreciated!

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Last edited by Big Panda; Dec 2, 2017 at 06:06 PM.

Dec 2, 2017 | 06:11 PM

Dr.Hess

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From: NW AR

You can use any exhaust from a FLHx up through 2007. So when you're searching, widen it out some.

While I wouldn't say it can't be welded, yeah, it's going to be tough. Some people cut that flange off and put the later style slip on mufflers on instead, so there's always that, too.

Dec 2, 2017 | 06:15 PM

Big Panda

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From: Los Angeles

Quote:

Originally Posted by Dr.Hess

You can use any exhaust from a FLHx up through 2007. So when you're searching, widen it out some.

Ah, good to know, thank you.

Quote:

Originally Posted by Dr.Hess

While I wouldn't say it can't be welded, yeah, it's going to be tough. Some people cut that flange off and put the later style slip on mufflers on instead, so there's always that, too.

I actually am happy to use this as an excuse to get rid of my chrome pipes. So if i can find something i will probably just go for it instead of just putting slip ons on.

Dec 2, 2017 | 08:21 PM

WP50

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From: W. Texas

Ck the classified section of the forum.
Yes up to 07 can work tho may need a change in the mount at the tranny.
I put 2-1 D@D fatcats from an 05 Road King on my 97 EG with a mount change at the tranny. Worked out great

WP

Dec 3, 2017 | 01:40 PM

rizzo

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From: Black Hills

As far as the black pipes go, I just use Black Hi Heat BBQ grill paint. Little effort and it holds up fairly well.

Dec 3, 2017 | 02:45 PM

Hackd

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Joined: Oct 2005

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From: Canton, Michigan

How much noise are you willing to tolerate? That will somewhat dictate any change to an aftermarket system.

The OEM Harley flange system (I had it on my 93 FLHS), is really funky. Best to just cut the flair off the exhaust pipe and get some later model slip-on mufflers. OEM Harley if you want quiet, or pick your poison.

I had to swap out the entire system on my FLHS this past March. The right exhaust pipe had developed some serious cracks where the front/back pipes meet. It's an obsoleted part now. If you can find a good used 'take-off' from a 'glide up to 2007, you can swap the whole thing over and get into some newer 'stuff'. I couldn't find one, so I ended up installing a ThunderHeader. It is a bit noisier than the SuperTrapp slip-ons I had installed. But it's a fairly easy bolt on.

Dec 3, 2017 | 08:42 PM

Big Panda

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From: Los Angeles

Quote:

Originally Posted by Hackd

How much noise are you willing to tolerate? That will somewhat dictate any change to an aftermarket system.

Tough question. Im not looking for an obnoxious level. My wife rides with me frequently and if its too loud shes going to complain. But a reasonable increase would be fine.

Quote:

Originally Posted by Hackd

The OEM Harley flange system (I had it on my 93 FLHS), is really funky. Best to just cut the flair off the exhaust pipe and get some later model slip-on mufflers. OEM Harley if you want quiet, or pick your poison.

I had to swap out the entire system on my FLHS this past March. The right exhaust pipe had developed some serious cracks where the front/back pipes meet. It's an obsoleted part now. If you can find a good used 'take-off' from a 'glide up to 2007, you can swap the whole thing over and get into some newer 'stuff'. I couldn't find one, so I ended up installing a ThunderHeader. It is a bit noisier than the SuperTrapp slip-ons I had installed. But it's a fairly easy bolt on.

It seems to me like the slip ons would be the easiest route. I'll look through the classified for a take off from that range and see what I can do. If I can't find a complete take off I will probably go the slip on route.

Thanks for the info guys