Mufflers Repacked
After reading about how awesome Big City Thunder baffles sounded I started to consider replacing the baffles with the BCT QQ’s. So I took out the baffles so I could measure them, and to my surprise one of them was missing the glass fiber insulation. That’s when I decided to just remove the insulation from the other pipe and run with just the baffles installed.
It sounded like $hi7!
I asked BCT about installing their baffles and they sent me this email…
“Thanks for the inquiry on Big City Thunder Products.
You remove the baffle only and leave the screening and insulation in place. This insulates the inner pipe from the outer pipe so you do not have a tinney sound.
Big City Thunder”
So, either way I needed to repack them. I went to a dealer that sells dirt bikes; they had lots of different repacking material to choose from. The stuff I ended up getting was a heavy white pad of material. It was much denser than the other stuff, and seemed like it would hold up the best.
Stuffing the wire mesh, wraped with glass, back into the pipe was a friggin pain in the ***. Two hours later I’m done and ready for a test ride. I’m also covered in fiberglass and itching like hell. Anyway, a quick shower and off I go.
What a difference this made! The exhaust now has a real nice low doooom doooom sound and all the annoying high frequency ticks are gone. As for the power, DAM!! I got all kinds of low to mid range torque I never knew I had since one of the mufflers was not even packed in the first place!
Anyway, I am much, much, happier with the way my Sporty sounds and performs now. I’m still thinking I may get some BCT baffles, but I’m in no hurry now.





