HELP! D&D Fatcat install problems
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Tourer
Joined: Mar 2007
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HELP! D&D Fatcat install problems
I'm trying to install a D&D Fatcat on my 2007 Streetglide. I can't get the muffler to clamp down on the header collector. I've tried everything I can think of. Here's what I'm faced with:
1. The angle of the header wants to slope down and the muffler wants to slope back up even with the 1/2" spacers. I tried to clamp the muffler on in every array of alignment (with the muffler straight inline with the collector, with it bolted down to the bag support, etc.). But, I can't even get the clamp to snug up. I've gone through four bolts -three broken, one stripped. How can I wrench this clamp down if the 1/4" bolt keeps breaking? How does D&D expect enough torque on these "nuts" (c-clamp nuts) if they are made of aluminum? First, I stripped the nut, then broke three bolts. The tightest I can get the clamp only causes the slightest amount of friction. I can still easily pull the muffler off!
2.How can one compress the muffler with a 3/4" c-clamp if the muffler only has 1/2" releaf cuts in it? It seems that I'm clamping on a solid piece of pipe. Something that a c-clamp with a 1/4" bolt just doesn't have enough brute to accomplish.
3.Shoudthe bracket that's welded to the header be on top of the trans bracket or underneath?
4.Should I use the trans bracket that is stock with the bike, or use the black one that comes with the pipe?
My only option is to upgrade to larger hardware or "fill-in" the gap with a sealant. That idea is just too much of a jerry rig and doesn't give me any confidence that the muffler will rattle off the back end of the bike. I can imagine my $560 exhaust dragging off the side of the bike at 60 mph.
Has anyone else experienced these problems? Any recommendations? Any help would be greatly appreciated.
1. The angle of the header wants to slope down and the muffler wants to slope back up even with the 1/2" spacers. I tried to clamp the muffler on in every array of alignment (with the muffler straight inline with the collector, with it bolted down to the bag support, etc.). But, I can't even get the clamp to snug up. I've gone through four bolts -three broken, one stripped. How can I wrench this clamp down if the 1/4" bolt keeps breaking? How does D&D expect enough torque on these "nuts" (c-clamp nuts) if they are made of aluminum? First, I stripped the nut, then broke three bolts. The tightest I can get the clamp only causes the slightest amount of friction. I can still easily pull the muffler off!
2.How can one compress the muffler with a 3/4" c-clamp if the muffler only has 1/2" releaf cuts in it? It seems that I'm clamping on a solid piece of pipe. Something that a c-clamp with a 1/4" bolt just doesn't have enough brute to accomplish.
3.Shoudthe bracket that's welded to the header be on top of the trans bracket or underneath?
4.Should I use the trans bracket that is stock with the bike, or use the black one that comes with the pipe?
My only option is to upgrade to larger hardware or "fill-in" the gap with a sealant. That idea is just too much of a jerry rig and doesn't give me any confidence that the muffler will rattle off the back end of the bike. I can imagine my $560 exhaust dragging off the side of the bike at 60 mph.
Has anyone else experienced these problems? Any recommendations? Any help would be greatly appreciated.
Cruiser
Joined: Apr 2007
Posts: 156
Likes: 0
From: Sanford, ME
RE: HELP! D&D Fatcat install problems
not sure if this will help...found a link to an install on a Dyna...
http://www.americancyclemag.com/tech...ails.asp?SID=8
Dennis
http://www.americancyclemag.com/tech...ails.asp?SID=8
Dennis
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Tourer
Joined: Mar 2007
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RE: HELP! D&D Fatcat install problems
I studied that last night getting ready of the pipes to arrive today. So, this confirms the pipe bracket goes under the trans bracket. That's what I thought. Just trying to figure out why the header wants to slope so far downward.
Ultimate HDF Member
Joined: Feb 2006
Posts: 5,939
Likes: 3
From: TX
RE: HELP! D&D Fatcat install problems
I could be wrong, but I thought that on the 07's the pipe bracket goes on top of the tranny tab. My 05 is on the bottom, but they had to change the bracket up for the new tranny. It should be very obvious.
You MUST use the tranny bracket provided by D&D. Are you trying to use the stock one?
Installation docs for a Dyna does not conform anything on a Bagger install. did you receive instructions with the pipes?
There is something not aligned properly. This should be quite simple and the head pipes should be "in line" with the muffler assembly - see mine in my sig photo. You do need to use the black spacers between the hanger and the muffler standoffs.
Perhaps you can loosen the all hardware back up and see if you can get things to line up better. I've been using these pipes since 2002 and installed many of them over the years. I have NEVER had any problems with the installation and I have NEVER broken any hardware during the install....
[&:]
You MUST use the tranny bracket provided by D&D. Are you trying to use the stock one?
Installation docs for a Dyna does not conform anything on a Bagger install. did you receive instructions with the pipes?
There is something not aligned properly. This should be quite simple and the head pipes should be "in line" with the muffler assembly - see mine in my sig photo. You do need to use the black spacers between the hanger and the muffler standoffs.
Perhaps you can loosen the all hardware back up and see if you can get things to line up better. I've been using these pipes since 2002 and installed many of them over the years. I have NEVER had any problems with the installation and I have NEVER broken any hardware during the install....
[&:]
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Tourer
Joined: Mar 2007
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RE: HELP! D&D Fatcat install problems
I don't have anything bolted down tight. I have the nuts barely one the bolts to allow alignment. I'm using the black trans bracket provided with the exhaust. I did recieve installation instruction. However, they are very general and don't give any details (troubleshooting) for the problem I have.
I have the collector tab under the trans bracket. I tried the tab on top of the trans bracket but it seemed obvious to me the tab wanted to be under. Nothing felt right about it. The front down pipe was in contact with my timing cover.
I have the collector tab under the trans bracket. I tried the tab on top of the trans bracket but it seemed obvious to me the tab wanted to be under. Nothing felt right about it. The front down pipe was in contact with my timing cover.
Road Warrior
Joined: Jan 2006
Posts: 1,282
Likes: 115
From: British Columbia
RE: HELP! D&D Fatcat install problems
When I tried the FC on my bike I had the same problem with the muffler clamp. I broke one bolt and finally got it to seal up with a good dose of ultra copper silicon. The muffler clamp is way to small for the chunk of iron it's trying to squeeze together. The pipe had excellent fit and finish and was simple to install. I wonder if you got the wrong pipe or a defect, something don't sound right.
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Tourer
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RE: HELP! D&D Fatcat install problems
I finally got it. I said F*** It and opened the relief cuts an additional 1/2". Then I was able to shape(aka bend)the opening down to a snug fit. So, when I started cranking on the clamp the muffler tightened up right away. Just had to snug it up a bit more and it was solid.
I did have to make up a new bolt since I had wasted all of my others. Just cut the threads down a bit more and cut the bolt off to length. That actually was the easiest thing I did tonight. I could have waited to buy some new bolts tomorrow, but I wouldn't be able to sleep tonight knowing I was getting my azz kicked by a muffler.
Now all I have to do is route the O2 sensors, hook them up to my ThunderMax, download a new baseline map, and fire that noisy bastard up! Life is good!.........................for now!
I did have to make up a new bolt since I had wasted all of my others. Just cut the threads down a bit more and cut the bolt off to length. That actually was the easiest thing I did tonight. I could have waited to buy some new bolts tomorrow, but I wouldn't be able to sleep tonight knowing I was getting my azz kicked by a muffler.
Now all I have to do is route the O2 sensors, hook them up to my ThunderMax, download a new baseline map, and fire that noisy bastard up! Life is good!.........................for now!
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RE: HELP! D&D Fatcat install problems
I'm trying to put a set on my FLHT 2006, and having a hell of a time, got $30 bucks in gaskets and still won't seal the front tube. D&D says start at the rear and tighten your way up front, what a bunch of bull ****. I think you should alway start at the ports. I think I'm going to end up with the tab on top of the trans. mount. The good ole aftermarket. Terry