Interested in your findings, please post after the modifications.

I have the Fulsac DX pipe with CVO cans and 2" inserts. Like you I find it a little loud. There is a rasp I cant get used to, and my hearing sucks after 40 years in live music.

 

Just heading out for a short afternoon ride. I pulled the 2" cores which have about 7000 miles on them. I forgot I had purchased an extra set of Fullsac muffler blankets. I left the old blankets in place and cut off about an inch off the width of the new, install them, along with the screens. i did not alter the 2" cores at this point. Want to see if I'm gaining ground before altering. Sound deeper and quieter at an idle in the the shop, will see if their better now. Also looking for a set of 1.75" Power Cores to try that route too.

 

I'll get a pic of the washer.

 

I was told if you remove the washer then you have the normal crushers.

 

I run the stock headpipe and the crusher mellow mufflers and to me it's perfect.Nice rumble on the interstate and in town.I wish they perked up more under full throttle but with exhaust they seem to shine in some area and slightly lack in another.Im thinking at some point you have to be happy with what you got or we're going to go crazy.��

 

Im running the Fullsac true dual conversion with CVO cans and 2" Fullsac baffles, no screens or matting. I think they sound great a nice quiet low tone till you get on it and then they have a good bark and no problem hearing my music on the highway. FWIW before I put the Fullsac baffles in I ran the CVO cans in stock form and they were WAY quieter, too quiet for me but they did sound nice.

 

LOL.......I've been accused of "having taken leave of my senses" on a number of occasions! HD Exhaust and Seat options, can certainly push the envelope!

 

First of all thanks to Idahokid for the Mellow baffle photo!
After replacing the Fullsac blankets in the CVO's the noise was still much louder than what I wanted.
Tonight I pulled the 2" Fullsac baffles out again and decided to weld in a washer similar to what the Crusher Mellows have. To do this I found 2- 2" OD washers in my shop. They only had a 1/2" hole in them but looking at the Mellow photo that Idahokid posted it was hard to tell but sure looked like it could be a 1/2" (this fact is an unknown to me).
I clamped the baffles in my bandsaw and cut them about 3/4 of the way through the diameter. I set the cut at 9" from the rear of the baffle. After cutting them I used a thin cut off wheel to match the cut to the thickness of the washers. I then clamped the baffles to a piece of steel using a couple pairs of vise grip clamps. This kept the baffles straight and true as I welded them back solidly.
Reinstalled the baffles and they sound deeper and quieter than with the straight through core. The annoying higher pitched is gone. Went out for a short spin and they were much quieter and easier on my ears. When I got back I decided to fab up a 16" long 13/16" drill bit so I could increase the size of the hole in the washer. Sounds even better now and still has a very very deep tone with no tinny sound what so ever. I'm going to try a put on a couple hundred miles with them in the next day or two. Will also run a couple of Auto Tune sessions to compensate for the increased back pressure.
I'm pretty sure I'm finally close to where I want to sound level to be. I can always increase the hole size of the washers if I feel the need. At this point I'm guessing that I won't need to do that.
The sound is deeper, a little louder, and less tinny, than what it was when I tested the TD's with my stock OEM SG mufflers. Also sounds absolutely fantastic to me at an idle. No more of that poof poof restricted sound when idling.
I'm not saying, or guessing that this baffle mod will reduce or increase overall performance, I consider the SGS to be an 830 lb cruiser, not a drag bike. Hopefully this will help make an all day ride more enjoyable for me and my tired old ears. I love the looks of my CVO cans and hope to like the Mellow/Fullsac modded baffles as well.

 

The **** we go through to get the perfect sound.There must be a 12 step program for us��

 

"The annoying higher pitched is gone"

Thanks for posting your results. Im going to give this a go, piece of cake. I was about to get some 1 3/4" baffles but its a pain in the *** living in CA. I need to have someone else buy them and ship to me.