Modifying Mufflers
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Joined: Aug 2008
Posts: 74
Likes: 0
For '08 (FLHTCU, 96ci/1584cc, black, of course), the mufflers have tapered baffles that cannot be simply drilled. Does anyone have any experience with these? The right can has the weird baffle, while the left can has a short baffle on the outlet side only--nothing on the inlet.
Took a look inside with an LED light wand and instead of the baffle plugs I am used to seeing (i.e. a flat metal slug brazed/welded in place, that can be easily drilled or punched out), there is a series of crimps (pinch points) in the inner pipe (baffle), which is what I believe BunnyBoy is saying when he says "tapered". So the baffle plugs are actually the inner pipe (baffle) pinched shut. I have done this mod on other exhausts, so it is not foreign to me, but it looks to me like this type of baffle plug cannot be easily drilled out with a hole saw, since the plug is actually part of the baffle itself.
So when you guys are talking about the hole saw deal, and removing the baffle. Are you talking about a hole saw that is bigger than the inner pipe at the exhaust end, and cutting it on the endcap, then pulling the baffle guts and part of the endcap out?
Last edited by MrDoo; May 22, 2009 at 07:14 AM.
Road Captain
Joined: Nov 2006
Posts: 728
Likes: 1
From: Yakima, WA
I have the same issue, I guess that is why I am confused about the drilling.
Took a look inside with an LED light wand and instead of the baffle plugs I am used to seeing (i.e. a flat metal slug brazed/welded in place, that can be easily drilled or punched out), there is a series of crimps (pinch points) in the inner pipe (baffle), which is what I believe BunnyBoy is saying when he says "tapered". So the baffle plugs are actually the inner pipe (baffle) pinched shut. I have done this mod on other exhausts, so it is not foreign to me, but it looks to me like this type of baffle plug cannot be easily drilled out with a hole saw, since the plug is actually part of the baffle itself.
So when you guys are talking about the hole saw deal, and removing the baffle. Are you talking about a hole saw that is bigger than the inner pipe at the exhaust end, and cutting it on the endcap, then pulling the baffle guts and part of the endcap out?
Took a look inside with an LED light wand and instead of the baffle plugs I am used to seeing (i.e. a flat metal slug brazed/welded in place, that can be easily drilled or punched out), there is a series of crimps (pinch points) in the inner pipe (baffle), which is what I believe BunnyBoy is saying when he says "tapered". So the baffle plugs are actually the inner pipe (baffle) pinched shut. I have done this mod on other exhausts, so it is not foreign to me, but it looks to me like this type of baffle plug cannot be easily drilled out with a hole saw, since the plug is actually part of the baffle itself.
So when you guys are talking about the hole saw deal, and removing the baffle. Are you talking about a hole saw that is bigger than the inner pipe at the exhaust end, and cutting it on the endcap, then pulling the baffle guts and part of the endcap out?
Cruiser
Joined: Jan 2008
Posts: 223
Likes: 0
From: texas
yeah well i did something similar to my wifes "V Star" and it sounded way better than stock. but then we did a big air intake and rejetted the carbs so i had to buy her a cobra pro hp 2/1. doesnt sound like a harley but it still sounds good. she has had her bike for 14 months brand new out of the showroom and she has put 22,000 miles on it. i told her id buy her a brand new harley of her choice. but she is one of those type that is just grateful and thankful that she is on 2 wheels. my Vic has Santa Rosa Vtwin aces and is loud as a B, im gonna do this mod to my stock 07 SG pipes though.
Seasoned HDF Member
Joined: Jul 2007
Posts: 6,336
Likes: 67
From: SW Minnesota
I bought a set of modified stock pipes from tkemple on ebay. What he does, is drill the two baffle plates out, as described, and then cuts out part of the baffle in "stages" from the inlet end. The more he cuts out, the louder it gets.
We have been very happy with his "Stage Two," which he recommends for tour bikes with a radio. The exhaust end looks stock, unless you get down on your hands and knees and shine a flashlight up the pipe, where you can see the baffle plate is drilled out. Other riders following us tell us they sound great but are not objectionably loud.
The pipes give the appearance of stock to Joe Law, but sound nice when cruising and bark when you get on it. I do think they sound a little tinny at idle.
If you call him direct, he will knock off what he would normally pay in eBay fees.
Someone mentioned the "honey comb." That is the catalytic converter. Some tour bikes, like our '06 Ultra, had them on the right side muffler.
We have been very happy with his "Stage Two," which he recommends for tour bikes with a radio. The exhaust end looks stock, unless you get down on your hands and knees and shine a flashlight up the pipe, where you can see the baffle plate is drilled out. Other riders following us tell us they sound great but are not objectionably loud.
The pipes give the appearance of stock to Joe Law, but sound nice when cruising and bark when you get on it. I do think they sound a little tinny at idle.
If you call him direct, he will knock off what he would normally pay in eBay fees.
Someone mentioned the "honey comb." That is the catalytic converter. Some tour bikes, like our '06 Ultra, had them on the right side muffler.
Seasoned HDF Member
Joined: Jul 2007
Posts: 6,336
Likes: 67
From: SW Minnesota
We watched Dr. Dyno at work at Sturgis. On bikes he was tuning with stock pipes, he had a length of 1/2 rod, sharpened on one end, that he inserted into the exhaust end, and rapped on with a hammer, and knocked the plugs right out.
I always wondered where those plugs went, as I did not see them blow out when he started the bike. If they ended up in front of the baffle, I would think they would have rattled like crazy.
I always wondered where those plugs went, as I did not see them blow out when he started the bike. If they ended up in front of the baffle, I would think they would have rattled like crazy.
Cruiser
Joined: Nov 2008
Posts: 178
Likes: 0
From: Texas
We watched Dr. Dyno at work at Sturgis. On bikes he was tuning with stock pipes, he had a length of 1/2 rod, sharpened on one end, that he inserted into the exhaust end, and rapped on with a hammer, and knocked the plugs right out.
I always wondered where those plugs went, as I did not see them blow out when he started the bike. If they ended up in front of the baffle, I would think they would have rattled like crazy.
I always wondered where those plugs went, as I did not see them blow out when he started the bike. If they ended up in front of the baffle, I would think they would have rattled like crazy.
Cruiser
Joined: Feb 2009
Posts: 102
Likes: 0
From: sw,pa
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Seasoned HDF Member
Joined: Jul 2007
Posts: 6,336
Likes: 67
From: SW Minnesota
[QUOTE=cajunfla;5043305]
Don't know if he has an ebay store, but search by seller tkepple03
I'll pm you his phone number.
Edit: Here's his current listings, but again, call him direct and save the ebay fees.
http://shop.ebay.com/merchant/tkeppl..._sopZ12?_rdc=1
I'll pm you his phone number.
Edit: Here's his current listings, but again, call him direct and save the ebay fees.
http://shop.ebay.com/merchant/tkeppl..._sopZ12?_rdc=1
Last edited by MNPGRider; May 24, 2009 at 09:07 PM.