Modifying Mufflers
Stage II
Joined: Jun 2009
Posts: 2
Likes: 0
03 Ultra
OK, I have read throuogh all of the posts at least 3 times. Then I went out and cut out the rear plugs; it sounded "rappy" therefore I tool off the mufflers and cutout the front (nearest the engine) plugs and it was even rappier. It does not sound throaty or perhaps more to the point like a normal harley. While loudness is not my #1 intent the overal sound is and the "rappy" part is not pleasant. Like everyone I am trying to do this on the cheap and I am now wondering if I should go after the inner baffles but I am not sure how to get them out of there or if there is another alternative short of buying new slip ons.
Outstanding HDF Member
Joined: May 2009
Posts: 2,160
Likes: 62
From: GA.
I wonder if the rappy sound is because you cut the rear plugs, rather than the front one? I don't think mine sound rappy at all. I also have true duals though, so maybe that makes a difference in sound too?
Tourer
Joined: Apr 2009
Posts: 282
Likes: 1
From: Las Vegas area
Here's a sound clip. Sorry for the quality, it is a cell phone recording. Bike is in my garage, phone is about 4 feet directly behind the bike on a 5 gal bucket.
http://bobernet.com/mufflers.mp3
http://bobernet.com/mufflers.mp3
Stage II
Joined: Jun 2009
Posts: 2
Likes: 0
Mine bike doesnt sound the same. "Rappy" is the only word I can think of that would describe the sound. Much like when you put a glasspack on a car. the larger issue is that it doesnt have the throaty HD sound which is what I am after. I believe my issue is with the baffles but I do not know how to get them out. It took a 1 1/8" holt saw to get the plugs out. Someone wrote to use a 2" hole saw but that will cut into the outter tapered cone well before the baffle which might be what is needed to get the baffle out; I am not sure. I tried a 1 1/4" hole saw as it is about the same size as outter lip of the baffle thinking it would cut any welds and allow the baffle to come out but all it does is cut the end of the baffle.
Seasoned HDF Member
Joined: Jan 2009
Posts: 5,151
Likes: 2,975
From: WACO
I can get takeoffs from the dealer here for $5.00 a piece. Bought a pair of 09 slashdowns. So can I take a hole saw to the baffles on them. They have the "tapered" baffles. Not the baffle plates. I ask this because i hammered a sharpened rod down one and punched thru the outside of the muffler. Duh.
Good thing it only cost $5.00.
Good thing it only cost $5.00.
Tourer
Joined: Apr 2009
Posts: 282
Likes: 1
From: Las Vegas area
If anyone is interested in going this route, I just listed a set of modified stockers with dyno tune and PCV map in the Touring parts classified section. My listing has pics, dyno sheet, and audio of the mufflers after mods.
Intermediate
Joined: Dec 2007
Posts: 40
Likes: 0
From: Houston TX
09 baffles
Here's how I did my 09 mufflers. (purchased on ebay for $25.00)
1. Took 3 inch holesaw and removed factory baffles from exhaust end. Once removed these other steps will make more sense.
2. Then took some 10 inch by 2 inch universal baffles and fitted them to some 2 inch exhaust pipe for a combined length equal to the internal length of the muffler can. (these baffles can be found at JC Whitney or Ebay etc.) (Mine were left over V & H baffles that I had left over in my garage)
3. Welded a 3.5 flange on the new baffle assembly.
4. Wrapped new baffle in fiberglass muffler repacking ($7.00 at JC Whitney)
5. Welded the new baffle assembly into the muffler can over the 3 inch hole previously cut with the holesaw.
They sound and perform great. I dont think I could have purchased a better sounding (or looking) aftermarket slip on.
1. Took 3 inch holesaw and removed factory baffles from exhaust end. Once removed these other steps will make more sense.
2. Then took some 10 inch by 2 inch universal baffles and fitted them to some 2 inch exhaust pipe for a combined length equal to the internal length of the muffler can. (these baffles can be found at JC Whitney or Ebay etc.) (Mine were left over V & H baffles that I had left over in my garage)
3. Welded a 3.5 flange on the new baffle assembly.
4. Wrapped new baffle in fiberglass muffler repacking ($7.00 at JC Whitney)
5. Welded the new baffle assembly into the muffler can over the 3 inch hole previously cut with the holesaw.
They sound and perform great. I dont think I could have purchased a better sounding (or looking) aftermarket slip on.
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Outstanding HDF Member
Joined: May 2009
Posts: 2,160
Likes: 62
From: GA.
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