My brother put a Fullsac True Dual Exhaust convertion kit on his 2000 FLH and after a year it giving us problems after a year of working great, now the slip on that connects to that side is coming loose and even comes out completely!

How can this get fix? Maybe the pipe has expanded and even though we tight the clamp to the max still comes loose.

I don't know if this is something to consider... but I was thinking that if we put something that prevents the slip on from moving backworth in the little rail that it hangs on from the mounting hardware then it shouldn't come loose? Has this been done before? Could this work?

Please help.

 

maybe try a new clamp

 

I re-use clamps many times, but I sometimes have to pay careful attention to how the old clamp is 'coming together'. The bolt goes through the metal strap that is essentially the clamping device. That strap has a spacer between the ends. The bolt, and spacer, both have a spline that may not align correctly after removing/reinstalling the clamp. When you force the two pieces together, and the splines are not aligned, it will not allow the bolt to pull the clamp together completely.

It can be very difficult to remove the bolt, and attempt to re-align it with the splines in the spacer after the clamp has been torqued several times. (The spline becomes distorted.) Most would consider this to much effort and just get a new clamp.

Also, the spacer between the metal strap ends can get twisted, and resist proper torque. This is again sometimes difficult to correct, but a little persistence can help.

If you find that a new clamp has the same condition, then the slipon may need to have the end compressed to get a better fit. Or, you could expand the end of the header which the slipon 'slips' onto.

A muffler shop could do this pretty easily for you, or you can get a cheap set of pipe expansion/compression tools at Harbor Freight. That will prolly be a one time use tool!

I really wouldn't suggest doing that with a chrome pipe/muffler because the chrome is brittle, and can crack very easily. The header pipe should be stainless steel, but the muffler (slipon) is probably chromed.

One other thing...
The slipons usually have a couple slices in the end that attaches to the header pipe which allows the muffler end to squeeze together, and clamp onto the header pipe. I have seen them come from the factory with a 'defect' where the slice is too close together, or even not cut long enough into the pipe and that can keep it from being pulled together close enough to actually clamp onto the header. This may be corrected with a dremel tool fitted with a metal cutting disk. Though, again, this does cut through the chrome plating and will expose the inner base metal to the atmosphere, which may cause rust to form.

Dam, didn't mean to write a book, but there it is!

 

Take it a muffler shop, get it where it belongs, tack weld and then remove and complete the weld...

 

I put a fullsac on mine... had the same problem.. until I tightened it differently.. I tightened the clamp on the muffler first.. then I attached the back hanger.. seems my pipe doesnt quite sit straight...

 

I don't think it would be wise to mess with the rear hanger- it needs to be able to move back and forth as designed. I would agree with the new clamp as a first step.

 

Weld the connecting pipe that goes from the Fullsac to the rear slip on?

 

Can you explain a bit more.

 

If I put the muffler on, then attach the hanger bolts in the back...when I tighten the front clamp the pipe isnt in square..so it doesnt get tight..
I put the muffler on..tap in onto the header pipe with a piece of wood and a mallet.. then tighten the clamp.. then I attach the 2 bolts for the rear hanger.

Stays tight...

 

It's many years since I used a Fullsac TD kit, but that sounds familiar! It's a cheap way to find if you like TDs, but after a while I bought a new set of Samson pipes.

EC, the exhaust is fastened to the engine and the engine is rubber mounted, so that rear hanger has to work properly, to allow the engine to rock on its mounts.