Geezer..attatching pipes without welding..how

[gk45241]

how do you get them bolted up so they are not leaking? Coke can shims? Whats the trick?

[Geezer]

Slot the end of the muffler the long way about 3/4" from the open end and then the clamp will draw it closed.

Geezer

[XS1100 Newbie]

Sometimes you can measure the od if the pipe on the bike, then the id on the muffler pipe, and go down to Napa or your local parts house, and see if they show a reducing bushing in their catalogs in the size you need. If they won't look it up, then give me a hollar, and i'll do the checking. Don't forget the od, and id.

[MindWebs]

Yep.

Yep, napa has'em

it is a 1 3/4 inch ID, to 1 3/4 inch OD by 12 inches long

they are about $4 to 7.00 each..(can't remember for sure)

if you leave it long and build a bracket like i did it works good..

but a word of advice with these HD sporty mufflers, Weld washers into the discharge end, it will lower the tone at cruising RPM, but keeps that Beefy sound to it. this makes highway runs MUCH more pleasent!!!!

if you use the longer lenth you can keep your center stand, you still cut some off the 12 inch lenth...

[Larrym]

Just to be sure...

Even when you get it close it can still leak.

I used this:

http://www.napaonline.com/MasterPage...Muffler+Cement

[mro]

but a word of advice with these HD sporty mufflers

2nd word of advice about HD parts and the XS.
Careful, don’t let your venerable XS11 know that you or a friend has a pick'em up truck.


mro
BTW,
Geezer's way works well and the clamp will hide the slot cuts.

[gk45241]

NOOOOO truck

I know she would come back and haunt me if She knew I could haul her if I had to.

My bike is tempermental still at best to say the least.

Does anyone have a closeup of the brackets they made to secure the rear of the pipes. I am going to get the pipe dope for the front this week and need to figure how to fab the rear brackets. I want to keep the pipes short as in the above pics if possible to keep it out of the way of the rear axle etc.

PICS PICS PICS
Thanks,
Gary

[MindWebs]

HD VS. Jap., Winner = JAP

hee,hee,hee...

ah yeah... about the pickup truck thing....

my bike snapped one of the pipes off at the welded connection on the input end (the HD factory weld on the inlet end). I had my bro tig weld it back together, I'm planning to sand blast the system and paint it black anyway.

I'll get some picks fro ya..

[gk45241]

Thats funny. Quality US made parts imported from China I'm sure..lol

My bikes so tempermental I am sure it would just be a matter of time before it will try to throw a mufler off anyway...

Pics appreciated.. thanks,
Gary

[MindWebs]

Pic's and instructions for fabrication.

OK, I suck at posting pic's but i'll give'er a shot.

I welded the SS washer in to lower the tone at 60 MPH.


Side Shot


A shot from the rear toward the front of bike


Angle shot from rear right toward front left


Extremely rough picture of the shape of the brackets
The squiggly lines are low angle bends (2 bends total)
All 1 piece of SS heavy sheet steel.


The way i did it was:

With the bike on the center stand, install the mufflers, now "prop" the outlet end up to the level you want.

Take a piece of cardboard and draw out the approx. shape of the bracket you want. Leave both ends longer then you need so you can slowly trim them down as you "test fit" your cardboard bracket.

to find the angle you'll need you can cut half way through the cardboard and it will "flex". now install your cardboard bracket and apply masking or duct tape to the area you cut making the joint stiff.

using cardbaord to create a template is an industry standard in many R&D shops and Fabricating shops. it is cheap, easy to cut and manipulate, and allows the user to scrap as many "prototypes" as he wishes with no costs in metals.

I'm sorry to be too lazy to pop them off and take good pic's.
but i tightened the hell out of those bolts and they are a pain to take loose.

Good luck Fabricators!!

Webs

[Poprock]

I'm running Sporty muffs on my SG. Had a muffler shop make a short adapter welded to the headers. The mufflers tuck up next to the header, well under the heat sheild. Harley muffler clamps snug them on. The shop guy welded a bracket slanting forward that mates to the original muffler mounting point. The mufflers are stock, baffles in place. They sound real good, same volume level as a stock system but with a little deeper pitch. No washers needed in mine. YMMV

[clobe26]

What i took was slotted the pipe ends, used "THERMAL HEAT WRAP" (sold at local auto parts stores) & Bolted a clamp over the slotted ends covered by the heatwrap....Looks Killer & functions nicely....no leaks! Hope this helps.

[gk45241]

all over but the heat wrap or heat shield

Need to apply some heat wrap or some of the sealent then the heat shields. I have a slight exhaust leak at the joint but should be able to get it to seal up. Thanks all for all the help. Brackets are temporary. I will be changing them as soon as I can get my hand on some better 16-18 gauge.Thanks to all for thier help. Is a louder than stock but a lot quieter than it was with the huge hole in te right stock muffler, and the tone is a little better. Not a Harley but who wants one.



Gary