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Cut the mufflers just rear of the dimple about 4" behind the smallest part of cone.
Next if you look close there is a slight bulge 1/2" behind the weld. I marked it with a sharpie to use as a guide once I break thru first tube. The exhaust is double walled here, the inner tube reduces and the outer tube expands at this point.
Use a cutoff wheel and carefully cut off the outer ring only, leave the inner tube in tact to sleeve over later.
Put the headers back on bike and figure out mounting etc for mufflers. For the Supertrapp mufflers I chose (443-1717) I need a 5" extension to make it work.
The inner tube is 1-5/8" OD. A piece of 1-3/4" exhaust pipe is a near perfect fit to slide over the stub. Weld it up and grind it down smooth.
Mock up shot. I cannot weld SS so will have to get the bike over to my buddies house. I plan to make a SS mount tab like the stocker and get ride of the strap at a later date.
2 of 3 bolts snapped on each header when I removed the heat shields. I used a dremel cutoff wheel to cut what I could of the weld and then a chisel and hammer to remove old threaded bung so I could weld new nuts into place.
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