Header OD and slip-on muffler ID dilemma

[Sojourner]

So my big box of parts came today finally, and already I've got a problem. I have a 4-to-1 header of unknown manufacture that has a 2 1/4" outer diameter end, and the slip on muffler has a 1 3/4" inner diameter. So here's the rub- I've looked around and all the slip-ons I can find max out at 1 3/4".

Not very "universal" after all.

So is there a creative solution to this problem? Summit sells a reducer, but I'm not a welder. Do you think it'd hold without welding, just by shear friction and a rigid mount?

[Big Rich]

What about MAC mufflers or SuperTrapp?

[Sojourner]

What about MAC mufflers or SuperTrapp?

I didn't see anything at MAC. SuperTrapp has a 2.25 ID slip on. You got $339 to give me? The cheapy Helix slip on I bought was like $60, and even that it a step up from what came on the bike...

[Big Rich]

I was thinking the aluminum or stainless mufflers:

https://www.denniskirk.com/universal-aluminum-external-disc-muffler.p43961.prd/43950.sku?_requestid=662259

[Sojourner]

Thanks, but even that's $181. I blew most of my parts budget on a Compufire unit ($203) and a Rick's stator ($125). I need something in the sub $80 range.

[gsgeezer]

I have an old Kerker four into one. It was very cheap for me to have a midpipe welded on, then I used a modern canister muffler. I have done that on a couple other old bikes and it worked out great!
(You can even buy a used can off fleabay, or elsewhere, pretty cheap.)

[Sojourner]

Ya, I'm thinking of hitting up Pep Boys tomorrow and seeing if they have a reducer (~2.125" to ~1.75") and having them weld it to the header. Then I can just use the cheap slip-on I just got (http://www.bikebandit.com/helix-20-t...versal-muffler).

[gsgeezer]

Ya, I'm thinking of hitting up Pep Boys tomorrow and seeing if they have a reducer (~2.125" to ~1.75") and having them weld it to the header. Then I can just use the cheap slip-on I just got (http://www.bikebandit.com/helix-20-t...versal-muffler).

Sounds like a plan!
Good idea about the stator upgrade. When I first got my 1000, I replaced the stator, since I read about the upgrade on the forum and I had to be in there anyway.

[Sojourner]

Well, about $25 later and I have a solution. Went to Pep Boys but they don''t do any welding (at least the one near me). They did however have the reducer I needed in stock which was 2.125" to 1.75" and cost a whopping $3 plus tax. So I went up to Midas and had them weld the reducer onto the end of my 4-to-1 for $20 + tax.

Kind of got robbed for around a 4" weld, but I don't have a welder, so I get what I got and I don't complain too loudly.