SuperTrapp installation advise:

[hlh1]

I'm installing a nice SuperTrapp header and slip on, on my 83 1100ED. All has gone well except that slipping on the "slip on" is requiring the persuasion of a rubber mallet and I still have another 1/2 inch of smacking to get it to line up with the hang point on the right passenger peg mount. I'm using a wood block so I hopefully don't bend anything. It's so tight that I won't need the clamp to hold on the slip on. Is this normal?

[Nessism]

Maybe the collector and/or the matching muffler connection is slightly out of round. This can happen when the band clamp is over tightened. Not sure what to suggest other than maybe trying to verify roundness...somehow. I say this from experience with a Supertrapp header I've got for my bike. It's a pain in the butt to get the muffler installed and rotated correctly so the hanger aligns.

[hlh1]

This one is brand new and never been installed before.

[mmattockx]

Check for rough edges and burrs on/in the overlap area to ensure nothing is hanging up.


Mark

[Nessism]

Maybe a little grease on the interface parts?

[hlh1]

Check for rough edges and burrs on/in the overlap area to ensure nothing is hanging up.


Mark

Looked nice and smooth before assembly.

[hlh1]

Maybe a little grease on the interface parts?

I'll try to separate it and lube, as you suggest.

[hillsy]

Maybe a smear of silicon instead of grease - silicon will act as a lube while it is wet but will then set and stop any leaks / blow by.

[alke46]

Once you get it separated, could you use a bit of emery cloth in the overlap area then apply either grease or silicone?

[hlh1]

Got it separated, lubed it, and it moved another 1/8 inch but I still need another 1/2 inch. I'm now considering cutting the slip on splits deeper.

[Boriqua]

If you have a caliper handy I would confirm roundness on the internal of the Muffler and the external on the header. Just because its new doesnt mean that one of the "fingers" on the supertrap isn't bent in some.

I would also mark where I think the muffler is supposed to slip to and take either a fairly aggressive steel wool or sand paper and smooth the area the muffler will slip on to then add the lube. From the pix the header look damn near new with a heavy coat of epoxy. I would want to take that down a little where the muffler goes. Not to bare metal but i would scuff it plenty.

If you want to be totally insane .. after checking round on both mating parts and giving a good hard buff to the header area I might take out my buffing fob and attach to my drill and use a little metal polish to smooth it out. After that a shot of silicone and you should be good to go.

I try and make the area as free as resistance as possible before I resort to banging with mallets.

I have also found with these things that rotating works better than straight force. Have you tried twisting it left and right as you install. Kind of cork screwing it down as you go back and forth.

If the supertrapp is stainless it may be a biatch to cut and if it is not stainless but plated, cutting it is an invitation to rust.

[hlh1]

I found that rocking it on and off was as good as the rubber mallet. I'll try the "aggressive steel wool" and retry.

[Fjbj40]

Heat the slip on, put it in the oven at 500

[hlh1]

Heat the slip on, put it in the oven at 500

This had crossed my mind. Guess I'll use welding gloves to install it then.

[mrbill5491]

Maybe use an exhaust pipe expansion tool?