Exhaust has me baffled!

[Guest]

First off to be clear I have searched and found the procedure to repack the pipes. I am a little stumped on how to get them out and put em back in because it looks like someone "tried" to before. Sounds like there's something clunking around in the one on the right.

How do I get the ends off?


And what the heck is that square patch job?


and do I need to separate the megaphones from the header?

Lastly, do I need to weld it all back together or is there a better way?

Thanks folks, want to get this right before I get it together and avoid the dreaded exhaust leaks.

Brion

[Redman]

ha ha

baffled...?

Pun intended ?

.

[ikantbreave]

well, yeah. BTW, if I need to weld is there a preferred method, MIG,TIG, ARC, or other? I don't know much welding but I know some folks that do.

[bwringer]

Repack?

Not with the stock pipes. There's no packing in there, just baffles.


If you're hearing noises, some of the baffles have likely corroded internally and come loose. If you can locate the problem area, one temporary fix is to install a sheet metal screw (go in from an angle you can't see) in hopes that the screw will immobilize the loose part.

Your pipes seem to have a few patches welded on, but the mufflers are welded to the headers at the factory.

[Steve]

First off to be clear I have searched and found the procedure to repack the pipes.

Actually, what you found is the procedure to repack the pipes that are repackable.

I am a little stumped on how to get them out and put em back in because it looks like someone "tried" to before.

You are stumped on how to get them out because you can't get them out.

Sounds like there's something clunking around in the one on the right.

That sound is likely because something inside has rusted apart. One of the greatest causes of this is starting the bike every so often while it is in winter storage, either to "charge the battery", "warm it up a bit" or "just because is sounds so good". None of these will get the bike warm enough to burn off the condensation that forms inside the pipes, so it just sits there, rusting away.

How do I get the ends off?

I won't tell you that you can't, but they were not made to be taken apart. Somebody that is handy with a torch can do wonders.

And what the heck is that square patch job?

Apparently, it's an attempt by a previous owner to fix the rattling.

... and do I need to separate the megaphones from the header?

Just like getting the ends off, they were never meant to be removed, but ...

Lastly, do I need to weld it all back together or is there a better way?

You will only need to weld it all back together if you get brave enough to cut it all apart.

[Nessism]

Looks like someone already tried to go into the muffler and fix the rattling baffle.

My suggestion is to cut the mufflers off at the head pipe and get some aftermarket mufflers or some cast off Harley mufflers which are typically dirt cheap. JC Whitney sells mufflers or hit your local HD shop and check the dumpster.

[gert du prez]

Hi,

cutting of the mufflers at the head and installing new mufflers, would that then require adjustments to the carbs ? or would everything be OK as long as you don't touch the heads ?

[Nessism]

Hi,

cutting of the mufflers at the head and installing new mufflers, would that then require adjustments to the carbs ? or would everything be OK as long as you don't touch the heads ?

If you get some mufflers that are quiet, the carb tuning will be fine. Even if you get free flow mufflers the carbs won't be as messed up as if you install pods.

[ikantbreave]

Awesome!!

Thanks for all the input and set-me-straightness. At least now I have a direction to go.

[Mysuzyq]

Thanks for all the input and set-me-straightness. At least now I have a direction to go.

Hopefully, it won't leave you exhausted.
Tony.

[coolksprt]

Not to hi-jack the thread, BUT I'm inclined on getting new mufflers. I know you guys joke about going to the Harleys trash and all, but I can't imagine you truely mean exactly that. So what are you trying to get at when you say this?

Kev

[derwood]

Harley owners, more than any other, tend to replace their mufflers as soon as they get their bikes. Its a fashion statement. So, consequently lightly used or new stock harley mufflers are a dime a dozen.