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Message started by twdy on 08/04/09 at 14:49:23

Title: Dyna Exhaust
Post by twdy on 08/04/09 at 14:49:23

I just removed the pipes off my bike, because I took my brothers stock 2009 HD Dyna FatBob pipes. Low and behold... they don't fit. The mounting bolts are out of place and do not line up, and even with an extension piece I don't think the angles are correct.
So, not any dyna pipe will fit! Does anyone have any suggestions?

Title: Re: Dyna Exhaust
Post by Dj12midnit on 08/04/09 at 15:58:58

What you need to do is adapt the muffler to the stock header pipe.

Title: Re: Dyna Exhaust
Post by Gort on 08/04/09 at 16:18:04

I have a Harley muffler on my Savage. I don't know what kind of Harley it came off. Here are the numbers stamped onto the muffler. 64941-01. It is an exact bolt up to the Savage. No drilling, no welding, no adapters, other than a sheet of copper used around the Savage header pipe where it fits into the Harley muffler. The Savage heat shield bolts in place without adapting anything. No leaks anywhere. For the $30.00 I paid for it, its not worth trying to adapt the wrong muffler.

Title: Re: Dyna Exhaust
Post by twdy on 08/04/09 at 16:33:07

gort, i'm probably going to look for a different muffler around here... none of the bolts line up, and that is my main problem right now. also, when i put the muffler onto the head, it won't slide all the way down. for now i painted my stock muffler black, and will have pictures up tomorrow when it is dry!

Title: Re: Dyna Exhaust
Post by Gort on 08/04/09 at 17:16:39

My Harley muffler does not fit flush against the collar on my Savage header pipe. There is 5/16" of header pipe between the collar and the mouth of the muffler. The header pipe won't go in any further. Other members have also experienced this in the past, however it isn't important and does not leak on my bike. Be sure you use a Harley clamp, not the Savage clamp.

Title: Re: Dyna Exhaust
Post by Boule’tard on 08/04/09 at 19:32:05

Twdy, I highly recommend you stick with the Dyna muffler and make it work.. you will not find a better one for $100, and you got this one for free? :D You've been given some good advice here and I can't add much, except that a couple of washers will help the rear mount and muffler rail go from near-perfect to perfect alignment. It is true that the header collar will not butt against the muffler. There is about an extra 3/8" of header behind it that doesn't matter, especially after you fit a heat shield. It's also true that you should put some copper shim stock between the header and mufflers to make the english and metric stuff match diameters. It also helps to cut a couple more relief slots in the muffler (go from 2 to 4) and put a washer behind the lower mount of your front heat shield, loosen the header collar at the cylinder and swing the header outward slightly.

I know this sounds like a pain, and the "it's a direct bolt on" claim is somewhat exagerated. But gee-gads! I just spent almost $400 on a whole exhaust system specially made, artisan-welded and all that for another bike, and it didn't fit as good as the Dyna on the Savage. You gotta tweak stuff no matter what you do ;)

Title: Re: Dyna Exhaust
Post by twdy on 08/04/09 at 20:01:40

I'll have to take a picture tomorrow for a little help. The muffler's mounting locations are several inches off of the Savage's mounting areas. I'm not very creative, but I'm sure there is a way to mount this darn thing! Is it possible this Dyna FatBob muffler would be different from the Dyna mufflers everyone else is using?

Title: Re: Dyna Exhaust
Post by Gort on 08/04/09 at 20:54:12

Yes, there seems to be a variety of mufflers, and this matter has been discussed in the past. You must get exactly the right HD muffler, and I've given you what I think are the the serial numbers on mine. Again, get the right one, because it bolts up EXACTLY to the Savage, as I've said before. You have to wiggle it around a little, and firmly push it onto the header pipe, but if you take your time and use the right HD muffler, you don't need to cut, bend, file or weld or fabricate anything anywhere, except for the use of a copper shim around the end of the header pipe. The space between the header pipe collar and the mouth of the muffler measures exactly at 5/16", if you push it on right. The Savage heat shield bolted on without modification. This was an easy install, and it never leaked.

Title: Re: Dyna Exhaust
Post by justin_o_guy2 on 08/04/09 at 22:45:04

If all else fails, sell those & get something that works, but IMO, the best looking exhaust on these things, short of a costly custom, is the dyna.

Title: Re: Dyna Exhaust
Post by John_D on 08/05/09 at 01:59:11

I put a cheap knockoff of a Dyna muffler on mine ($10 @ salvage yard, woo! :D). I put an extension in, because it didn't have the rail mount, and I needed it to get the mounting holes to line up. I had them put a couple degrees bend, about 8 I think, because if you look at the stock muffler, there's a small bend near the inlet, to make it line up with the hanger. I also had them spread/shrink the outlet/inlet of the adapter to fit the header and muff. Worked like a charm, although I went with the really heavy duty clamps to ensure no chance of leaks, the Harley clamps just weren't doing it. Here's some pics! ;)

http://i626.photobucket.com/albums/tt347/redneck72102/Bike%20Pics/Bike%20Mods/th_IM000253.jpg (http://s626.photobucket.com/albums/tt347/redneck72102/Bike%20Pics/Bike%20Mods/?action=view&current=IM000253.jpg)

http://i626.photobucket.com/albums/tt347/redneck72102/Bike%20Pics/Bike%20Mods/th_IM000264.jpg (http://s626.photobucket.com/albums/tt347/redneck72102/Bike%20Pics/Bike%20Mods/?action=view&current=IM000264.jpg)

Then just slap on a Harley heat shield from a 2 into 1 pipe, and voila!
http://i626.photobucket.com/albums/tt347/redneck72102/Bike%20Pics/Bike%20Mods/th_IM000269.jpg (http://s626.photobucket.com/albums/tt347/redneck72102/Bike%20Pics/Bike%20Mods/?action=view&current=IM000269.jpg)

http://i626.photobucket.com/albums/tt347/redneck72102/Bike%20Pics/Bike%20Mods/th_IM000268.jpg (http://s626.photobucket.com/albums/tt347/redneck72102/Bike%20Pics/Bike%20Mods/?action=view&current=IM000268.jpg)