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Message started by MeLikeBike on 06/16/13 at 19:59:52

Title: dyna muffler install holes not lining up right
Post by MeLikeBike on 06/16/13 at 19:59:52

Hi guys,
I'm putting on the dyna, but when I push the muffler as far as I can (it does not reach the raised lip on the headerpipe), the hole in the frame is lining up too close to the enlarged hole in the muffler bracket. So when I think I get everything lined up nice, then tighten the muffler bracket nut, it shifts a little then pulls the head of the bolt through the rail.

Did anyone else have to deal with this? I suppose I could drill another hold in the frame, but I don't wanna.

In other words:

bolt |'''''|
|_|

_______/''''''\______ Rail slot on muffler

'''''''\______/'''''''''''

''''''''''''''''''''''\
O | Frame
_____________________/

Title: Re: dyna muffler install holes not lining up right
Post by Serowbot on 06/16/13 at 23:20:48

Digital cave paintings... Cool!... ;D ;D ;D...

I had this problem recently,.. with a cat model...
Drill a new hole in the bracket...
... don't have a drill?...
hacksaw a bit off the head pipe...
... don't have a hacksaw?..
Buy some tools... ;D...

When modding a bike,.. if it don't fit... make it fit... ;D...

Title: Re: dyna muffler install holes not lining up right
Post by bobert_FSO on 06/17/13 at 05:36:34

I sawed off a small amount of the the header pipe so the muffler would reach the stop ring on the header.

Also, you could alternatively not shove the muffler on the header as far as it will go. Back the muffler off a little. As long as there is enough header/muffler overlap to get a good clamp and seal with a clamp, it should be good to go. Most exhaust systems do not have a built-in "stop" when being mated up.

Title: Re: dyna muffler install holes not lining up right
Post by ToesNose on 06/17/13 at 06:30:19

Yea I hate it when the holes don't line up. :D. :o

Title: Re: dyna muffler install holes not lining up right
Post by Badass94Cad on 06/17/13 at 10:00:38

I affixed the Dyna muffler with only one of the two holes on the stock mounting bracket, the closest to the engine. Some people have adapters made that will also push the muffler further back, aligning it better on the bracket. 8-)

Title: Re: dyna muffler install holes not lining up right
Post by apache snow on 06/17/13 at 10:03:14

Yeah, using the Ryca adapter I use both bolts to hold down the muffler. :)

Title: Re: dyna muffler install holes not lining up right
Post by Oldfeller on 06/17/13 at 10:07:14

BIG fender washers ....... bridge the gap.

Title: Re: dyna muffler install holes not lining up right
Post by MeLikeBike on 06/18/13 at 19:36:14

I drilled a new hole, and things line up okay. I just can't stuff the exhaust leak that I have now. I've tried at least 8 times with different cans...ended up using some aluminum flashing cut in a strip and rolled a few times because those Harley clamps don't seem to tighten down enough. But still little leaks.

took it out for a ride..sounds great, when I push it and switch gears. I'm a little used to the quietness to the stock muff. Maybe a bit loud after a long ride, though.

I'm hoping the leak will fill with soot or something...but I can always goop it with some ultra copper. I have some of the high temp red from my engine head replacement...maybe the red is hi temp enough?

Title: Re: dyna muffler install holes not lining up right
Post by justin_o_guy2 on 06/19/13 at 21:56:12

https://www.google.com/search?q=t+bolt+clamps&ie=utf-8&oe=utf-8&aq=t&rls=org.mozilla:en-US:official&client=firefox-a

Title: Re: dyna muffler install holes not lining up right
Post by MeLikeBike on 06/20/13 at 17:22:53

I got the HD pipe clamps off ebay...I though that would do the trick. Are those Tbolt clamps any better?

Title: Re: dyna muffler install holes not lining up right
Post by justin_o_guy2 on 06/20/13 at 21:35:01

Well,, I dunno,, What did ya pay for yours?
Why arent they working?
Do you need to slot something some so the clamp can Squeeze it?

Be careful not to bump your head while squeezing,, seems to be a problem around here..

Title: Re: dyna muffler install holes not lining up right
Post by MeLikeBike on 06/21/13 at 05:03:37

They aren't (weren't?) working because they couldn't seem to get tight enough, I guess. So I shimmed around the exhaust pipe AND around the muffler. And so I think it still leaks, but not enough to keep delaying me from riding it while the summer arrives with some beautiful weather here in Pittsburgh.

I *did* slot it with a dremel cutoff wheel (a little thinner than the hacksaw blades it seems, based on the hacksaw picks here at ss.com). At first, 4 extra slots, but now I have about 10 slots because there just wasn't enough squeezability.

The flashing that I used is plastic coated, at least a little, so it's melting and stinking nicely now, and I was able to tight down on the clamp a little more after riding last night (expansion of stuff + melting of the plastic stuff). So maybe between the further tightening and the melting plastic and the soot and all, it will seal itself more.

One thing about those HD clamps. With the tin can gaskets, once you tighten, if you monkey with it too much, the clamp will pinch the wrap into the clamp's joint, and thereby ruin your seal.

Title: Re: dyna muffler install holes not lining up right
Post by MeLikeBike on 06/21/13 at 08:01:12

btw, anyone buy this from Ebay?
http://www.ebay.com/itm/Chrome-Exhaust-Muffler-Pipe-Heat-Shield-Cover-Heel-Guard-For-Suzuki-Boulevard-/360670220683?pt=Motorcycles_Parts_Accessories&hash=item53f99ed18b&vxp=mtr

pretty generic, but probably fits the bill. Just not sure if it's as thin as tin foil or something.

Title: Re: dyna muffler install holes not lining up right
Post by justin_o_guy2 on 06/21/13 at 08:23:28

Check shipping weight. Send an email & ask them what it weighs,

Title: Re: dyna muffler install holes not lining up right
Post by apache snow on 06/21/13 at 08:42:29

No, I bought this one from motorcycle superstore in a 2x7. Its around the same thickness as automotive exhaust tubing, .062.

http://www.motorcycle-superstore.com/3/13/118/31163/ITEM/Cobra-Universal-Heat-Shield.aspx?WT.ac=SLIsearch

Title: Re: dyna muffler install holes not lining up right
Post by Greg on 06/21/13 at 09:22:22

667A77747F76120 wrote:

I got the HD pipe clamps off ebay...I though that would do the trick. Are those Tbolt clamps any better?

They are the only thing that would seal mine. The HD clamps are poop.

Title: Re: dyna muffler install holes not lining up right
Post by MeLikeBike on 06/21/13 at 10:50:46

Is there consensus on this from others? The primary "how to" page that talks about the harley muff installs mentions the HD clamps first and foremost (and it sure makes sense), so I didn't start digging for alternatives. But if most of the people used the tbolts, we should update that post, since it's so popular.

Title: Re: dyna muffler install holes not lining up right
Post by MeLikeBike on 06/21/13 at 10:52:41

Title: Re: dyna muffler install holes not lining up right
Post by mhart731 on 06/21/13 at 22:08:04

I agree on the "make it fit" theory. I found out mine didn't line up when I had to turn round on the highway and ride the rest of the way home with just the head pipe... Found some U-type washers that I stuck under the bolt and tightened down. It has done well so far. I also wrapped a metal zip tie (leftover from muffler wrap) around the bracket and frame to keep it from falling all the way off just in case. But I pretty much have a rat bike anyway.

Title: Re: dyna muffler install holes not lining up right
Post by strang on 06/23/13 at 04:57:38

I had all the same hassles and ended up mig welding it on. My welding won't win any prizes but it's leak free. I spent hours muckin' around with both types of clamps - not worth it in my opinion. If you don't have a welder, ride the bike to someone who does and 10mins and say 30 bucks later, job done.
On mine the dyna ends up at an angle to the bracket but a section of the muffler still sits on the bracket and I was able to use one hole - so that seems to be enough. I might cut the bracket and reweld it in perfect position next year, but for now i wanna ride 8-)

Title: Re: dyna muffler install holes not lining up right
Post by justin_o_guy2 on 06/23/13 at 06:19:22

I wonder if a guy could get a Mapp Gas torch, like from Lowes & some solder & flux, clean that joint up good & lay some heat on it & just solder it up[..
"Course, a Mapp gas torch with the fancy "Lights when ya squeeze the trigger" head on it is about $50.00, BUT, then ya Have it & theyre Great for lighting charcoal in the BBQ Bricket Chimney. DRive a short hunk O conduit in the ground, get a piece of stout wire & make a hanger for the chimney, load it, hang it, light from the bottom, its quick,,

wear welding gloves to protect the arm till you figure out just how much
it can pop & spit hot chunks while you lite it, Not all charcoal is the same,

Title: Re: dyna muffler install holes not lining up right
Post by HondaLavis on 06/30/13 at 20:06:17

I had the same hassles, and I wound up MIG welding it just like strang. I initially bought one of those same Mapp torches from Lowes with that very intent! Despite all of my best efforts, neither I nor my father - who has used Mapp and Oxy-acetylene more than a few times - could get the pretty blue flame. The guys on support just said "Huh, I guess your valves are bad. Take it back to Lowes."

I'll let you decide if I asked to exchange it or to just get my cash back.