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General Category >> Rubber Side Down! >> HD Dyna Mufflers65747-94 Can I put baffle back in?
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Message started by antmanbee on 12/23/17 at 09:24:36

Title: HD Dyna Mufflers65747-94 Can I put baffle back in?
Post by antmanbee on 12/23/17 at 09:24:36

I have a pair of these mufflers and the baffles are out.
I don't know what the baffles look like or if I can get them and put them back in.
Does anyone know about this?

Thanks

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by batman on 12/23/17 at 09:41:32

You should be able to buy freeze plugs (they are inserted in auto heads to seal the water passages-any auto parts store) .I believe you need them sized 1 1/4 inches,(can't remember! but they come in all sizes) they can be driven in from the inlet side of the muffler about half way down,with a wooden dowel,(their shaped like a bottle cap ,insert domed end first), forming a baffle.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by antmanbee on 12/23/17 at 09:51:22

Are freeze plugs what the stock HD baffle was?

Usually I see cylindrical devices with a bunch of small holes in them.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by batman on 12/23/17 at 12:21:03

The stock H-D baffles is just a round flat solid plate ,people knock them out or drill them ,either because they think it will make their bike faster or they like noise . The freeze plug idea isn't mine it has been used by a few members on the site ,it's cheap ,and it works .I think Dave came up with the idea. when you look in the muffler you should see an inner pipe drilled with holes all around and nearly the whole length , theobject is to drive the plug so that is centered in that section of holes, so the exhaust gases are forced to go out the first half of the holes around your new baffle and return through the holes and exit the muffler , if you can look through the muffler the stock baffle is damaged or missing .

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by Rotorhead on 12/24/17 at 13:59:20

If you're not hot for a science project, you may just want to put them up on craigslist or ebay ("UNRESTRICTED Harley mufflers! More power and LOUD!"...they will sell) and pick up a turnout. For my nickel it wouldn't be worth the time to re-engineer the baffles when turnouts can be had for a song. I got my softail muffler for ten bucks, brand new.

Otherwise I think it would be hard to find the "stock" baffles without getting another set of mufflers.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by batman on 12/24/17 at 19:36:59

Rotorhead,Yes let's lie and say "more power",and louder when you sell the mufflers, when you can buy a freeze plug for 2-3 bucks and a length of dowel or pipe for a couple more , and drive it down the muffler , a job an 8 year old could to in ten minutes with a bit of adult guidance .Science project? If this sounds hard I hope you have someone to work on your bike.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by antmanbee on 12/25/17 at 04:41:12

I'm going to pop a freeze plug in it, not sell.
Does anybody know for sure what diameter plug?

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by Dave on 12/25/17 at 05:49:44

It is a 1-1/4" diameter.

Take a flashlight and look down the muffler. You should see a series of holes in the inner pipe, then there will be a gap without holes, then the holes will start again. If I remember correctly - there are more holes on one side of the gap than on the other side. You may also see the remnants of the steel plug that the factory put in.....before the previous owner drilled a hole or knocked it out.

You want to install the freeze plug from the engine (inlet) side, and it will go in easier if you put the flat part of the freeze plug in first and have the formed side on the backside. Drive it down to the area between the front and rear set of holes. (This forces the exhaust to go through the holes and into the outer shell of the muffler).

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by antmanbee on 12/25/17 at 08:08:35

Thanks Dave.

Just the information I needed.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by jenkrider on 01/03/18 at 11:13:56

I may try this too. My (wife's) Savage blew the guts (I guess it was the baffle) out of the HD muffler going down the highway. I was following her and saw something kinda orange fly out of the pipe - It was at night and looked cool but I was like 'WTF was THAT?'
Now the bike is loud as nuts and has got a serious low to midrange stumble. I kinda tuned it out using the idle mix screw, but now it backfires on decel.

Thought we were stuck with it like this because I didn;t want to get into re welding or replacing the whole exhaust - this happened like 2 years ago.

I am glad to see there may be a way to fix this. What keeps the freeze plug in? Friction?

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by Dave on 01/03/18 at 11:17:49

6B646F6A7368656473010 wrote:

The freeze plug may not work for you if the interior pip has disintegrated and blowing pieces out the back of the pipe. The freeze plug works if the little bulkhead inside the pipe has been knocked out or drilled.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by jenkrider on 01/04/18 at 08:31:57

Gotcha,
I will shine a light in there and see what is going on.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by JamesThomas on 01/06/18 at 09:53:44

Wow, talk about synchronicity. I came here today to post this very same question. I just received a beautiful dyna "shorty" muffler off ebay for $22 (free shipping) that the seller said was intact. It wasn't. The baffle plug was drilled out with a 1/16" rim around where the the plate should be.
I needed to know if the plate was solid or had some hoes in it. Now I know it is solid.
The inside diameter of my dyna muffler is 1 3/4" not 1 1/4". Last night when I discovered the missing plug, I sat and wondered what to do. Within arms reach on my desk was a small glass jar with a metal lid (shaped just like a freeze plug) that fits perfectly snug. More synchronicity.
Now all I need is a dowel and someplace to put the seeds that were in the jar. :)

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by batman on 01/06/18 at 11:02:03

James,That jar lid might not hold up to the heat over time,and may bend going in ,you should be able to use a freeze plug as they come in many sizes and are made of much thicker metal. I'd really go that way if you want a low cost, strong ,long lasting fix.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by Dave on 01/06/18 at 11:26:13

604B474F597E4245474B592A0 wrote:

The inside diameter of my dyna muffler is 1 3/4" not 1 1/4".

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by IslandRoad on 01/06/18 at 12:03:19

I got a pair of Dyna mufflers taken of a brand new bike. The interior diameters, weren't the same. I used the larger one. I assumed it had something to do with the different lengths of the Dyna's header pipes, maybe something to do with balancing back pressure, or something like that. Just guessing though.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by JamesThomas on 01/06/18 at 12:25:23

310A0710010D16100B030E11620 wrote:

[quote author=604B474F597E4245474B592A0 link=1514049876/0#12 date=1515261224]
The inside diameter of my dyna muffler is 1 3/4" not 1 1/4".

Although the inlet size of the muffler is 1-3/4" - the interior baffle pipe with the holes has always been 1-1/4" on the mufflers that I have seen.

I suppose different models might have different size interior pipes. :-?
And I agree with Batman - the interior pile gets red hot when cruising down the highway and does need to be made from a quality material. However......you won't have any problem knowing when the jar lid decides to give up the challenge.[/quote]

You're right. I took it out into the sun light and got a good look at what was happening and it does taper down inside....and yes, I'll go with a sturdier freeze plug.
Love this forum. Thanks for the helpful comments. :)

The seeds go back in the jar.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by jenkrider on 01/08/18 at 09:09:09

I installed a freeze plug last night...Upon inspection the interior pipe with holes looked to be mostly intact. So I drove the plug about halfway in, thus forcing gas into the first holes and out the last holes. Kinda hard to see that far in there so I guessed.

Erring on the side of caution, I did drill a few holes in the freeze plug. I figured this was a good safety measure to keep flow in the case that I didn't go far enough in. Figured I could always add another plug immediately after the first one if needed, if the holes allowed too much flow.

Fired it up and is much quieter and sounds more like it used to. Still having pretty major backfiring though (needle jet shimmed with 2 washers and idle screw adjusted already)

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by verslagen1 on 01/08/18 at 10:16:09

Backfiring can be caused by air leaks.
while running, light a candle and pass it by all of the joints, flickering indicates a leak.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by jenkrider on 01/08/18 at 10:32:36

Verslagen,
Will try this. This is the first start up of the 'new' engine you may have read about in my gaskets for sale thread. So it is possible there is a leak around the intake or something like that.
The bike sat for some months after the old engine died but I don't remember it backfiring this[i] much.
The swap and reasons are a different story, maybe I will write up a separate post.[/i]

To try and stay on topic here, advice for anyone hesitant is that the plug was really cheap and easy to hammer in. I used a junk socket and extension to hammer it in.

Title: Re: HD Dyna Mufflers65747-94 Can I put baffle back
Post by verslagen1 on 01/08/18 at 12:07:23

don't try the candle trick on the intake if you want to keep your eyebrows. :o

If you haven't cleaned the carb, you should.