Check out the tech section for instructions to install a Sportster muffler.  

Then call the local Harley dealer and ask if they have any Sportster or Dyna muffler "take-offs".  Those are the mufflers they took off when HD owners upgraded to different mufflers.

I found a really nice Dyna muffler at the HD dealer. It was marked for use with a FXD 1340/1450. They had Sportster mufflers, too.  They would sell any of them for $20.

Be sure to ask for on that has no crossover. That's a small fitting on the top or bottom of the muffler that attaches to the other muffler of the pair. I think that means the muffler had to be made for the 2003 or older model.  If you get one with a crossover, you'll have a hole in the muffler.

Gulfstream wrote on 12/31/69 at 16:00:11:

i bought the sportster seat mod from kwik bay, it came with a set of instructions. they were/are kinda hard to read, and see the pics, as they're not great photo copies. i opted to build my own, which i documented in the tech section. i can find the origional instructions and fax them, but i dont have scan capabilities.

I think the Dyna muffler is a little louder than the stock muffler, but I have never measured it.  I doubt anyone has measure how loud any of these mufflers are, but some people have experience with several different mufflers and might give you some valuable subjective .  

The Dyna and Sportster mufflers are stock on those motorcycles and are certified to meet noise restrictions on those motorcycles.  I think this is 80 decibels.  Of course, I guess that's meaningless when the muffler is installed on the Savage.

Anyway, the best thing about Dyna and Sportster mufflers is they are widely available at HD dealers as take-offs for a reasonable price.  

I am guessing it is getting late in the game for finding a muffler without the crossover. Is the hole in a place it wont hide? Can I get it welded up? Will it mess the whole muffler up to weld/ braze it? I guess I could wrap the muffler in wet rags except for the place to weld, to keep the heat from bluing the chrome??

It should be no problem finding a Dyna muffler, I used one off of my 05 Dyna Superglide. The Dyna's crossover tube is in the headpipe, not the muffler...unless that changed with the 07 models but I highly doubt it. Can't speak for the Sportster mufflers. Any model Dyna muffler from 99 on should work.

Here's a picture of a Dyna muffler, not sure what year.  Note it has an adapter in the inlet.



And here's a picture of a pair of 2005 Sportster mufflers.  The fitting on top of the inlet is the crossover. You DO NOT want the mufflers with a crossover.