The short answers to your questions:
Basicly any year Dyna muffler will do, just NO crossover.
You will need one harley muffler clamp - 1 3/4" - new about $10. Two clamps if you do the adapter pipe. - about 7" in length - does not have to have the "bend" in it.
If you take your header pipe and the harley muffler to an exhaust shop, they can make an adapter that will fit the head pipe and the dyna canister - cost you about $10.00. - this will ensure a leak free fit. I had this setup for a bit, then went to a Hard Chrome pipe.
Then just bolt everything on, and put some anit-seize on the header bolts when installing them. Torque to specs!!!!
An exhaust pipe heat sheild to make everything neat will run you up to $40 - depending on your choice.
Then you MUST rejet your carb - send a pm to Lancer for a jet kit from him - about $15 if I remember right.
Even stock, the Dyna canister is louder that the stock Savage canister.
Close up of the adapter pipe connected to the head pipe and the dyna cansister:
Complete shot as it looks on the bike - yes I know there are no clamps on it, test fitting
:
I was able to get a leak free seal with this set up and it sounded great, until I put my Hard Chrome pipe on (thanks Lancer!!!) - pic below is my bike with the Hard Chrome pipe:
I flipped my rear brake arm around, and I got the heat sheild from J&P online. I thinking about either finding a straight brake arm, or flipping it back, I think I will have the clearance.
Hard Chrome pipe sounds awesome!!!!
Hope this helps - and its an easy thing to do!!!
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