Arthur wrote on 03/16/10 at 18:15:53:The Dyna inlet is not large enough to allow the Savage header pipe to slide far enough in to allow a secure fit.
You either open it up, or use enough pressure to force it on until it stops.
I still don't understand this. My header pipe is 2 and 7/16 to the collar. The header goes a full 2 inches into the Dyna before it stops against the lip on the inside of the muffler, leaving only 7/16 left. I don't see how 5/16 versus 7/16 makes any difference here. 2 inches of surface is plenty for the clamp. Getting the header into the Dyna isn't the problem. See pictures below.
Arthur wrote on 03/16/10 at 18:15:53:The finished assembly angles in towards the back of the bike, as I have shown in pictures. The angle is not that bad, nor is it 7-10 degrees off.
This is where the problem lies, and I think it's a difference in the manufacturing of the header pipe. On my bike, it's more than 10 degrees. In fact, if I allow the muffler the follow the natural angle of the header pipe, THE FAR END OF THE MUFFLER IS BANGING AGAINST THE REAR WHEEL HUB. The rear end of the muffler needs to be bent out to the right about 4 INCHES before it will line up with the support bracket, and this puts stress on the exhaust pipe and the flange/studs. (Not to mention the fact that you can only get 1 bolt into the support bracket.)
This muffler WILL NOT fit properly or safely on MY bike, and I can easily see why it doesn't work for some other people too.
Now, I've already found a solution to my problem so I no longer have much interest in this. But for the sake of all the future newbies who might stumble into this mess like I did, please start attaching some disclaimers to the whole "bolt on a Dyna muffler" mantra. It doesn't "just work" for everybody.
Joe