SuzukiSavage.com - Installing new muffler

Built2Last Serious Thumper Offline Tempt Fate Posts: 1447 FTF Gender:	Re: Installing new muffler Reply #15 - 07/29/11 at 22:16:54 Thanks TieFIghter but I need to work with what I got...
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Howitzer Full Member Offline SuzukiSavage.com Rocks! Posts: 141 Boston, MA Gender:	Re: Installing new muffler Reply #16 - 07/29/11 at 23:03:10 JB Weld over the slits?
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EJID

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Re: Installing new muffler
Reply #17 - 07/29/11 at 23:29:02

Loosen the clamp w/ the slit problem and slide it back to cover the end of the slits. Hopefully that will still leave enough of the clamp putting pressure on the header to create a tight seal. Also, before clamping it all back together I would use some good hi-temp sealer on the joint then pound it together and let it cure overnight before firing it up, or you will blow the sealant back out.

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05 S40 15" Memphis Slim, FXDWG Bars, Moved Rear Signals, Saddlebags, Fork Bag, Mini-Tach, Raptor, Cone Filter, Fishtail Muffler, Mix Screw Out 2.5 Turns, 4" Fwd Controls, 147.5 Main/55 Pilot @ 4500

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Built2Last

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Re: Installing new muffler
Reply #18 - 07/30/11 at 05:30:56

TieFighter, I had this adapter custom made at the local muffler shop (I took in the muffler and the header pipe) but my dad insisted we had to make these giant slits to get a good clamp... which works in theory but now I gotta plug these slit holes because all of the sealant basically slide to the top of the header pipe when I slid the adapter on.

I'm thinking that I'm just gonna buy another HD clamp, slide the other clamp forward, slather it up with sealant, then throw on another HD clamp... then a 4" chrome heat guard will cover up the mess Cheesy

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Built2Last Serious Thumper Offline Tempt Fate Posts: 1447 FTF Gender:	Re: Installing new muffler Reply #19 - 07/30/11 at 05:31:17 Howitzer wrote on 07/29/11 at 23:03:10: JB Weld over the slits? I am not Jesse James I don't think you can have too many heavy duty HD clamps on your muffler
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Routy

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Re: Installing new muffler
Reply #20 - 07/30/11 at 06:49:45

bill67 wrote on 07/29/11 at 19:04:05:

Its a direct fit on a Harley right. Grin

Still kinda IRKS the hell outta me....back in time when I use to warn the newbies of the exhaust leak problems w/ the Harley/Dana.....and other after market mufflers,....and I got my a$$ jumped on by the oldtimer "Direct Fit" bunch here,.....about how I didn't know a dam thing about it because I had never done it. Since that time, nothing but horror stories, many of which ended up welding them on.

Its one thing to know what you're getting in to, then just having to deal w/ it,....much better than reading all about it being a direct fit...pc a cake job, only to find out the truth after it ends up being a "hack job"

Sorry builtolast,......I know this didn't help you, but I had to vent a little. You'll get it,...one way or another.

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Rich
'07 S40 Blvd stocker, except drilled OEM exhaust and white spacer mod...1/2 (.055)

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Built2Last

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Re: Installing new muffler
Reply #21 - 07/30/11 at 06:54:13

Routy wrote on 07/30/11 at 06:49:45:

bill67 wrote on 07/29/11 at 19:04:05:

Its a direct fit on a Harley right. Grin

Still kinda IRKS the hell outta me....back in time when I use to warn the newbies of the exhaust leak problems w/ the Harley/Dana.....and other after market mufflers,....and I got my a$$ jumped on by the oldtimer "Direct Fit" bunch here,.....about how I didn't know a dam thing about it because I had never done it. Since that time, nothing but horror stories, many of which ended up welding them on.

Its one thing to know what you're getting in to, then just having to deal w/ it,....much better than reading all about it being a direct fit...pc a cake job, only to find out the truth after it ends up being a "hack job"

Sorry builtolast,......I know this didn't help you, but I had to vent a little. You'll get it,...one way or another.

Mines no hack job, it's done right, but since it's my first time I didn't get the sealant set right, its a minor fix I'm just trying to work out to do it the best way. I can still ride her and she is pretty freakin loud, it just bothers me that there's a little air coming out of the tiny slits.

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Built2Last Serious Thumper Offline Tempt Fate Posts: 1447 FTF Gender:	Re: Installing new muffler Reply #22 - 07/31/11 at 10:02:28 So, take her apart again, clean out the old sealant, reseal and throw on 2 clamps?
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Serowbot

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Re: Installing new muffler
Reply #23 - 07/31/11 at 10:15:57

Routy's famous,... it can't be done, so I won't even try rant... Grin

...

Don't use any sealant... it'll just blow out....
One good clamp... get it in the right place, at the base of the slits, and it will seal... I use a tin can as a crush seal...
I've put these on a half dozen bikes now...
It's not a "direct fit"... but it's as easy an adaption mod as you can do...
Makes a great intro to the world of customizing...
Direct fit is for cookie cutter bikes... Wink

...

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Ludicrous Speed !... ... Huh

...

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Built2Last

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Re: Installing new muffler
Reply #24 - 07/31/11 at 10:22:32

Serowbot, so now I'm gonna have to clean all this sealant crap out?? I hope this stuffs easy to get out.. what if some of its in the muffler, because I did fire her up right after I got it assembled.. ruh rohs. Angry

But also, the slits are longer than the clamp, so air will still be blowing out of those.. I'm thinking another HD clamp will cover it completely..

It's raining here and I have no garage, you should come over with your drill help me mod some kitchen appliances.

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28651 Tucson Az Gender:	Re: Installing new muffler Reply #25 - 07/31/11 at 10:58:07 Well,... apparently you cut some serious slits in there... ... I'd try using lead foil tape... from a hardware store... You'll need to pry the squashed slits back apart to make room, then re-crush over tape... I've never needed to myself... but, that's what I'd try...
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Built2Last Serious Thumper Offline Tempt Fate Posts: 1447 FTF Gender:	Re: Installing new muffler Reply #26 - 07/31/11 at 11:01:34 I think a crushed can and another HD clamp with a lil sealant in the slits will work out.. my dad gets carried away with hacksaws... I don't know what his problem is...
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: Installing new muffler Reply #27 - 07/31/11 at 12:16:47 Howitzer wrote on 07/29/11 at 23:03:10: JB Weld over the slits? This is humor, correct?
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Howitzer Full Member Offline SuzukiSavage.com Rocks! Posts: 141 Boston, MA Gender:	Re: Installing new muffler Reply #28 - 08/01/11 at 10:36:04 Gyrobob wrote on 07/31/11 at 12:16:47: Howitzer wrote on 07/29/11 at 23:03:10: JB Weld over the slits? This is humor, correct? Afraid not...Someone enlighten me about the humor? This is more inexperience than being cheeky.
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Gyrobob

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Re: Installing new muffler
Reply #29 - 08/01/11 at 18:35:09

Howitzer wrote on 08/01/11 at 10:36:04:

Gyrobob wrote on 07/31/11 at 12:16:47:

Howitzer wrote on 07/29/11 at 23:03:10:

JB Weld over the slits?

This is humor, correct?

Afraid not...Someone enlighten me about the humor? This is more inexperience than being cheeky.

Oh,.. sorry. Embarrassed

JB Weld is great stuff,.. some of the best epoxy you can get at Home Depot, Lowe's, etc. It is, though, just epoxy with some metal powder in it. It is not at all able to handle the high temperatures typical of the exhaust system forward of the muffler. It would just discolor and flake off.

Try a test. Go get a little washer, put some JB weld on it, and put it on the top surface of your exhaust pipe just forward of the muffler. Let it cure overnight, then go for a 20 minute ride the next day. Let us know what you find out.

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