SuzukiSavage.com - Drilling Stock Muffler

Routy Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2280 Winston Oregon Gender:	Drilling Stock Muffler 09/15/11 at 18:52:41 I've had PMs asking about drilling the stock muffler, so here it is again, Simply 8 1/4" holes evenly spaced,.... drilled on a 1 5/8 dia circle. Be careful when drilling thru, as some have reported breaking bits while striking material on the backside. The holes in mine are 5/16 now,......can't say it is much louder than 1/4" holes.
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VOLKY YaBB Newbies Offline 2006 S-40 Boulevard Posts: 49 Florida Gender:	Re: Drilling Stock Muffler Reply #1 - 09/15/11 at 20:37:48 Any difference in sound?
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Routy Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2280 Winston Oregon Gender:	Re: Drilling Stock Muffler Reply #2 - 09/16/11 at 05:14:54 VOLKY wrote on 09/15/11 at 20:37:48: Any difference in sound? Definently,.....and most have liked the better,......and a little louder sound.
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VOLKY YaBB Newbies Offline 2006 S-40 Boulevard Posts: 49 Florida Gender:	Re: Drilling Stock Muffler Reply #3 - 09/16/11 at 14:06:20 Im doing the same thing. I will let you know what i think.
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prsavage Senior Member Offline atgatt Posts: 306 Nanaimo BC Gender:	Re: Drilling Stock Muffler Reply #4 - 09/16/11 at 20:26:33 My stock muffler came to me with four holes each 1/2" evenly spaced around center main hole. Sound was way better than my wife's stock setup. I had absolutely no blue on the chrome and no backfiring either. I don't know what my jets were though. I'll check one day when I get the bike running again.
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Routy Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2280 Winston Oregon Gender:	Re: Drilling Stock Muffler Reply #5 - 09/16/11 at 23:03:24 The only real reason for more smaller holes might be in the case of wanting it back to stock. The small holes will plug very easy w/ a mig welder.
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VOLKY YaBB Newbies Offline 2006 S-40 Boulevard Posts: 49 Florida Gender:	Re: Drilling Stock Muffler Reply #6 - 09/17/11 at 11:29:43 Well, I drilled hole on my muffler also. It does sound better (bit louder) but I can still hear the whistling sound from the stock sound. Oh well, at least it sounds better. I'm still shopping for a Harley Dyna muffler to replace. Does anyone has a video clip of the harley Dyna muffler?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Drilling Stock Muffler Reply #7 - 09/17/11 at 12:09:55 with that much rust evident on the back end, most likely the internals look worse. you might consider this... http://suzukisavage.com/cgi-bin/YaBB.pl?num=1268121565/0
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VOLKY YaBB Newbies Offline 2006 S-40 Boulevard Posts: 49 Florida Gender:	Re: Drilling Stock Muffler Reply #8 - 09/17/11 at 12:32:00 How about a Harley Dyna muffler?
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Arizuno Full Member Offline SuzukiSavage.com Rocks! Posts: 227 Prescott, AZ Gender:	Re: Drilling Stock Muffler Reply #9 - 09/18/11 at 20:14:00 This afternoon I opened up the drilled holes from 3/8" to 1/4". Much better, and good enough.
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Routy Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2280 Winston Oregon Gender:	Re: Drilling Stock Muffler Reply #10 - 09/20/11 at 04:44:33 Arizuno wrote on 09/18/11 at 20:14:00: This afternoon I opened up the drilled holes from 3/8" to 1/4". Much better, and good enough. Was that difficult ? Never mind, we get the picture
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bill67 Serious Thumper Offline old tired Posts: 8517 genoa city wisconsin Gender:	Re: Drilling Stock Muffler Reply #11 - 09/20/11 at 06:07:13 Routy wrote on 09/20/11 at 04:44:33: Arizuno wrote on 09/18/11 at 20:14:00: This afternoon I opened up the drilled holes from 3/8" to 1/4". Much better, and good enough. Was that difficult ? Never mind, we get the picture Its not hard to do that you just have to run the drill in reverse
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Routy Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2280 Winston Oregon Gender:	Re: Drilling Stock Muffler Reply #12 - 09/20/11 at 14:05:54 Yes, but you need some filler rod !
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deepvalley

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Re: Drilling Stock Muffler
Reply #13 - 09/21/11 at 16:04:52

Hey guys and gals!
I am new to this forum but I tried this years ago and it works great until the rust eats the metal out between the holes! I drilled 3/8s inch holes evenly spaced. Grin

It then has a sick very unharmonius "blat" sound. My solution to that was to completely remove the rear plate, not an easy task but the sound was fantastic and My lil lady seemed to run better. Hope everything works out for you! Grin

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bill67 Serious Thumper Offline old tired Posts: 8517 genoa city wisconsin Gender:	Re: Drilling Stock Muffler Reply #14 - 09/21/11 at 16:47:46 The best solution is to take a long bit and drill down the pipe,Thats the way I've did it for year,Some bikes sound good,The S40 not so hot.You lose a little low end and gain a little high end power.I've heard all the pipes on this site and none sound good to me,A single just doesn't have a good sound to me anyway.
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