I think that asbestos wrap probably made the job a bit simpler!
Not much of that stuff around these days.
I ended up following the same install guide as you. Second time round it all seemed pretty simple really
Originally, I had it stuck in my head that I wanted both bolts connected on the rail - I got over that pretty quickly after trying to re-jet with exhaust leaks - ya live and learn I suppose
bobert_FSO wrote on 01/04/17 at 09:24:19:I must have done something wrong, because I had a pretty easy time mounting my dyna.
Loosen the header bolts at the end to allow the header pipe to move around a little as needed.
Since the dyna muffler doesn't slip on all the way to the stop ring, I cut the tail of the header pipe just enough to allow the muffler to hit the stop ring. I think I was able to cut on the section there the inner and outer pipe still come together, not on the part where the pipe swells and the two pipes separate.
Cut a few slots in the dyna inlet, not long enough to cause holes when the muffler is pushed up against the stop ring.
I wrapped a couple of layers of asbestos gasket material around the header pipe. Enough to fill the difference between the sloppy fit of the header pipe and muffler. It serves the same function as the soft gasket in the inlet of the stock muffler. I don't know if you can get this stuff anymore. I got it when I inherited stuff from my grandfather's garage. Thanks, Grandpa!
Use a really good t-bolt clamp the will clamp around the entire pipe joint. The wider the better.
Mount the muffler to the muffler bracket using only one bolt. Bend the stock muffler bracket as needed to line everything up.
Snug, but don't tighten the rail mounting bolt and the head clamp bolts at the head. Allow for some movement.
Tighten the t-bolt clamp. If the alignment between the header and the muffler is a little off, the slots cut in the muffler inlet will allow the inlet to bend a little as needed. Sock this clamp down hard.
Finish by tightening up the head clamp bolts and the muffler rail bolt. Stick a 4 in shield over the joint to hide it.
This method worked great for me. the muffler does blow a little soot on the rear brake lever, but so what. The muffler doesn't blow directly on the brake lever. Bending the stock mounting bracket on the bike helped with that. I got a nice straight-looking line between the header and muffler without that droopy look caused by the angled adapter.