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HighFlo Quiet Muffler Details (Read 658 times)
DragBikeMike
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Re: HighFlo Quiet Muffler Details
Reply #15 - 12/30/20 at 18:25:09
 
Here is the inlet adapter bushing installed in the 2 x 2.5 exhaust reducer.  It’s a snug fit (lite drive fit).  It gets locked in place by two 8-32 countersunk screws.  Once the reducer is installed in the muffler, it’s permanent.  It’s not easy to remove once the muffler is assembled.   The large hole in the side of the reducer is for my O2 sensor.  If you’re not running an air/fuel ratio meter you don’t need the hole.
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Adapter_Bshg_Inlet_Install_in_Reducer2.jpg

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Re: HighFlo Quiet Muffler Details
Reply #16 - 12/30/20 at 18:26:00
 
The adapter bushing on the rear end (outlet end) is similar to the inlet end.  It is 2.53” OD by 1.75” ID by 3/8” thick.  It gets permanently fixed to the baffle tube with two 8-32 countersunk screws.  Here you see it slipped over the baffle tube.
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Adapter_Bshg_Outlet_Rough_Install2.jpg

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Re: HighFlo Quiet Muffler Details
Reply #17 - 12/30/20 at 18:27:17
 
Here’s how the adapter bushing is fastened to the baffle tube with countersunk screws.
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Adapter_Bshg_Screwed_to_Baffle_Outlet.jpg

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Re: HighFlo Quiet Muffler Details
Reply #18 - 12/30/20 at 18:27:57
 
The baffle is about ready for perforations.  You can see the exit end will need to be trimmed slightly.
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Baffle_Assy_No_Perf2.jpg

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Re: HighFlo Quiet Muffler Details
Reply #19 - 12/30/20 at 18:28:50
 
The center plug is carved out of a 1-1/2” galvanized pipe plug, another routine item available at most hardware stores.  
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Plug_12.jpg

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Re: HighFlo Quiet Muffler Details
Reply #20 - 12/30/20 at 18:29:36
 
It’s set up with a light drive fit into the 1.65” ID baffle tube, then drilled through for a ¼-20 bolt and nut.
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Plug_Finished2.jpg

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Re: HighFlo Quiet Muffler Details
Reply #21 - 12/30/20 at 18:30:15
 
The plug looks like this once its installed.  It will force the hot exhaust gas to flow out through the perforations in the baffle tube.
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Baffle_Finished_22.jpg

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Re: HighFlo Quiet Muffler Details
Reply #22 - 12/30/20 at 18:30:56
 
The baffle tube and plug are drilled to accept a ¼” bolt.  The bolt locks the plug in-place.
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Center_Plug_Bolt.jpg

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Re: HighFlo Quiet Muffler Details
Reply #23 - 12/30/20 at 18:31:40
 
There are a total of 216 holes drilled in the baffle, 108 on each side of the plug.  The holes are 11/64” (.17”).  A drill-press works good but a hand-held drill will get the job done.  Make sure to clean up all the burrs.
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Perforating_Baffle2.jpg

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Re: HighFlo Quiet Muffler Details
Reply #24 - 12/30/20 at 18:32:28
 
The 2 x 2.5 exhaust adapter will need two slots cut so the muffler clamp can pinch it tight onto the header pipe.  A Harley muffler clamp is in order, they are heavy duty and get the job done.  Start the slots with a hacksaw and then finish up with a flat file.  An exhaust pipe expander works good for holding the reducer while making the cuts.
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Reducer_Clamp_Slots.jpg

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Re: HighFlo Quiet Muffler Details
Reply #25 - 12/30/20 at 18:33:12
 
The exhaust pipe expander works great for holding the work piece.  It also comes in handy for installing the baffle into the muffler.  You don’t need to tighten it very much, just enough to grip the pipe, not enough to expand the pipe.
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Pipe_Expander2.jpg

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Re: HighFlo Quiet Muffler Details
Reply #26 - 12/30/20 at 18:34:02
 
If you run an O2 sensor you will need a bung.  I don’t have welding equipment so I make bungs that can be mechanically installed.  Grade 2 bolts & nuts work good.
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O2_Sensor_Bung_Bolt_on2.jpg

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Re: HighFlo Quiet Muffler Details
Reply #27 - 12/30/20 at 18:34:38
 
To accommodate the O2 sensor bung you have to drill a 1” hole through the muffler and the reducer.  The thin wall material requires that you use a hole saw or a step drill.  Step drills work really good and they don’t tear up the thin wall material.
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O2_Sensor_Hole_Drill_Gear2.jpg

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Re: HighFlo Quiet Muffler Details
Reply #28 - 12/30/20 at 18:35:21
 
You end up with this.  All lined up and ready for the bung.
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O2_Sensor_Hole_Muffler__Adapter2.jpg

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Re: HighFlo Quiet Muffler Details
Reply #29 - 12/30/20 at 18:36:08
 
When it’s ready for final assembly, pile on the JB Weld Extreme Heat Paste and insert the bung through the inside.  Apply more paste to the threads and install the threaded collar.  The small bolt and nut are only used to hold the bung in place while tightening the collar, then remove the nut and pull the bolt out from the inside.
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O2_Sensor_Bung_Rough_Install2.jpg

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