Dave wrote on 03/11/23 at 04:33:20:Dyna mufflers on the Savage work well, look and sound good, and they are pretty easy to find.
For some reason they do not last forever on the Savage - the inside eventually comes apart. They often rattle or the muffler flow gets blocked when the inside is broken.
If you have ever followed a Dyna muffler Savage at night - you can see the inside perforated pipe glowing red hot.....eventually the heat takes it's toll.
Interesting. Mine didn't fall apart, its the sloppy weld that I made fell apart.
This being said, I don't have the original muffler anymore, or if I do I have no idea where it may be. However the original header I believe is stainless steel, at least the outer pipe. Stainless steel turns blue from excess heat, and when welding stainless and it turns blue its a sign of excess heat as well. I actually own a machine that removes blue/black burn marks from stainless welds. Apparently not only it is a cosmetic cleanup, but it prevents further corrosion when the discoloration is removed.
https://youtu.be/UL-wEdWYpxkHowever, the Harley muffler is most certainly not stainless, it chrome plate steel. The chrome on mine is pitting and peeling real bad, and the header is blue, so I'm probably running too hot. I did not rejet my carb after I installed the muffler, as I have no experience with carbs, and I don't know anyone good enough to do it.
See pic from a while back. The muffler was nearly perfect when I originally bought it in 2016, there was maybe 3k miles total on the bike when this picture was taken, and the muffler and header are already looking like this.
In any case. I have already bought a new (used) Dyna muffler in near perfect condition. I will use a stainless sleeve to slip over the tips on the header and the muffler,weld them together, and sand to a smooth finish. I'll also try to hit the header with the stainless cleaning machine to see if it works.