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Old Jul 24th, 2008, 7:42 pm   #1 (permalink)
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Coring stock mufflers?

Has anyone tried this yet on their bike? I know the SS, Monster and SBK guys have done it with good results in improved sound quality. I'm sure the process is similiar. I just can't take the weak sound of the stock cans.
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Old Jul 24th, 2008, 8:04 pm   #2 (permalink)
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I have done it. All you need is a hole saw that fits over the exit pipe and cut through. Drill out the rivets holding the aluminum decorative cap. Next cut off the end of the muffler after you make a few witness marks for alignment later. I used an air chisel to break the internal weld holding the exit pipe and then pulled out the pipe which takes some work as the inside end is slightly flared. Now weld back up the end using stainless rod or brazing as you do not want rust. Paint the welded area black and install the end pieces with new pop rivets and Bob is your uncle. Be sure to align the two drain holes on the bottom. If you do a search you should find at least one more post on this subject.
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