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Author Topic: Installing Fullsac Baffles on 09 CVO Road Glide  (Read 147348 times)

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gordy

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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #195 on: April 12, 2009, 11:06:34 PM »

Spazz-has anyone informed you that the Canadian CVO's have catalytic converter material in the headpipe?
Bribe and I know that the SERG's have.
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LarryB

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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #196 on: April 13, 2009, 05:50:17 AM »

Spazz-has anyone informed you that the Canadian CVO's have catalytic converter material in the headpipe?
Bribe and I know that the SERG's have.
Not so sure. Aren't the Canadian bikes the same as all international models? just pull the right side muffler and look inside the head pipe
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jamesrgarner

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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #197 on: April 13, 2009, 08:41:48 AM »

I finally got my done Friday and rode 350 Saturday; it made an amazing difference in power and sound.  Now I've got to do something about a tune - I'm thinking about going with a super sert. 
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ragrep

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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #198 on: April 13, 2009, 12:54:14 PM »

Feedback on the intall-

Fullsac performance are great people. They spent plenty of time on the phone going over the attributes of their product. It's a quality piece too- nice welds, and the baffle design looks impressive. Saturday I removed the stock baffles and installed 2" Fullsac baffles. Following the Fullsac directions- the job was fairly simple- the only time consuming part was being patient enough to carefully grind the welds completely to get them to break loose- you dont want to go too far too fast. I set the pipe on a block of wood and tapped the old baffle forward into the pipe a bit to get the welds to break loose, then turned it over and set the pipe bewteen two blocks of wood, used a 3/4" x 12" extension with  a 1-1/8 inch impact socket- placed it down in the opening until it hit the top of the baffle and gave it a few taps, and it quickly worked its way out.

Fullsacs instructions say to drill the baffle mounting hole 1-1/2 inches from the end of the pipe, and the instructions in the post say 1-3/8 inches. I used the 1-1/2 inch mounting and they fit fine.  Note- I didnt like the look of the mounting bolt & nut that fullsac sends, so I used a stainless 1/4 inch buttonhead- it forms to the pipe nicely and the finished look is a little nicer, more factory looking than a chunky hex head bolt on the underside of the pipe

I also replaced the header pipe with a non-cat header from another 09.

Ok- how do they sound?- very nice. I've owned Samsons, Hookers, V&H, Supertrap, Kerkers, and you have to consider that loud and tone is so subjective from one ear to the next. All I can report is that they( 2"baffles) are definitely not too loud, actually far from it. At idle they have a deep impressive sound, and at 50%+ throttle( acceleration) you can hear them yeah, but their not obnoxious to scare old ladies in the car next to you. At cruise speed, not too loud, actually  the wind noise overshadows the pipe noise. But at least now, I cant hear the air cleaner sucking air over the exhaust.  Someone said they sound like Rinehart's- well they do have a nice deep note now, but they dont have the snappy sound that Rineharts produce. Anyway the sound was better than I expected, and the performance result was very noticeable.

Overall- if you are the slight bit handy, you can do the job yourself- the baffle replacement is worth the $120.  I think the stock can looks great, so why toss it, and spend $500 on somthing else with similar performance? And if you want, you can change the end caps for a different look. The throttle response was much better, I noticed a little drop in torque( by feel only) between 2000 & 2500rpm, but more pull than before between 2500 to 4000. I know the bike needs to be tuned, I expect everything to improve after that. (I would like to have heard the 2.25" just to compare though.)

Thank you to "birdman" for posting the PC5 map- I'm not running lean any more. " I love the smell of fuel in the morning"

Final note- after the baffle replacement and header replacement, the exhaust flow is noticeably reduced in the left side can- definetly stronger in the right side. Which doesnt bother me, I think it will result in more of a 2-into -1 effect- which  should help with torque values a little.

Picture of the standard baffle next to the Fullsac baffle-



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GtreetSlide

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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #199 on: April 14, 2009, 04:43:34 PM »

I finally got my done Friday and rode 350 Saturday; it made an amazing difference in power and sound.  Now I've got to do something about a tune - I'm thinking about going with a super sert. 

I just tuned my new 103 (fullsac baffles) with the new TTS unit. It was quick and easy, only requiring 2 or 3 test runs using their software on a laptop. Doc wrote up easy to follow instructions that made it really simple. I highly reccomend the TTS masterTune. It runs great getting 40 mpg when running around in the hills and the motor runs so much cooler it's really sweet.  :bananarock:

jb
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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #200 on: April 21, 2009, 08:30:17 AM »

I took some pics of the cat removal I did a week ago.  I'm pretty damn lucky I have a bud with a band saw and welding equip.  Otherwise this would have cost me a small fortune.  I will say that I enjoyed doing this mod myself.  I learned a lot and had fun while doing it.

Pre Cut w/ a line drawn to match the exhaust back up after weld.


Cutting the exhaust


'Tis what it looks like inside (BTW this shtuff is razor sharp so be carefull when tearing it out)


Using an air chisel to remove the cc

« Last Edit: April 22, 2009, 08:13:26 AM by EagleGlider »
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fourstar

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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #201 on: April 21, 2009, 04:48:11 PM »

Did you photoshop that weld?  I can't even see it!
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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #202 on: April 21, 2009, 06:40:47 PM »

Did you photoshop that weld?  I can't even see it!

:ROFLOL:


OMG...  now that's funny...

I grabbed the pre- cut & weld photo showing the header before we started...   :wall:

So yes, there's no weld on that pic.

I'll try and remember to add the post weld shot later if daim bramage doesn't kick in again...

Thanks for pointing that out...  too funny.
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fourstar

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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #203 on: April 21, 2009, 11:16:58 PM »

I was going to send my pipe to you if you could weld like that!
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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #204 on: April 22, 2009, 08:12:11 AM »

I was going to send my pipe to you if you could weld like that!

Here's the weld .  My good friend Mikey showing off his work, a master welder  :2vrolijk_21:


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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #205 on: April 22, 2009, 07:06:30 PM »

Hey Eaglerider,

Tell Mikey that his weld looks better than the factory ones.

Cheers, Ken  8)
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fourstar

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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #206 on: April 22, 2009, 07:31:42 PM »

Hey Eaglerider,

Tell Mikey that his weld looks better than the factory ones.

Cheers, Ken  8)

Real nice Ken!  Some poor Chinese kid probably worked his a$$ off on those welds!!  :D
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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #207 on: April 22, 2009, 07:37:15 PM »

 :huepfenlol2:
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FLSTFI Dave

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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #208 on: April 24, 2009, 07:34:35 AM »

Here's the weld .  My good friend Mikey showing off his work, a master welder  :2vrolijk_21:




You're friend did a great job.  Yesterday my neighbor did the same thing for my pipe.  He was an air frame welder for Boeing, and did a great job too.

Man the bike sounds so much better with the cat free head pipe, 2.25 fullsac baffels the TTS Master tune with Steve Fullsacs map.  It also runs stronger and cooler.

Fullsac is a class act, great service too.

This set up is not as loud as Rinharts in my opnion, but a little deeper.  Nice deep low tone at idle, you can hear the stereo at 75 and wind nice is as loud as the pipes.  Crack the throttle and they get louder, above 4500rpm they really bark.  I am very happy with the sound, seems fitting for a bagger.
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LarryB

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Re: Installing Fullsac Baffles on 09 CVO Road Glide
« Reply #209 on: April 25, 2009, 07:33:19 AM »

You're friend did a great job.  Yesterday my neighbor did the same thing for my pipe.  He was an air frame welder for Boeing, and did a great job too.

Man the bike sounds so much better with the cat free head pipe, 2.25 fullsac baffels the TTS Master tune with Steve Fullsacs map.  It also runs stronger and cooler.

Fullsac is a class act, great service too.

This set up is not as loud as Rinharts in my opnion, but a little deeper.  Nice deep low tone at idle, you can hear the stereo at 75 and wind nice is as loud as the pipes.  Crack the throttle and they get louder, above 4500rpm they really bark.  I am very happy with the sound, seems fitting for a bagger.
Question, I've heard many hear speak of running in high rpms. I did do this while doing my V-tune session. But if you're running at 4500 rpms, what gear are you in? I'd be causing a sonic boom if I did that
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