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[Heatwave]

Can't use Stock '09 headers because of the new smaller O2 sensors and their placement just forward of the collector on each head pipe of the '10 model year....don't know if the '96 stock 2-1-2 headers have the CAT or not...   If anyone knows, I'd like to know too cuz I'll replace the cat version on my SESG with the non-cat ones...otherwise I'll wait until V&H (or others) catch up with the new bung size and placement on their head pipes.

 

2009 non-cvo (96") 2:1:2 headers are cat-free
2009 CVO (110") 2:1:2 headers have a cat
2010 ALL 2:1:2 headers have a cat regardless of engine size

[LarryB]

get out the dremel, cut the bungs out and weld in new ones, prob solved

[Heatwave]

get out the dremel, cut the bungs out and weld in new ones, prob solved

You mean cut out the old bungs, patch the holes, cut new holes in the proper location and weld in new smaller thread bungs. I don't think most guys would have any interest in modifying a 2009 header to meet the specs of a 2010 bike...that was probably HD's reasoning for the changes. If they didn't make the changes the '09 headers could have replaced future headers for years to come....against EPAs wishes.

[Texas 103]

You got me there.  So much for my off the cuff answer.  It kind of sucks that our 09's are now a one of a kind exhaust also.  Hopefully it won't take as long for the aftermarket stuff to hit for the 2010's as it did for the 2009's.  I also hope that you find that the head pipes don't have the cat in the 96" models.  It's starting to sound like last year all over again.  If you want to make any immediate changes to the exhaust, it will be limited in choices once again.

Just talked to Edd5, he stopped at Doug Lofgren's place on the way back from Sturgis, Haven't gotten the whole scoop yet . I'll see Ed this weekend and see if he will add to this thread..... Greg

[michaelbmenaker]

I've followed this and several other related threads with great interest since I ordered my '10 SESG.

Over and over again, members of this forum have recommended, based on their own experience, recommend Fullsac. For $300 (plus shipping to fullsac) your mufflers are recored and your headpipe has the catalytic converter removed. The new 02 sensors are still upstream of the cats. As your only paying for the modifications, not the pipes or muffler bodies, the price compares very favorably to other options.

I'm having my dealer ship the headpipe and mufflers to fullsac for 2" baffles and the removal of the cats before tuning with a SERT and a dyno tune.

Given the good experiences of so many on this board, I'm very comfortable that I'll be happy with the results. I will post the dyno sheets in a couple of weeks.

[LarryB]

the beauty of this whole thing was this, We did the cat removal ourselves, purchased the fullsacs from Steve for 120.00 and installed ourselves. so cost wise we got maybe 130.00 inluding a dremel grinder.

[Fullsac Performance]

I've followed this and several other related threads with great interest since I ordered my '10 SESG.

Over and over again, members of this forum have recommended, based on their own experience, recommend Fullsac. For $300 (plus shipping to fullsac) your mufflers are recored and your headpipe has the catalytic converter removed. The new 02 sensors are still upstream of the cats. As your only paying for the modifications, not the pipes or muffler bodies, the price compares very favorably to other options.

I'm having my dealer ship the headpipe and mufflers to fullsac for 2" baffles and the removal of the cats before tuning with a SERT and a dyno tune.

Given the good experiences of so many on this board, I'm very comfortable that I'll be happy with the results. I will post the dyno sheets in a couple of weeks.

The band saw is running! I'm ready! Can't tell you how much I enjoy cutting up brand new Harley parts.
Might have to post a few pics of the first 2010 headpipe surgery.

Steve

[jfh]

You mean cut out the old bungs, patch the holes, cut new holes in the proper location and weld in new smaller thread bungs. I don't think most guys would have any interest in modifying a 2009 header to meet the specs of a 2010 bike...that was probably HD's reasoning for the changes. If they didn't make the changes the '09 headers could have replaced future headers for years to come....against EPAs wishes.

Don't have to remove or patch the old bungs on the '09 pipe.  Screw in plugs are readily available from a variety of sources.  Then just install the new smaller bungs in the new 2010 location. Manufacturer claims the new smaller sensors were developed to provide more options for mounting locations on a variety of other applications besides our bikes.

Best solution will likely be to send the 2010 pipe to Fullsac for Steve to perform his cat disappearing act.

[Heatwave]

I've already done the Fullsac recore (2.25") of the SE slip-ons from my 2010 SEUC. I ran several hundred miles today with the stock A/C and the bigger baffles to check out the sound. I did not find them particularly loud. No decrease or increase in performance using seat-o-pants meter. Still running stock A/C with no engine modifications. All that changes next week. Bike goes into dealer for a baseline dyno run (with the original stock baffles re-installed for the baseline dyno).

Then the heads go to Scott at Hillside Cycle. The stock headpipe goes to Fullsac for a CC removal. Once the heads, and header pipe return, the dealer will be reassembly engine with the modified heads, clean header, 2.25" Fullsac baffles, 58mm TB, Pro Super Tuner, Woods TW408-6 cam, adj. pushrods, Ventilator A/C and roller rockers. Based on feedback from Scott at Hillside and Bob Woods, it should make for a strong combination once its tuned. I hope to have results to post sometime after Labor Day.

[BostonboyDH]

Heatwave,  Have you installed the Cycle shack baffles 1544 yet and if so do you like them? I just installed a set in my 09 SERG and so far I'm pretty happy with them. There doesn't seem to be anybody else on this forum that has used them yet, I'm happy with the sound nice low rumble and not to loud, and I did not get any popping or pinging. I haven't killed the cat yet but have a 09 non cat ready to go on and get tuned. I'd like to know your oppinion!!!!       Thanks, Bosstnboy "DH"

[Heatwave]

Heatwave,  Have you installed the Cycle shack baffles 1544 yet and if so do you like them? I just installed a set in my 09 SERG and so far I'm pretty happy with them. There doesn't seem to be anybody else on this forum that has used them yet, I'm happy with the sound nice low rumble and not to loud, and I did not get any popping or pinging. I haven't killed the cat yet but have a 09 non cat ready to go on and get tuned. I'd like to know your oppinion!!!!       Thanks, Bosstnboy "DH"

I was going to use the Cycle shack baffles but unfortunately I realized after looking at the picture on-line that the baffle's end plate faces inward. All other baffles I've seen have their end plates facing outward. This may not matter to some but I had already ground out the welds on my SE mufflers and drilled the hole to use a ss buttonhead bolt from the outside and a ss lock washer and nut from the inside to hold the baffle tightly in place.

Since the lip of the end plate faces inward on the Cycle Shack baffle, there's no way to get a lock washer and nut on the inside of the baffle to tighten the bolt/nut. Essentially the only way to hold the Cycle Shack baffle is with a sheet metal screw, which over time will likely work its way loose or out altogether.

How did you tighten the Cycleshack baffle to your muffler?

[BostonboyDH]

  Heatwave ,  they are held in place with the pop rivets that came with the set. There was however a little bit of modification that needed to be done to these baffles in order to get them to fit inside the stock SERG muffler body they are about an inch and a half to two inches longer than the stock baffle at the receiver pipe end, but I took them to a muffler shop and had them cut to the same length as the stock baffle and had a little flair put on the cut end to match the flared end same as the OEM, also there are four threaded holes in the end plate that are used to attach them to the other style 4 inch muffler bodies but I inserted 1/2 inch quarter twenty stainless button head screws with lock tite, I had many phone calls with Buzz at Cycle Shack and he has been very helpfull in helping me get these to fit I also gave him one of my OEM baffles so that he can make these work in our bikes with out the mods that I had to make I hope to be putting on the catless header pipe that I have and get it tuned soon. I'm not looking for big HP but I do want the best TQ and a nice low rumble. I'm not the Loudest bike on the block but definitely not the Quietest either!!!      BOSSTNBOY "DH"

[Heatwave]

  Heatwave ,  they are held in place with the pop rivets that came with the set. There was however a little bit of modification that needed to be done to these baffles in order to get them to fit inside the stock SERG muffler body they are about an inch and a half to two inches longer than the stock baffle at the receiver pipe end, but I took them to a muffler shop and had them cut to the same length as the stock baffle and had a little flair put on the cut end to match the flared end same as the OEM, also there are four threaded holes in the end plate that are used to attach them to the other style 4 inch muffler bodies but I inserted 1/2 inch quarter twenty stainless button head screws with lock tite, I had many phone calls with Buzz at Cycle Shack and he has been very helpfull in helping me get these to fit I also gave him one of my OEM baffles so that he can make these work in our bikes with out the mods that I had to make I hope to be putting on the catless header pipe that I have and get it tuned soon. I'm not looking for big HP but I do want the best TQ and a nice low rumble. I'm not the Loudest bike on the block but definitely not the Quietest either!!!      BOSSTNBOY "DH"

Sounds like you got a good solution but it took abit of work to get there. The Fullsacs were a straight forward install and were the exact same length as the stock baffles, so it was a perfect swap out.

[BostonboyDH]

  Heatwave,   I have not seen to many post here from members that don't like the Fullsac, and I my self at first was going to use them I called Steve and talked to him about his cores before I started researching what other baffles were available. The Fullsac is a wide open flow through design whereas the Cycle Shack design has a v notch in a perforated tube thus adding a little more restriction  which should help the TQ numbers especially when staying with stock cams. From what I read in this forum and the numbers posted from the other members the Fullsac is a product that does perform very well.  The Cycle Shack baffles are about $35.00 cheaper if that is an issue and I doubt that it is considering we've all put out $30,000 to $35,000 to start, but some do feel like their getting the best bang for the buck!!!
  I guess I just needed to try something a little different in staying with the OEM muffler bodies, But you best believe that if my dyno numbers are not comparable to what others are getting with the Fullsac I will swap them out in a heart beat!!!  After the many lengthy phone conversations I've had with Buzz at Cycle Shack about getting his baffles to fit in my 09 muffler bodies and also stressing the fact in what the members here want to do with their CVO Bikes and the fact that he asked me for one of my OEM baffles I'm sure he will, if he does not already have a baffle ready to fit right in.
                  I guess I was the LAB RAT!!!!           BOSSTNBOY  "DH"