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[RayG]

I just received my Crusher Mellows & the Vance & Hines Power Duals for my 08 and the bungs are to small.  The book indicates that they are for 09 and I made sure that Rebecca was aware of the conversation.  I replaced the oil pan to an 09 & sent out some private emails to members on this site for their assistance for any other complication like drilling & tapping the tranny for the bracket that might come up.  I either have to change the Headers or change the 02 Sensors if that would work.  Does anyone know if the 09 sensors can be used?  I have called Rebecca back and she isn't sure, I also called Vance & Hines and a few others and I guess everybody is busy because I can't find an answer to my question.  Even though I tried my best to explain the 08 to 09 conversation when ordering I fully expected some complications.   

[skratch]

i don't think so, but i could be wrong.  in addition to being smaller, they are also heated, which the 18mm are not, so the wiring on your 09 wouldn't even support them.

[sadunbar]

I think your simplest and most cost effective solution at this time, Ray, would to have 18mm bungs welded into your pipes, and use your existing 02 sensors...  Just be sure to research the best location to install the 18mm bungs...   

I have done the conversion you are currently doing, only on my 07 bike.  Fortunately the pipes I used had both 9mm and 18mm bungs installed.

[sadunbar]

RayG...

A few of photos you might find useful...

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[charles05663]

Sadunbar,

To you have the crossover pipe wrapped to reduce heat transfer to the oil?

 

[sadunbar]

Sadunbar,

To you have the crossover pipe wrapped to reduce heat transfer to the oil?

 

Yes - to keep from heating the oil pan/oil... 

I don't know how effective it is, but it's simple enough I thought it was worth the effort...

[RayG]

Awesome description & photos on the installation!  I believe that Vance & Hines makes the correct Headers with the 18mm bung in the right place.  In talking with Rebecca yesterday she mentioned that there was only one part number from her supplier which is Drag.  I crossed referenced the numbers to 2010 to 2015.  I know they make them for the 09 but they did not list them in their catalog so she sent them anyway?  There has to be the right set up without having to weld the right size bungs.  I noticed that you drilled the bracket off to the left versus the photos I've seen elsewhere on the internet that are in the middle?  I just had the 09 oil pan installed with all the hoses for the S&S 124 consisting of the external oil lines so I will have to be creative on drilling & tapping.  I may fabricate a piece of plastic to catch the debris and have it fall outside the pan or stick some electrical Duxseal on the inside where I'll be drilling & tapping so it can catch any metal.  It looks like you used a 5/16 bolt for a stud rather than the 1/4 X 20?  That may be the way to go for the thinner walls that our older bikes have.  I completely stripped the bike to a rolling chassis so I wouldn't be charged all the labor for the installation of a new warrantied motor & 5 months later it has become more challenging to reassemble that I thought.  I put in the Baker Street door to tighten up the main shaft.  I ordered allot of parts in hopes of getting a few more seasons before the hairline crack in a neck vertebrae got worse but a recent MRI said to late,  I've already had 5 surgeries in that area and the next one would fuse all but the very top & bottom disk.  No more surgeries and no more rough stuff, which means my riding days are over.  Can't take the jarring potholes anymore.  But that's a whole different story, we have had some prominent members face injuries and/or having to take to much medication that can diminish the fun in riding.  We all have stuff we have to deal with & we will all have to make that decision some day. 

Thanks for taking the time to take & post the photos.  I've said it before but without the caring members on this site we would have a difficult time gathering the assistance we need in all areas for our bikes.

I'll let you know how I make out on the exhaust.

Sincere Thanks

[sadunbar]

Ray - I used 1/4-28 bolts.  I offset their location so I could use bolts (drilled thru) vs. set screws (tapping a blind hole).  I used half nuts on the outside of the case, then the hanger bracket, then locknuts to secure it all.  I don't have a photo that shows it, but once was all tightened, I covered the heads of the bolts with epoxy.  It's been about three years now and has all stayed secure and has not leaked a drop of oil thru the threads.

[RayG]

That's a great idea.  The photo sure made the bolts look larger, and using Jam nuts saves some space.  I use Jam nuts for my hard bags.  I use a stud set up using jam nuts so I can have a little more security for the bags.  Only takes a minute to take the nylon locking nuts off.  The clearance helps with the Bitubo's also.  As soon as Easter is over I will spend a little time to find the right headers.  No rush to finish, not going to register or put plates on it unless I can't sell or trade for a backhoe.  Going to be a weird year that's for sure.