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[jimcb1]

How hard is it to put fullsca cores in

[Ghost__Rider]

30 minutes tops with right tools...

[SOCAL296]

It is not hard but 30 minutes is an underestimate. If you can remove your mufflers you can do the recore. Just take your time or you will scratch up your chrome

[grc]

I'm pretty sure I saw a short video either on this site or on the Fullsac website showing the process, so I'd suggest looking for that to see if you feel comfortable doing it yourself.  You will need a power tool to grind off the welds that secure the original core to the shell.  A high speed die grinder would be the tool of choice for those who have one, otherwise you could probably get by with one of the more powerful Dremel tools.

Jerry

This is one video I found:

[Ghost__Rider]

Yeah, I've done several sets, maybe hour on the first set, but I can do them in 30.

[mark]

Since this is the first time you'll go slow, so about 30 min per muffler.  If the mufflers have any age on them, rust may have bonded the muffler body to the core.  I had to beat on the core very aggressively to get it to break loose.

[srnoyes]

I tried to use a dremel tool with a cutting disc at first but went ahead and bought a die grinder and a carbide grinding tool. It was worth every cent. I couldn't get the disc up in there in between the exhaust center pipe and the outer chrome shell. Grinding out the welds went SO much faster with the right tool. When I removed the first one I found that they had really screwed up the fiberglass packing. They had ripped it all to shreds ramming everything in with no thought what so ever. Now my chrome is blue because there was no insulation protecting it from the heat! So I called FULLSAC and asked them what to do. They recommended that I go ahead and take the other one apart and see what they had done there. If they screwed both sides up then I would have to go to a motorcycle shop and buy some insulation. Once I pulled it out, I found that I had enough fiberglass pad, once cut in two pieces, to do both sides with the muffler sleeves I also purchased. I cleaned up the crap the HD installer had tore up and jammed in the stock exhaust After that hurdle was cleared everything went back together like a dream. They should so throaty and have a great rumble with the 2.0". When I called them talk about the purchase choices on the cores, the lady I spoke with said that if you want to hear the radio and not go deaf the 2.0" is the way to go. the 2.25 and 2.5" are really loud she said.

[jimcb1]

Do you really need the insulation with the 2" cores

[GregKhougaz]

Do you really need the insulation with the 2" cores

Not a question of need but some do for sound and heat.  I did.  Here's an old thread but very instructive and the procedure remains the same:  Installing Fullsac Baffles on 09 CVO Road Glide

[srnoyes]

After seeing the blued chrome on the muffler with the trashed insulation I believe it would be a mistake to not insulate. Thankfully the blued chrome is covered by the heat shielding and you can't see it. I didn't understand the insulation to have much of anything to do with the sound but I'm not an expert so could talking out my butt!

[SOCAL296]

Do you really need the insulation with the 2" cores

Yes. It sounds tinny without it.
With that said I read on Fulsacs site that they doubled up the packing on the newer models and you should remove 1 layer then use a screen Fulsac now sells. Their site has videos

[North Star]

Yes. It sounds tinny without it.
With that said I read on Fulsacs site that they doubled up the packing on the newer models and you should remove 1 layer then use a screen Fulsac now sells. Their site has videos

What video? The only ones I see on their site is of Steve's hooliganism! 

[HOGMIKE]

What video? The only ones I see on their site is of Steve's hooliganism! 

Here's one............
http://fullsac.com/product/2006-2015-cvo-power-core/

There are others, you just have to search beyond the "fun" stuff!
 

[Trigger-Man]

I did the Fullsac conversion on my 2011 SERG ....here's a pic of what the 2011 factory core looked like.

Curious to know what the 2015 factory cores look like. Would someone who pulled them please post pics

[Schnobel]

I tried to use a dremel tool with a cutting disc at first but went ahead and bought a die grinder and a carbide grinding tool. It was worth every cent. I couldn't get the disc up in there in between the exhaust center pipe and the outer chrome shell. Grinding out the welds went SO much faster with the right tool. When I removed the first one I found that they had really screwed up the fiberglass packing. They had ripped it all to shreds ramming everything in with no thought what so ever. Now my chrome is blue because there was no insulation protecting it from the heat! So I called FULLSAC and asked them what to do. They recommended that I go ahead and take the other one apart and see what they had done there. If they screwed both sides up then I would have to go to a motorcycle shop and buy some insulation. Once I pulled it out, I found that I had enough fiberglass pad, once cut in two pieces, to do both sides with the muffler sleeves I also purchased. I cleaned up the crap the HD installer had tore up and jammed in the stock exhaust After that hurdle was cleared everything went back together like a dream. They should so throaty and have a great rumble with the 2.0". When I called them talk about the purchase choices on the cores, the lady I spoke with said that if you want to hear the radio and not go deaf the 2.0" is the way to go. the 2.25 and 2.5" are really loud she said.

Your packing look like mine?



Couldn't believe what a lousy job of quality control HD did when they installed the insulation in my 2012 SEUC. The left side was Ok so did the same thing and split up that insulation between both cans.

If you didn't order the insulation mesh from Fulsac you should. Makes everything go back clean and keeps the packing where it should be.